INDUSTRIAL TRAINING IN TCC LTD

presented byJOHAN GEORGE K12 MI01 040

CONTENTS2

INTRODUCTION

PRODUCTS AND PRODUCTION PROCESS CASE STUDY

INTRODUCTION3

TCC is the first unit in India to manufacture Rayon grade Caustic Soda.

It is the heart of the industrial sector in udyogamandal sector

Only chlor-alkali process industry in Kerala

Only manufacturer of caustic soda in Kerala

HISTORY4

• FACT• MCIC

Chlor alkali unit

INITIAL INVESTMENT IN TCC

5

Investor Rs in crores % SHARE AS OF 2013

GOVT . KERALA 11.9 80FACT 8.11 2KSIDC 6.5 17SANMAR PROPERTIES AND INVESTMENT

3.5 1

TOTAL 30.01 100TABLE-1 INITIAL INVESTMENT AND % SHARES IN TCC

GROWTH STAGES6

YEAR GROWTH1956 A continuous Caustic Fusion Plant 20

TPD for producing Caustic Soda flakes1958 Started Chlorine Liquefaction Plant 1960   Capacity enhanced to 30 TPD further 

to 40 TPD.1975 Added another 100 TPD Caustic Soda

Membrane Unit thereby increased the production capacity 200 TPD

1997 100 TPD Caustic Soda manufacturing unit using Membrane technology capacity 125 TPD.

2005 Addition 25 TPD2006 Addition 25 TPD

table 2. growth stages of TCC

MISSION AND COMPANY POLICIES7

MISSION TCC is committed to have Customer satisfaction and with its major concern for environment and Safety

QUALITY POLICY committed to enhance customer satisfaction by continually improving Quality Management System.

ENERGY POLICY TCC always committed to conservation of energy by all possible means

GOALS OR OBJECTIVES OF MANAGEMENT8

Cost effectiveness in all our operations

Regular upgrading of technologies used in processing

Compliance with laws and statutory regulations

Technological up gradation to reduce specific energy consumption

Contacting other organisations and enriching our experiences on energy conservation

Using renewable energy sources to the extend possible

Low energy fuels also to be tried depending upon feasibility

ACHIEVEMENTS9

YEAR ACHIEVEMENTS1981 Best Performance Award for Safety in the

State from Directorate of Factories & Boilers, Government of Kerala

1988-89

Best Pollution Control Award under group "Heavy Inorganic Industries" in Kerala, from Kerala State Pollution Control Board

1989  Award for Best Performance in Safety in India under "Chemical Industries" group from National Safety Council.

1989-90

Prize for Productivity from Kerala State Productivity Council.

1993 -94

Best Performance award for Energy Conservation in the State of Kerala under group "Chemical & Fertilizers – above 3000 KVA" from Government of Kerala.

Table 3. achievements of TCC

ACHIEVEMENTS10

YEAR ACHIEVEMENTS1994-95

Best Performance award for the Productivity in the State of Kerala under group "Large Industries" from Kerala State Productivity Council

1995-96

Best Performance award for Productivity in the State of Kerala under group "Large Industries" from Kerala State Productivity Council.

1998 Best performance award for Energy Conservation in the State of Kerala under group "Major Industries" from Energy Management Centre, Govt.of Kerala.

1998 Performance award for Energy Conservation under group "Chlor-alkali Sector". Ministry of Power, Government of India.

Table 4. achievements of TCC

ACHIEVEMENTS11

YEAR ACHIEVEMENTS2003 Kerala State Energy Conservation Award

(2000) in the category of Large Scale Industry

2005 National Energy Conservation Award "Chlor-alkali Sector

2012 achieved zero effluentTable 5. achievements of TCC

SALES12

ITEM SALES

YEARIN LAKHS

2012-2013 136892011-2012 124582010-2011 110642009-2010 105722008-2009 120632007-2008 93602006-2007 8869

2006-2007

2007-2008

2008-2009

2009-2010

2010-2011

2011-2012

2012-2013

8500

9500

10500

11500

12500

13500

14500

SALES IN LAKHS

SALES

Table 6. Sales data from annual reportFig 1 .sales trend of TCC

CUSTOMERS

HINDUSTAN LEVER

IRE LTD FACT HNL KMML BPCL TDC MERCHAM

HOCL HIL HINDALCO

KGCL SPBL KWA KCPL IOCL

13

Rayon, Textiles, Paper, Pulp, Plastics, Aluminium

Pharmaceuticals, Mineral Processing, Petrochemicals

Pesticides, Fungicides

Rare Earths

Water Purification etc..

