1
A Project Report
On
General Overview of Mechanical Engineering Department
In
Submitted in Partial Fulfillments of the Requirements for the Award of the Degree of
B.TECH IN MECHANICAL ENGINEERING
Prepared by
Momin Mohd. Azhruddin A.
Presidency College of Engineering
Project Duration: 14/07/2011 to 11/08/2011
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ACKNOWLEDGEMENT
I AM GLAD TO SAY THAT I GOT A GOLDEN OPPORTUNITY TO GET TRAINING AT GUJARAT ALKALIES & CHEMICALS LIMITED (G.A.C.L) ABOUT 30 DAYS. I GOT THE TRAINING AT MECHANICAL DEPARTMENT OF COMPANY AS IT IS RELATED TO MY BRANCH. I AM GRATEFUL FOR SUPPORT & GUIDANCE OF
MR.AMIT.PATEL.MR.M.B.OZA.MR.JAYESH.PATEL.MR.DILIP.PATEL.MR.S.B.PATEL.MR.PANKAJ BHAI.MR.J.V.PATEL.MR.BRIJESH.SHAH. MR.SAAVAN.ACHARYA.
FOR THEIR ENCOURAGEMENT AND HELP DURING OUR TRAINING PERIOD DUE TO WHOM I PURSUED MY TRAINING SESSION.
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WHAT DOES THE NEW LOGO OF GACL SAY?
Taking into the
Considerations the aspects of the global warming and the need to address to the
cleaner and greener environment,
The logo of the company Gujarat Alkalies and Chemicals Limited, Vadodara has been conceived to represent a responsible corporate. Keeping the Importance of the rising issue of the pertinent to the environment, GACL have designed a logo that would reflect the company's mission to keep earth green.
The “Green Attitude” of company addressing the aspects of global warming.
The colours Blue and Yellow reflect the rising temperatures can adversely affect some regions with excessive rainfall while some others with heat waves and drought.
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INDEX
1 History
2 Company Profile
3 Board of Directors
4 Awards Received by G.A.C.L.
5 Corporate profile
6 Organization Structure
7 Products of G.A.C.L.
8 Milestone of G.A.C.L.
9 Manpower Strength
10 Policies
5
11 Overview of CLM Plant
12 Pump
13 Compressor
14 Vales
15 Blowers
16 Boilers
17 Cooling
towers
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HISTORY OF GACL
Gujarat Alkalies and Chemicals Limited (GACL) was incorporated on 29th March, 1973 in the
State of Gujarat by Gujarat Industrial Investment Corporation Limited (GIIC), a wholly owned company of Govt. of Gujarat, as a Core
Promoter.
GACL has two units located at Vadodara and Dahej, both in the State of Gujarat. It has
integrated manufacturing facilities for Caustic Soda, Chlorine, Hydrogen Gas,
Hydrochloric Acid, Chloromethane, Hydrogen Peroxide, Phosphoric Acid, Potassium
Hydroxide, Potassium Carbonate, Sodium Cyanide, Sodium Ferro cyanide. The Dahej unit also has 90 MW Captive Power Plant (CPP) for regular and economical power
supply.
The Company commenced its operations in 1976 with 37,425 Metric Tons Per Annum (MTPA) Caustic Soda Plant based on the
then, state-of-the-art Mercury Cell process at its Plant which is situated 16 km North of Vadodara near Village Ranoli on the main Railway track route between Ahmadabad
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and Mumbai.
Right from the inception, GACL has been following the strategy of continuous capacity
expansion in core areas. The first stage expansion of the Caustic Soda Plant raising
the capacity to 70,425 MTPA was undertaken in October, 1981 followed by a diversification
program to produce 2000 MTPA of Sodium Cyanide in December, 1982.
In 1984, the second stage expansion to increase the capacity of Caustic Soda Plant
to 103,425 MTPA was undertaken. Simultaneously, the Company undertook the
diversification project for manufacture of 10,560 MTPA of Chloromethane using
Chlorine, a co-product of the Company and in 1991, the capacity of Chloromethane
production was doubled.
As power is the major input for production of Caustic Soda and constitutes about 65% -
70% of the cost of production, the Company along with other Corporations like, M/s.
GSFC, Petrochemicals Co-operative Ltd. and Gujarat Electricity Board promoted a gas based power unit in Vadodara under the
name of Gujarat Industrial Power Company Ltd. (GIPCL) during the year 1985. As a promoter of GIPCL, the Company gets low
cost power, as the plant is gas based and is depreciated.
Since production of Caustic Soda is highly power intensive, in order to reduce power
cost and to eliminate mercury pollution, the Company during the year 1989 converted one of its Cell Houses producing Caustic
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Soda from Mercury Cell Technology to environment friendly Membrane Cell
Technology, thereby eliminating the use of mercury. The Capacity of Caustic Soda was
also increased to 132000 MTA.
The conversion of second Mercury Cell to Membrane Cell was carried out during March,
1994, thereby eliminating the total use of mercury from the Complex for production of Caustic Soda and increasing the capacity of plant along with this conversion to 170000 MTA including Potassium Hydroxide facility.
