Committed to continuous process improvements to optimize the plant performance, CFCL in consultation with the Process licensors, has implemented various measures to improve Energy efficiency. After the data collection in 2004-2005 and freezing baseline a suitable energy model was selected and the Revamp project was finalised. Based on commercial considerations revamp project implementation was split into two stages. The schemes having stand alone energy saving were selected for implementation in Stage-1 of the Revamp. With this, the Stage-1 revamp was converted into Energy Saving Project with partial bottlenecking. Energy Saving Project of CFCL-1 & CFCL-2 was completed in March/April 2009. In first year of operation there were few bottlenecks related to some critical equipments, which were overcome with in-house study, adopting OEM's guidelines and consultations with process licensors. Over three years of successful operation since 2009, CFCL has achieved the desired Energy levels through stabilised plant operation, optimised parameters and adopting two year operation philosophy. Paper describes our journey from feasibility study to actual achievement i.e. in terms of Energy, GHG emission reduction, better productivity. With higher IPP of Urea and continual increasing Energy cost, CFCL has achieved desired returns on investment made on Energy Saving Project.
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