CUSTOMERS OF TCC

PRODUCTS14

Caustic soda Flakes @30 % concentration @45% concentration

Chlorine Liquid chlorine Chlorine gas

HCl acid Bleach

DEPARTMENT PROFILE15

OPERATION DEPARTMENT MARKETING DEPARTMENT PERSONNEL DEPARTMENT MATERIALS DEPARTMENT ENGINEERING DEPARTMENT TECHNICAL SERVICE DEPARTMENT FINANCE DEPARTMENT PROJECT & SYSTEMS DEPARTMENT

DEPARTMENT PROFILE16

department-OPERATIONS DEPT. Headed by-AGMOP

PRODUCTION PROCESS17

saturator

PPT A

PPT B

CLASSIFIER

CBT

The salt storage yard

barium carbonate

Sulphate precipitation

Sodium bisulphate

calcium

flocculants

Particles from gravity settling

PRODUCTION PROCESS18

CBT

PBFPFBT

SBF

UPBT

anthracite material packing to remove solid particles

HCL acid to increase Ph

ion exchange processIon separator for ultra

purification

HE

HT

PRODUCTION PROCESS-CAUSTIC SODA19

CHEMICAL REACTION20

ANODE CATHODE

PLANTS [CAUSTIC SODA]21

UHDE1-25MTPD

UHDE2-25MTPD

AGC-125MTPD

TOTAL-175MTPD

PRODUCTION –CAUSTIC SODA O/P22

UHDE-1, UHDE-2, AGC

MAIN STORAGE TANK [32%

MAX]

EV-1

EV-2

EV-3

MAIN STORAGE TANK [48%

MAX]PLATED DRUM

TRIPPLE EFFECT EVAPOURATOR

FLAKES STORAGE

cutting the plates we get flakes

PRODUCTION –CHLORINE O/P23

UHDE-1, UHDE-2, AGC

Chlorine gas storage

HCl plant

Drying Tower

Compressor

HE

Liquid chlorine

storage tank Freon gas @-11°C

PRODUCTION-HCL ACID24

Water is sprayed to dissolve the fumed HCl gas to acid

Oven for HCl production

There is an igniters for burning the hydrogen and chlorine gasAbsorpti

on tower

HCl Storage Tank

PRODUCTION –SODIUM HYPO CHLORITE25

Chlorine gas storage

Waste chlorine from seal overflow or leakage

32 % NaOH lye

Chlorine is passed

through NaOH solution

Sodium hypochlorite

Cl2 + 2 NaOH → NaCl + NaClO + H2O

SWOT ANALYSIS26

OPPORTUNITY New project is mainly for helping isro for making solid propellant

SWOT ANALYSIS27

STRENGTH Only chlor alkali unit in state Financed by government Building block of many other industry

Low human intervention in process Raising demand of product Accidents are very least in TCC Raising demand of product

SWOT ANALYSIS28

WEAKNESS Lack of manpower Lack of profit motive Unrevised price policy

SWOT ANALYSIS29

OPPORTUNITY New project is mainly for helping isro for making solid propellant

Increasing the hydrogen utilization from the present level of 76% to 95% by installing an additional Hydrogen Blower.

SWOT ANALYSIS30

THREAT High price of electricity Competitor from abroad Infrastructure is obselete

FUNCTIONS31

Maximizing production confirming to specification

Optimizing consumption of electricity

Minimize overheads

Fixes the monthly target

Modification of production process

Act as emergency controller

QUALITY OF NAOH PRODUCTION OF UDHE-I

32

1 2 3 4 5 6 7 8 9 1011121314151617181920212223242526272829303132333435363738394028.5

29

29.5

30

30.5

31

31.5

32

32.5

33

33.5

PRODUCT QUALITY OF UDHE-I

lower limitupper limitmean limitmean

%NaO

H

QUALITY OF NAOH PRODUCTION OF UDHE-II

33

1 2 3 4 5 6 7 8 9 1011121314151617181920212223242526272829303132333435363738394028.5

29

29.5

30

30.5

31

31.5

32

32.5

33

33.5

PRODUCT QUALITY OF UDHE II

MLLLUL% NaOH IN UDHE 2

% Na

OH -

UDHE

II

QUALITY OF NAOH PRODUCTION OF AGC34

1 2 3 4 5 6 7 8 9 1011121314151617181920212223242526272829303132333435363738394028.5

29

29.5

30

30.5

31

31.5

32

32.5

33

33.5

PRODUCT QUALITY-AGC

LLULMLMEAN % NaOH

% Na

OH -

AGC

EFFLUENT STANDARD35

SL.NO POLLUTING PARAMETER

LIMITING VALUES UNITS

1 pH 6 - 8.5

2Suspended

solids30 Mg/l

3Oil and

grease10 Mg/l

4 Chlorides 1000 Mg/l

EMISSION STANDARDS36

SL.N

OEMISSION SOURCE PARAMETER

LIMIT(mg/

mm3)

1 HCL UNIT1.CL 15

2.HCL 35

2 SALT HEATER1.SO2 1200

2.NOX 450

3 BOILER

particulate

matter150

2.SO2 200

4SODIUM

HYPOCHLORITE1.CL 15

Zero effluent37

No discharge to the river in any form

This is achieved either by recycling from the source into appropriate process step

utilizing for useful purposes such as horticulture after required treatment or rectification.