As part of this Membrane Cell Conversion Project, a new facility for manufacture of 16500 MTA of Potassium Hydroxide Lye
based on Membrane Cell was also set up. The Company has further set up facility for converting part of this Caustic Potash Lye
into Potassium Carbonate with a capacity of 13200 MTA. In order to add further value to
its products, the company had set up manufacturing facility for production of
11000 MTA Hydrogen Peroxide (100%) at Vadodara Complex during the year 1996 to utilize Hydrogen gas, which is a co-product
from Caustic Soda Process.
In 1995, as a part of diversification program and to meet the growing demand of its
products in the State of Gujarat and nearby areas, the Company had set up a plant for
manufacture of Technical Grade Phosphoric Acid with capacity of 26400 MTA (85%
Phosphoric Acid) at a new location at Dahej, District Bharuch. The Company also set up Membrane Cell based grass root Caustic-
Chlorine Unit with a capacity of 100000 MTA
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at Dahej. Along with this, a captive 90 MW co-generation Power Plant was set up so as to ensure uninterrupted and low cost power
for its captive operations.
COMPANY PROFILE
Name of the Company
GUJARAT ALKALIES AND CHEMICALS LIMITED (GACL)
Registered Office / Vadodara Complex
P.O. Petrochemicals-391 346Dist. Vadodara, Gujarat, India.Phone-+91-265-2232681-2Fax-+91-265-2232130
Dahej Complex
P.O. Dahej-392 130Taluka- Vagra, Dist. Bharuch, Gujarat, India. Phone-+91-2641-256315-6-7Fax-+91-2641-256220
URL
www.gacl.com
www.gujaratalkalies.com
Size of the Organization
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Large Organization
Solicitors
Messer’s Amarchand & Mangaldas & Suresh A. Shroff & Co. Mumbai.
Cost Auditors Messer’s Diwanji & Associate
Cost Accountants Vadodara.
BOARDS OF DIRECTORS:
Shri. A.K.JOTI (I.A.S)…………… Chairman
Shri. G.C.Murmu (I.A.S)
Shri. M.M.Srivastava (I.A.S)
Shri. D J Pandian (I.A.S)
Shri. G.M.Yadwadkar
Dr. Sukh Dev
Shri. J N Godbole
Shri. Guruprasad Mohapatra (I.A.S.)……………. Managing Director
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AWARDS & RECOGNITION
The Company is a proud recipient of the following recognitions and
awards:
Sr. No.
Name of the Award Purpose of the Award Name of the Organization
Date of receiving the Award
Year 2009-101) Excellent achiever
Award.For valuable
contribution in chemical industry
Gujarat Chemicals
Association, Ahmadabad
February, 2010
2) Award for Excellence – 2009.
Certificate of Meritin the field of Export
Promotion
Federation of Gujarat
Industries, Vadodara
May, 2010.
3) NSCI safety Award -2009.
Appreciation letter by National Safety
Council
National Safety Council established by
Ministry of Labour &
Rehabilitation, Government
of India
October, 2010.
4) Excellence Certificate for
‘Securing Participation Position
in Good House Keeping Contest
2009-10’.
Baroda Productivity
Council, Vadodara
For the year 2009-10.
5) CHEMEXCIL Award For Outstanding Export Performance
Export Promotion Council,
Government of India
For the year 2008-09 & 2009-10.
Year 20081) Amity Corporate
Excellence Award, 2008
For one of the best and the most
admired business
Amity International
Business
20th
February, 2008
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organizations for its unparallel
performance.
School
Year 20071) 3rd National Award for
Excellence in Cost Management - 2006
for the manufacturing unit in the Public
sector.
For efficient management in cost
works of the manufacturing unit.
Institute of Cost & Works Accountants
of India (ICWAI).
2nd July, 2007.
2) National Energy Conservation Award - 2007 : Second Prize in the Chlor-Alkali
Sector
For consistent performance on
energy conservation.
Bureau of Energy
Efficiency (BEE),Min. of Power, Govt.
of India
14 December
2007
Year 20062.) AIOE Industrial
Relations Award 2005-2006
Corporate initiative in the field of industrial
relations, social security and
promoting Bi-partism
All India Organization of Employers
05 January 2007
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3.) Safety Innovation Award -2006
In the field of Safety Excellence
Institute of Engineers, New Delhi
06 September
20064.) Indian Society for
Training & Development (ISTD) Certificate of merit
2005-06
For Innovative Training Practices: 2005-06 National
Level
Indian Society for Training & Development (ISTD), New
Delhi
01 July 2006
5.) SCOPE Meritorious Award 2004-05
In the field of Good Corporate
Governance
Standing Conference of
Public Enterprises (SCOPE),
Delhi
26 June 2006
6.) TERI's Certificate of Appreciation for Environmental
Excellence award – 2005
For case study of Recovery of Calcium Chloride project at
Dahej which uses the waste effluent to
make useful product reducing pollution in
sea.
TERI - The Energy & Resources
Institute, New Delhi
26 June 2006
7.) Greentech Safety Silver Award 2006
Safety Excellence at Dahej Complex
Greentech. Foundation, New Delhi
08 April 2006
8.) Greentech Safety Gold Award 2006
Safety Excellence at Vadodara Complex
Greentech. Foundation, New Delhi
08 April 2006
9.) FGI (Federation of Gujarat) award for
Excellence in Environment – 2005
(Dahej)
For Environment Preservation &
Pollution Control at Dahej Complex
FGI (Federation of
Gujarat), Vadodara
03 April 2006
10.)
IMC Ramakrishna Bajaj National Quality
Certificate of Merit 2005 Award in Manufacturing
Category at National level
For Quality Management
Systems adopted at GACL (as per quality
criteria of management
systems of Malcolm Bald ridge, (USA)
Indian Merchants' Chamber, Mumbai
06 March 2006
11.)
Appreciation Prize for the case study on
"Economics of Quality"
For "Economics of Quality" for the
systems at GACL
Quality Council of
India, Ministry of Commerce & Industry,
Govt. of India
03 March 2006
12.)
Jamnalal Bajaj Uchit Vyavahar Puraskar
2005
For Fair & Ethical Business Practices
Council for Fair Business
Practices (CFBP), Mumbai
24 February
2006
13.)
Recognition by ICSI (Institute of Company Secretaries of India) considering GACL in
the list of Top 25 Companies for the
year 2005
For National Excellence in
compliance of law, ethics and best management
practices in the field of Corporate Governance
Institute of Company
Secretaries of India (ICSI), New Delhi
13 January 2006
Year 2005
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14.)
First Prize Winner In Category - C for
Chemical Process Industries for " House
Keeping "
House Keeping Baroda Productivity
Council, Vadodara
28 December
2005
15.)
Certificates of Appreciation & Honor
for Safety Performance (Vadodara) &
Certificate of Honor (Dahej)
Safety Performance Gujarat Safety Council & Factory
Inspectorate, Govt. of Gujarat
16 December
2005
16.)
National Energy Conservation Award 2005: National Level (Chlor-Alkali Sector) 1st prize (Vadodara Complex) & Merit Certificate (Dahej
Complex)
Energy Conservation at Vadodara Complex
Bureau of Energy
Efficiency (BEE),Min. of Power, Govt.
of India
14 December 2005 by His Excellency
the President of India.
17.)
IMEA-2005 Award India Manufacturing Excellence Award for
Housekeeping & Effective Deployment
of QMS
Excellence in Housekeeping &
Effective Deployment of QMS
Frost & Sullivan,
Mumbai,(USA based
organization)
09 December
2005
18.)
Green Tech Environment
Excellence Award - 2004-05 (Silver)
Environment Excellence at
Vadodara Complex
Greentech Foundation, New Delhi
22 October 2005
19.)
Green Tech Environment
Excellence Award - 2004-05 (Gold)
Environment Excellence at Dahej
Complex
Greentech Foundation, New Delhi
22 October 2005
20.)
AMA-Metro chem. Outstanding Manager
of the Year Award 2005 (Declared for
MD, GACL)
Outstanding Manager of the Year
AMA (Ahmadabad Management) Association)- Metro chem., Ahmadabad
17 July 2005
21.)
Greentech Safety Excellence (Silver)
Safety Excellence at Dahej Complex
Greentech Foundation,
12 May 2005
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New Delhi22.)
Greentech Safety Excellence (Gold)
Safety Excellence at Vadodara Complex
Greentech Foundation, New Delhi
12 May 2005
23.)
Merit Award for ICWAI (Vadodara)
National Merit Award for Excellence in Cost Management - 2004
Institute of Cost & Works Accountants
of India (ICWAI)
12 March 2005
24.)
Certificate of Appreciation for
Safety Performance
Safety Performance at Vadodara Complex
Gujarat Safety Council & Factory
Inspectorate, Govt. of Gujarat
18 January 2005
25.)
Certificate of Honor for Safety
Performance
Safety Performance at Dahej Complex
Gujarat Safety Council & Factory
Inspectorate, Govt. of Gujarat
18 January 2005
Year 200426.)
National Energy Conservation Award
2004 1st prize (Chlor-Alkali Sector)
Energy Conservation at Dahej Complex
Bureau of Energy
Efficiency (BEE),Min. of Power, Govt.
of India
14 December
2004 awarded by
Hon'ble Prime
Minister of India
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27.)
Greentech Environment
Excellence (Silver)
Environment Excellence at
Vadodara Complex
Greentech Foundation, New Delhi
04 November
200428.)
Greentech Environment
Excellence (Gold)
Environment Excellence at Dahej
Complex
Greentech Foundation, New Delhi
04 November
200429.)
Greentech Safety Excellence Award
(Silver)
Safety Excellence at Dahej Complex
Greentech Foundation, New Delhi
21 June 2004
30.)