Reduce , reuse and recycle is the basic principle adopted for attainment of the zero discharge status

The effluent treatment system

38

consist of the following1. High density polyethylene pipes for the

collection and routing acidic/alkaline effluent

2. Acidic alkali proof brick lined tanks, collection pit and reaction pit

3. Buffer storage for treatment4. Acid or alkali proof brick lined pits for

acidic and alkaline water collection in brine purification

5. Acid and alkaline effluent can be used for maintaining pH and they combine to form ultrapurified brine

SOURCES OF EFFLUENT39

CCF washing or spillage HCL plant

Hydrogen safety seal overflow Chlorine blower seal for hydrogen and cl line drains condensate tank overflow, H2 holder overflow, HCL receiving tank sump spillages

Absorption water head tank overflow H2so4 tank bay spillage

SOURCES OF EFFLUENT40

Chlorine liquefaction H2SO4 spillage

AGC plant Receiving tank bay spillage from cell house

Condensate from separator after H2 cooler

Bisulphate from seal leaks Caustic spillage from product cooling area

 

SOURCES OF EFFLUENT41

Dm water unit Acidic/Alkaline effluent from regeneration steps of cationic or anionic and mixed bed resin tower

  Secondary brine purification plant

Acidic or alkaline effluent from regeneration steps

  Chlorine cylinder filling station

Cylinder washing effluent

SOURCES OF EFFLUENT42

Sodium hypochlorite plant Chlorine line seal overflow Effluent from lab spillages

UHDE I & I Alkaline condensate from hydrogen lines

Sources of oil spillage Main furnace oil storage tank area Furnace oil day tank area in CCF and boiler houses

Oil spillages from boiler house

ALKALINE EFFLUENT43

HDPE pipes are laid to collect and bring alkaline water from the secondary resin towers and DM water units to a collection pit having the capacity of 25m3.

The main sources are CCF, regeneration steps and resin towers for DM water and secondary brine purification system

Treatment Sodium hypochlorite productionCylinder washingAcidic effluent neutralization

ACIDIC EFFLUENT44

HDPE pipe are laid to collect and bring the acidic water to the collection pit identified for acidic water.

The source are regenerated steps in DM water units and secondary brine purification system

MSRL tank is provided as a buffer tank for storing acidic effluent.

The acidic or alkaline effluent can be used to regulate the pH of the effluent

pH of the ultra purified brine to the electrolysis.

Acid effluent from HCL plant and alkaline effluent from CCF can be used to produced the raw material ie purified brine

EFFLUENT TREATMENT45

The mixed effluent is led to the effluent collection pit directly.

Acidic and alkaline water from various sources collected in buffer storage tank are used for treatment and neutralization as per the requirement.

There is an online pH measuring instrument that will monitor the pH of the water and make the treatment accordingly

NaHSO3 is added to kill any chlorine present. pH is monitored continuously. After neutralization it is pumped out to drain lending to delay pond . from the delay pond, water is being pumped for horticulture.

AIR POLLUTION46

The major sources of air pollution are Stack emission from molten salt heater in ccf plant

Stack emission from boiler house Vent to HCL synthesis unit

EMISSION CONTROL47

STACK EMISSION FROM MOLTEN SALT HEATER AND BOILER Here furnace oil is used as the fuel. For ensuring proper combustion the burner is equipped with air fuel ratio controller.

A significant quantity of hydrogen from UDHE 1&II and AGC is utilized here as a fuel thus reducing furnace oil consumption

Consumption of furnace oil

48

YEAR CONSUMPTION OF FURNACE OIL IN KL

2009 5216.12

2010 5315.11

2011 3296.89

2012 2932.11 2009 2010 2011 20120

2

4

6

8

10

12

Series3

CONSUMPTION OF FURNACE OIL IN KL

EMISSION CONTROL49

EMISSION CONTROL IN VENT EMISSION hydrogen is always kept in 10% excess than the stoichiometric requirement

For immediate corrective action a bubbler system, where stack gases are drawn continuously trough bubbler having methyl orange indicator

The HCL concentration is checked frequently and maintained in the range 30 to 32% for complete absorption of HCL gas.

A tail gas absorber is mounted over the unit and fresh water is fed to this unit to absorb residual gases from HCL synthesis unit below.

This ensures that HCL gas is almost nil in stacks

Added advantage50

Ensure 100% utilization of raw material Maintenance cost will be reduced by 29% Frequency of plugging of pipe lines due to scale formation is less

Tax benefit is also there as company is having high quality environmental management

The chemical ingredient requirement for the process also decreased

FINDINGS51

Depends heavily on electricity Accidents are very least in TCC, Pricing policy is unrevised No strikes reveals workers management healthy relation

TCC has high regard from customers in matter of quality of product and timely delivery

SUGGESTION 52

Find the opportunity of producing more products

Improving combustion efficiency of furnace oil by using fuel additions

Use of roof transparent sheets wherever possible, to avoid electric lighting during day time.

Persuade to use more safety equipments

Necessary steps to increase net profit

Revise the pricing policy

53