Dr. H.C. Srivastava Memorial Award 2003
Developing Eco-Friendly cold
bleaching process using Hydrogen
Peroxide of GACL for Hand Processing Sector of Textile
industry
ATIRA: Ahmadabad
26 February 2004 at National
Conference of Textile Research
Association, Mumbai
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CORPORATE PROFILE
GACL is a forward-looking company, set up in the year 1973. 30 years is a long time. Long enough to test the character of any organization. Be it recession, inflation, increased competition or changing governments, we've lived it all. And for sure, all the turbulences have made GACL a stronger and a progressive company. Our stern resolve to manufacture quality chemicals and trek customer satisfaction to a new height has yielded unbelievable results.
From an initial capacity of 37,425 TPA Caustic Soda, GACL have grown to be the largest producer in India, with a capacity of 3, 58,760 TPA. Spread over 2 complexes at Vadodara and Dahej.
Knowing that the time ahead may prop-up newer hurdles, GACL has already started to diversify and expand its existing infrastructure to consolidate its supremacy in Chlor-Alkali and other integrated downstream products.
World Class Technology :
Technology moulds generations. GACL’s endeavor to continually upgrade technology has allowed GACL to optimize resources, thus bringing down the cost of production and increasing revenues. Acquired through the best and prestigious collaborations means that they meet international specifications for our products. Besides, GACL’s manufacturing plants are eco-friendly, which ensure that the environment is well looked after.
The location of both the plants 'Vadodara' and 'Dahej' has
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dual advantage of proximity to the raw material suppliers and the end users.
While the capacity utilization is about 70% in the Caustic Soda Industry, GACL's plants are working at almost 100% capacity.... thereby utilizing the assets to the fullest extent.
Self-Reliance:
Various factors that influence the success of any corporation, the self-sufficiency ranks the foremost. We at GACL understand this all too well. Power, being a major input to the electrolytic Caustic Soda process, we promoted a joint captive power plant, Gujarat Industries Power Company Limited to meet our energy requirements for Vadodara Complex. Our complex at Dahej is also integrated with a captive co-generation plant of capacity of 90 MW.
Cost effective natural gas was substituted as fuel in place of Naphtha for Captive Power Plant. The plant load factor has increased and surplus power is supplied to State grid. This has helped achieve economies of operations.
Green all the way:
Nature bestows human race with umpteen benefits. Clean air, Lush green trees, GACL's commitment towards the environment is undying. Safe and unadulterated nature is high on our list of priorities; we are an organization with Green Attitude.
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A dedicated senior executive heads a Safety and Environment Department to maintain high standards of safety and a harmonious relationship between environment and technology. The company has planted more than 1, 00,000 plants and it keeps maintaining the same. With tree plantation being a regular feature, it plants 1000 sapling every year.
As a matter of strategy, the company has placed sensors at strategic locations in and around the complex to monitor ambient air quality.
For disposal of solid waste, GACL has secured dedicated landfill site conforming to the hazardous Waste Management Act. Being a member of Effluent Channel Project, it releases its liquid effluent in this channel and adheres to the necessary parameters of the Gujarat Pollution Control Board before discharging it into the channel.
People: Our Valued Assets :
World-class technology and self-reliance are baseless without brains that work ardently to produce high quality chemicals. People are our real assets, whom we nurture and harness to get the very best out of them.
Our conviction is:
People make the organization. A sense of belonging is a must for dedication and
loyalty. Employees give their best when the company cares for
them.
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Excellent labour relationship helped the company in achieving very high manpower production turnover per employee per annum. This is also a result of a thin and lean workforce, which is lead by the professional management.
Spreading Our Wings:
The unshakeable desire to deliver quality products to our customers means that our products are well accepted, both in India and the world over. Domestic customers are assured of prompt delivery of quality products at their doorsteps through our well-established network of dealers and consignment stockiest. Overseas customers are serviced directly or through agents.
Caustic-Chlorine being its prime product, the company has diversified into value added products like Sodium Cyanide, Chloromethane, Hydrogen Peroxide, Potassium Carbonate, Phosphoric Acid, etc. These value added products provide dual benefit to the organization by hedging against cyclical fluctuations in the Chlor-Alkali Industry. GACL sells 26 products today, maintaining its leadership in Caustic-Chlorine industry with 18% market share and has emerged as a major player in the segment of value added products.
VISION, MISSION &
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GROWTH STRATEGY
VISION
To continue to be identified & recognized as dynamic, modem & ecofriendly chemicals company with enduring ethics & values.
MISSION
To manage our business responsibility & sensitivity in order to address the needs of our customers & stakeholders.
To strive for continuous improvement performance, measuring results precisely & ensuring GACL's growth & profitability through innovations.
To demand from ourselves & others the highest ethical standards and to ensure products & processes to be of the highest quality.
GROWTH STRATEGY
To remain the largest producer. To maintain highest quality & be the first choice of
customer. To have downstream value added products & product mix
for better margins. To ultimate good to remain leader in the Chlor alkalis.
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DEPARTMENTS AT GACL
1)Technical Department:
Development DepartmentProduction DepartmentEngineering DepartmentQuality Control DepartmentSafety & Environmental Department
2)Non- Technical Department:
Marketing DepartmentPurchase DepartmentExport DepartmentDispatch DepartmentFinance DepartmentHR DepartmentPersonnel DepartmentSecurity DepartmentAdministration DepartmentTime Keeping DepartmentSecretary DepartmentMS Department (Management System)
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ORGANISATION STRUCTURE
Mm
GM(HR&A)
CS&GM(Legal)
GM(MM)&CIO
CFO Sr. ED(Commercial)
Sr. ED(Tech.)
DGM(MM)
CGM &CMO
Addnl. GM(Mktg.)
CM(Engg.
Service)
MD
CM (MS)
GM(Operatio
ns)
GM(Engg.
Service)
CM(Security & Vigilance)
GM(Operations)
ED(Ranoli)
ED(Dahej)
ED(CPP)
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PRODUCTS OF GACL
As per the classification and the differentiation of the products, the products are classified in to SEVEN (7) different Groups.
The Groups are Listed and described as below.
1) Caustic Soda Group
Caustic Soda Flakes (NaOH)
Caustic Soda Lye
Caustic Soda Pills
Sodium hypo chloride (NaOCl)
Liquid Chlorine (Cl2)
Compressed hydrogen Gas (H2)
Hydrochloric Acid (HCl)
2) Caustic Potash Group
Caustic Potash Flakes (KOH)
Caustic Potash Lye
Potassium Carbonate
3) Chloromethane Group
Methyl Chloride (CH3Cl)
Methylene Chloride (CH2Cl2)
Carbon Tetrachloride (CCl3)
Chloroform (CHCl3)
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4) Sodium Group
Sodium Cyanide (NaCN)
Sodium Ferro cyanide [Na4Fe(CN)6 :10H2O]
5) Phosphoric Acid Group
Phosphoric Acid (H3PO4)
Calcium Chloride Flakes (CaCl2)
Calcium Chloride Powder
6) Hydrogen Peroxide Group
Hydrogen Peroxide (H2O2)
Bleach win
7) Other products
Dilute Sulphuric Acid (H2SO4)
Scale win (Water treatment chemical)
Aluminum Chloride Anhydrous (AlCl3)
Poly Aluminum Chloride (The New Product)
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MILESTONES OF GACL
Government of Gujarat promoted GACL in 1973. It's first Caustic Soda, Liquid Chlorine and Hydrochloric Acid Plants went on stream in 1976.
Year
Achievements
1982 Commissioned Sodium Cyanide plant with a capacity of 2000 TPA.
1986GACL went in for a diversification project to manufacture
Chloromethane.1987 Commissioned Caustic Soda Flaking unit with a capacity of 26400 TPA
1989First revamp to energy efficient and environment friendly Membrane
Cell technology.
1992 Commissioned Sodium Ferro cyanide plant (100 TPA) based on in-house Research & Development.
1994
Converted balance manufacturing facilities to Membrane Cell & expanded its Caustic Soda capacity to 153500 TPA.
Expanded caustic flaking unit to 53000 TPA.
Commissioned caustic potash plant with a capacity of 16500 TPA.
1995 First certification IS/ISO 9002:1994.
Phosphoric Acid Plant started production at Dahej.
1996 Hydrogen Peroxide plant commissioned.
1998 Commissioning of 300 TPD of Caustic Soda & 90 MW power plants at Dahej.
2000 Commissioning of Caustic Potash/Flakes, Vadodara.
2001 Increase in H2O2 Capacity to 12540 MTA.
2003 Up gradation of ISO Certificate from 9002:1994 to 9001:2000.
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2004
ISO 14001:1996 Certificate for Vadodara Complex and Dahej Complex.
Commissioning of Calcium Chloride plant at Dahej.
2005 ISO 18001:2000 Certificate for Vadodara Complex and Dahej Complex.
2006 Commissioning of Poly Aluminum Chloride Plant at Dahej Complex
2007
Commissioning of Poly Aluminum Chloride at Vadodra with same capacity.
Commissioning of Hydrogen Peroxide at Dahej with capacity of 12540 TPA.
Commissioning of Anhydrous Aluminum chloride with capacity of 16500 TPA.
2008 Commissioning of wind power project at Moti Sindhodi, Kutch with 23.75 MW (1.25MW*19Nos.) rs 122.02 crores.
2009
Commissioning of second phase wind mill project of 39 MW at Gandhidham started on 12.01.2009. In the month of February 2009 all
WTG have been commissioned.RA-10 commissioned in the month of October in MC-2 2009
Dr. M filter commissioned on 20.11.2009.G-5B electrolysers(E-1,2,8 and partly 7) are commissioned on 15.12.2009
One more electrolysers commissioned for 50 TPD production of CSL stated at Dahej CSL plant.
2010 21 MW wind mill project commissioned on 22.03.2010.
2011 25 TPD CaCL2 plant at sodium Cyanide complex of Baroda has been commissioned on 20.01.2011.
2011 25 TPD stable Bleaching powder plant at Dahej is commissioned on 2nd
march 2011.
2011 42 TPD Hydrogen Peroxide plant (phase-2) is commissioned.At Dahej on 27.06.2011
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MANPOWER STRENGTH
Manpower is the real strength of any organization & that is
so in GACL also. The total manpower strength at GACL
includes both management & Non- Management Category.
As on 31/5/2011 details Ranoli Dahej Total
Management 424 218 831
Non Management 366 465 831
Trainee Management 7 2 9
Trainee Non Management 21 10 31
Contractual Management 6 2 8
Contractual Non Management 44 34 78
Apprentice Management 10 11 21
Apprentice Non Management 56 41 97
Total 934 783 1717
Thus, the total manpower strength at GACL
has 1717 employees
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POLICIES AT GACL
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31
32
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OVERVIEW OF CLM PLANT
SECTION 100
(THERMAL CHLORINATION)
Thermal chlorination of methane is carried out in four
cylindrical reactors simultaneously.
Gases like methane, chlorine, nitrogen, recycle gases are
passed in these cylinders.
There are basic four reactions involved in production of
chloromethane by thermal chlorination of methane gas.
CH4+CL2 = CH3CL+HCL
CH3CL+CL2=CH2CL2+HCL
CH2CL2+CL2=CHCL3+HCL
CHCL3+CL2=CCL4+HCL
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SECTION 300-400
(HCL ABSORPTION AND DEHUMIDIFICATION)
The product mixture coming from section 100 contains HCL along
with product which must be removed as it is highly corrosive in nature, so
if there is HCL along with product it would be difficult to handle the
process fluid. This product mixture enters in to six columns & where in
HCL is removed by the process of absorption, there after another
processes are carried out in these columns like de-acidification,
neutralization, dehumidification & drying is carried out. Dehumidification &
Drying columns are provided to get moisture level in the product gas
mixture below 50 ppm.
SECTION 500
(COMPRESSION AND LIQUIFICATION)
The process gas from last column is taken to section 500 where
the gas is being compressed & cooled so that the product will liquefy
under these conditions.
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SECTION 800
(DISTILLATION)
In this section the liquefied & pressurized mixture is taken for
distillation to get pure product. There are total ten columns
provided to separate four products from impurities. First two are
provided for Cl separation, then two for C2, three for C3 & last
three for C4 separation from low boilers & other impurities.
Cl-Methyl Chloride
C2 - Methylene Chloride
C3 - Chloroform
C4 - Carbon Tetra Chloride
SECTION 200
(PHOTOCHLORINATION)
This section is provided to raise the higher derivatives of
methane as a product keeping market demand in mind, feed for
photo chlorination can be adjusted in such a way that either
production of C29 C3 & C4 can be optimized as per market
requirement.
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SECTION 700
(CRUDE PRODUCTION HANDLING)
Crude product from almost each section is dumped in
TK-701 tank plus HCL formed in liquid phase is also dumped in
this tank. Product after purification in this section is taken to 800
sections for distillation.
SECTION 900
(PRODUCT HANDLING AND STORAGE)
Product handling & storage is the last section of CLM
plant. As all four products have their properties differing from
each other so their storage conditions are also different.
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CLASSIFICATION OF PUMPS
Pumps are classified o n the basis of the
principle by which the energy is added to the fluid
and their design feature.
PUMPS
(1) Dynamic Pressure (2) Positive Displacement
Pumps Pumps
a) Centrifugal pump (a) Reciprocating pumpb)Turbine pump (b) Rotary pumpc) Propeller pump
CENTRIFUGAL PUMP
(PRINCIPLE OF OPERATION)
The centrifugal pump works on the principle of forced vortex flow which means the certain mass of
liquid rotated by an external torque. The rise in pressure head of the rotating liquid takes place.
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MAIN COMPONENTS OF C.P.
The main components of C.P. are shown in
figure,
The main components are....
(1) Casing
(2) Impeller
(3) Wear-Ring
(4) Shaft
(5) Shaft-sleeve
(6) Bearing
(7) Bearing Frame
(8) Breather
(9) Cir-Clip
(10) Seals etc....
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42
Wear Rings Pump Case Shaft Sealing Shaft Bearing Bracket
Front and back renewable wear rings arc furnished in order to
achieve the best pump performance and ease the
maintenance
The pump case is of rigid design with a generous wall thickness, giving good protection against
erosion and corrosion
SCP pumps can be fitted with most scaling arrangements;
- Soft packing
The heavy duty console with incorporated assure silent and
reliable operation
Front and back renewable fully endorsed. Single-piece casting gives reliability, long trouble-free operation and high efficiency
For high temperature applications (90-160 C) an arrangement foot hot water is provided. This modification includes a cooling chamber for introduction of the cooling medium
■ Vertical arrangement is mainly used in systems for water-supply, miming, civil engineering, waste water applications, irrigation systems etc.
Ample dimensioned single and double row ball bearings improve
the stiffness and infinite shaft deflection
STCP
VSCP
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The shaft is protected by a replaceable shaft sleeve stainless sled
CENTRIFUGAL PUMP PARTS
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(1)CASING
The basic function of casing is to provide support to the
components. The casing has to contain the impeller attached to
the shaft and allow them to rotate smoothly inside thus activating
the process. The casing is usually made of C.I. because it has
excellent cast ability coupled with machine ability and low cost.
The following three types of casing are used for general
purpose:-
Volute casingVortex casing,Casing with guide blades.
(2) IMPELLER
The impeller is rotating device in the pump that draws
and delivers out the fluid in a specified direction under pressure .
There are two types of impellers.
Linear Axial Impeller
Francis Impeller
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(3)WEAR RINGS
Wear rings are attachment given to soft areas to prevent
erosion and wear. These are made of hard and wear resistant
materials. Wear rings provide an easy and economically
replaceable leakage proof Joint between impeller and casing.
(4)SHAFT
The basic function of shaft is to transmit the torque
or power.
(5)THE SHAFT SLEEVE
The shaft sleeve covers the shaft tightly and protects it
from corrosion erosion and wear , it must have a close tolerance
in order to have a close running fit. It should have the same
thermal expansion similar to the shaft material have. A sleeve
material used in G.A.C.L. is S
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SFA LS AND STUFFING B
The seal blocks the fluid that is being circulated through
casing from escaping to rear Part of the pump through the
contact between shaft and casing. There are two types of seal:-
Mechanical Type Seal.Packing Type Seal.
BEARINGS
The main function of the bearing is to support the
rotating assembly by taking load and guide the shaft in order to
avoid the vibrations. The most common bearing is ball bearing.
Bearings are usually made of A1SI -52100 STEEL.
BEARING FRAME
The bearing frame is usually made of steel. For absolute
corrosion resistance and good appearance stainless steel
housing or frame can be used.
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CIR CLIP & STAR LOCK WASHER
Cir clip & Star lock Washer is provided for locking the Bearing.
PREATHER
To provide inlet & outlet of air for bearing frame.
VARIOUS TERMS DEFINITIONS
USED FOR C.P.
SUCTION HEAD
It is the vertical height of the centerline of the c.p. above the
liquid surface in the tank of pump from which the liquid is to be
lifted.
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The vertical distance between the centre line of the pump and
the liquid surface of the tank to which liquid is to be delivered is
known is delivery head.
STATIC HEAD
It is the sum of suction head and delivery head
MANOMATRIC HEAD
The manomatric head is defined against which a C.P. has to
work.
PRIMING
Priming of a c.p. is defined as the operation in which the
suction pipe casing of the pump and a portion of delivery pipe
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up to delivery valve is completely filled up from out-side source
with the liquid to be raised by the pump before starting a pump.
By this way the air from those parts of pump will be removed
and these parts are filled with the liquid to be pumped.
CAVITATION
Cavitation is defined as the phenomena of formation of vapour
bubbles of flowing liquid in a region where the pressure of liquid
falls below its vapour pressure and sudden collapsing of these
vapour bubbles in a region of higher pressure.
The metallic surface above which these vapour bubbles
collapse is subjected to the high pressure which cause pitting
thus cavities is formed on the metallic surface and also
considerable noise and vibration is produced due to the
cavitation, the efficiency of C.P. is decreased.
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PREAUTIONS FOR CAVITATION
The following precautions should be taken against cavitation….
The pressure of the flowing liquid in any part of the
hydraulic system should not allow falling below its vapour
pressure.
The special materials or coatings such as
Aluminum-bronze and stainless steel which are cavitation
resistant should be used
CAVITATION IN C.P.
In C.P. the cavitation may occur at the inlet of the Impeller of
the Pump or at the suction of the Pump where the pressure is
considerably reduced.
The cavitation in a pump can be noted by a sudden drop of
efficiency and head.
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NET POSITIVE SUCTION HEAD
The term NPSH is very commonly used in
the pump Industry. Actually the minimum suction
conditions are more frequently specified in terms
of NPSH.
NPSH means the total head required to
make the liquid flow through the suction pipe to
the pump impeller.
USES OF THIS TYPE OF PUMPS IN GACL
For handling alkaline fluids,
For anti corrosive application,
For handling HCL
RECIPROCATING PUMP
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In reciprocating pump liquid is drawn
through an Inlet check valve into the
cylinder by the withdrawal of piston &
forced out of discharge check valve on
the return stroke. They are also called
piston pumps, plunger pumps &
diaphragm pump.
MAIN PARTS
Piston
Piston rod
Bearing frame
Mechanical seal
Grand inlet
Coupling
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Outlet valve
Connecting rod
Crankshaft
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-
Most of piston pumps are double acting. Two or more cylinders are used in parallel with common Suction & discharge headers adjusted
to minimize the fluctuation in discharge rate.It is independent of the speed with normal operating limits &
decreases slightly with increase in discharge pressure because of added friction & leakage.
USES OF THIS TYPE OF PUMP
For brine separation,
For chemical dosing in boiler feed pump.
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COMPRESSORS
RECIPROCATING COMPRESSOR
CENTRIFUGAL COMPRESSOR
SCREW COMPRESSOR
RECIPROCATING COMPRESSOR
There are 14 reciprocating
compressors of different kinds in C.L.M
plant of G.A.C.L.
There are 8 RG compressors, 4
Instrument air compressors and 2
Nitrogen compressors we find in C.L.M
plant.
Main parts used in reciprocating
compressor are piston, piston rod, cross
head, crank shaft, connecting rod,
cylinders, flywheel, Intercooler, after
cooler, pulley, motor, suction valve,
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discharge valve, etc.
In reciprocating air compressor, air is
compressed by the movement of the piston
in the cylinder. Piston is reciprocated by
flywheel and crank shaft. The rotary motion
of flywheel and crank shaft is transferred to
reciprocating motion of piston by crosshead.
Piston rod moves the piston in the cylinder
and compresses the air in the cylinder.
In G.A.CL the
reciprocati
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ng compressors are two stage compressors. In
two stage compressors two cylinders are used.
L.P. cylinders are larger in volume than H.P.
Cylinders. In two stage compressors the gases
first compressed into L.P. Cylinder and after that
it is cooled in intercooler. Intercooler cools the
gases to the temperature which is equivalent to
the temperature desired at the suction side of
the H.P. cylinder. If the gases are not cooled than
in the second stage the temperature of the gases
will so high that it can damage the compressor.
After the gases cooled in intercooler, it is entered
in H.P. cylinder and it compressed to desired
pressure.
Reciprocating Compressors are also of two types:
Lubricating and Non-lubricating compressors.
In non-lubricating compressors the parts
are lubricated accept piston and piston ring. In
non-lubricating compressor the Non lubricating
parts are made of Carbon Filled Teflon (CFT). Non
Lubricating parts are used to avoid
contamination of lubricating oil with Process Gas.
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V-TYPE COMPRESSOR
V-type compressor is special type of
reciprocating compressor. Its L.P. and H.P.
cylinders which form V shape. In v- type
compressor the compression of nature gas take
place, it is a two stage double acting and non
lubricating compressor. In v type compressor at
the suction side of L.P. cylinder natural gas
enters and compressed and its temperature and
pressure increases, after that the compressed
natural gas enters intercooler and its
temperature is reduced.
Then low temperature compressed natural gas
enters into the H.P. cylinder and is compressed
to desired pressure. Then highly compressed
natural gas enters into the after cooler and cools
down and fed to the process.
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CENTRIFUGAL COMPRESSOR
In centrifugal compressor, centrifugal force is
exerted over the fluid. Here energy is transferred
by dynamic means from the rotating impeller.
When the impeller rotates at high speed, suction
is created at the impeller eye and air is drawn
from the accelerating nozzle. Due to this the
velocity of air is increased and the pressure,
temperature is decreased.
CENTRIFUGAL COMPRESSOR
Air Thrown at
rim of impeller
Housing
Air out
ImpellerAir enters
in a center
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The diffuser is provided with impeller.Diffuser converts velocity of air into pressure and
the air is compressed, Impeller is used to increase the energy of the fluid by whirling it
outwards and increasing the angular momentum of the fluid.
In G.A.C.L. these compressors are used at Hydrogen Peroxide unit. In H202 plant, two stageCentrifugal compressors are used to compress the air.
In this inter cooling is done by the cooling water which surrounds the tubes through which
compressed air is passed.
SCREW COMPRESSOR
Screw compressor is positive displacement type
compressor. In screw compressor the
compression is accomplished by the enmeshing
two matins helical grooved rotors which are
housed in a cylinder.
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FIG: SCREW COMPRESSOR
The male rotor is usually a driving
element with series of grooves along the length
of the rotor. Male rotor grooves mesh with
similarly formed helical flutes on the female
rotor which is usually driven element.
The entrapped gas is compressed as it
passes through the two rotors. Here a narrowing
Passage is formed as the gas will pass through
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the gap of two rotors. The gas is passed due to
rotating motion of the two rotors. The gases will
be passed due to rotating motion of rotors and
will be discharged at outlet. Gas will come from
the bottom of the screw compressor and it will
get compressed between the two rotors.
VALVES
At G.A.C.L various plants contain thousands
of valves of different size and shapes with variety
of designs. Basically all valves serve a common
purpose to slow down or to stop the flow of the
fluid. Other types of valves are designed to
throttle or to reduce the pressure and the flow
rate of the fluid.
They will permit flow In One direction only
under certain condition of temperature and
pressure. This is done by placing an obstruction
that can be moved along inside with little or no
leakage of the fluid.
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Various types of valves used in G.A.C.L are....
Sate valve
Ball valve
Butterfly valve
Globe valve
Check valve
N.R.V valve
Gate valve
Needle valve
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BLOWERS
Various types of blowers used in GACL are
Centrifugal blower
Lobe blower.
BOILERS
In G.A.C.L. mainly gas fired boilers are used for the purpose of steam
production. This steam is used in various plants of G.A.C.L. in CLM plant it is used
in distillation tower.
COOLING TOWERS
In G.A.C.L. there are 5 cooling towers, all are induced draft cross flow and having different cooling capacities. There are
baffles provided for better contact between cold air & hot water. Cold water is collected in tank at the base of tower
& from there it is sent to cooling systems through pump.
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