B.Tech Mech Engg., University of Kerala
CHAPTER 1
INTRODUCTION
The industrial revolution led to the development of factories for large-scale
production, with consequent changes in society. Originally the factories were steam-powered,
but later transitioned to electricity once an electrical grid was developed. The mechanized
assembly line was introduced to assemble parts in a repeatable fashion, with individual
workers performing specific steps during the process. This led to significant increases in
efficiency, lowering the cost of the end process. Later automation was increasingly used to
replace human operators. This process has accelerated with the development of the computer
and the robot.
Industry in the sense of manufacturing became a key sector of production and labour
in European and North American countries during the Industrial Revolution, which upset
previous mercantile and feudal economies through many successive rapid advances in
technology, such as the steel and coal production. It is aided by technological advances, and
has continued to develop into new types and sectors to this day. Industrial countries then
assumed a capitalist economic policy. Railroads and steam-powered ships began speedily
establishing links with previously unreachable world markets, enabling private companies to
develop to then-unheard of size and wealth. Following the Industrial Revolution, perhaps a
third of the world's economic output is derived from manufacturing industries—more than
agriculture's share.
There are many other different kinds of industries, and often organized into different
classes or sectors by a variety of industrial classifications.
Industry classification systems used by the government commonly divide industry
into three sectors: agriculture, manufacturing, and services. The primary sector of industry is
agriculture, mining and raw material extraction. The secondary sector of industry is
manufacturing. The tertiary sector of industry is service production. Sometimes, one talks
about a quaternary sector of industry, consisting of intellectual services such as research and
development (R&D).
Industrial visit is a part of the engineering course, during which students visit
companies and get insight of on the internal working environment of the company. The
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industrial visit also provides an insight on how companies work and also useful information
related to the practical aspects of the course which cannot be visualized in lectures. The
students get the opportunity to see the mechanisms which are used in the present day
industries by these kinds of field visits
As a part of our curriculum we visited 3 industries and undergo an inplant training on
an industrial plant. The factories visited are
Hindustan Machine Tools Limited, Kalamassery unit
The Fertilisers And Chemicals Travancore Limited, Udyogamandal
Travancore Titanium products Ltd, Thiruvananthapuram
The inplant training is done in Travancore Cochin Chemicals, Kochi
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CHAPTER 2
HMT Ltd, KALAMASSERY
2.1. HMT (India)
HMT, formerly Hindustan Machine Tools, is a state-owned manufacturing company
under the Ministry of Heavy Industries and Public Enterprises in India
Hindustan Machine Tools was incorporated in 1953 by the Government of India as a
machine tool manufacturing company, in 1977 it become a public limited company under the
name HMT Ltd. Over the years diversified into watches, tractors, printing machinery, metal
forming presses, die casting & plastic processing machinery, CNC systems & bearings. HMT
is headquartered at Bengaluru (Bangalore). Successful technology absorption in all product
groups through collaborations with world renowned manufacturers and further strengthened
by continuous in-house R&D. Today, HMT comprises six subsidiaries under the ambit of a
holding company, which also manages the tractors business directly.
HMT Limited took over Praga Tools Limited as one of its subsidiaries 1988. Praga
Tools Limited was established in May, 1943 as Praga Tools Corporation Limited to
manufacture machine tools with its head quarters at Secunderabad. It was renamed as Praga
Tools Limited in 1963. It is mainly involved in manufacture of machine tools including CNC
machines.
HMT Limited has 18 manufacturing units. The constituent subsidiaries are given
below while the holding company retains the tractors business group.
HMT’s tractor business commenced its operations in 1971 in technical collaboration
with M/s MOTOKOV, Czechoslovakia. HMT started the operation with the manufacture of
25 HP tractors at the manufacturing plant in Pinjore, Haryana state. Over the years, it has
developed tractors ranging from 25 HP to 75 HP.
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The five subsidiaries namely
HMT Machine Tools Ltd
HMT Watches Ltd
HMT Chinar Watches Ltd
HMT (International) Ltd
HMT Bearings Ltd
2.2. HMT Ltd, KALAMESSERY UNIT
The HMT Ltd installed their 4th unit in kalamassery in the year 1964. The HMT Ltd,
kalamassery unit consist of two operating divisions. They are the printing machine division
and the Machine tools division. We visited the machine tool division. The facility was
installed with the foreign collaboration of Societa Nebiolo, Turin, Italy. As years passed the
HMT Ltd, kalamassery unit has grown in to a state of art facility with features like
Online material management system
Production monitoring system
Fully fledged Design Dept with cad facilities
High tech tool room
Heat treatment plant
Foundry of annual capacity 2500 MT
Wide variety of CNC machines
HMT Ltd, kalamassery uses best application engineering with a capacity of handling
products up to 10 tons.
2.3. MAJOR FACILITIES INSIDE HMT Ltd, KALAMASSERY
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We visited the HMT Ltd, kalamassery unit’s Machine tool facility. The facility consist of
various machining equipments. We studied the working of the various machining
equipments. The HMT Ltd, kalamessry build machine that can weight upto 10 tonnes. The
various machines we saw in the unit are
Pattern making: - this facility is used by the HMT itself. In this facility the pattern of
the various machine tools are created. The HMT have a foundry and the machine tools are
molded in the foundry. The design of the tools is made in this pattern making facility. The
patterns are then transferred to the foundry and molding is done. The patterns are made of
clay. The property of the clay is improved by adding additives. The single pattern consist of
a number of tools because the size of the tools are small then is is easy that way. If the size is
very large the single mod patterns are used
Foundry: - It is a factory that produces metal castings. Metals are cast into shapes by
melting them into a liquid, pouring the metal in a mold, and removing the mold material or
casting after the metal has solidified as it cools. In metalworking, casting involves pouring
liquid metal into a mold, which contains a hollow cavity of the desired shape, and then
allowing it to cool and solidify. The solidified part is also known as a casting, which is
ejected or broken out of the mold to complete the process. Casting is most often used for
making complex shapes that would be difficult or uneconomical to make by other methods.
Fabrication: - It refers to building metal structures by cutting, bending, and
assembling. The cutting part of fabrication is via sawing, shearing, or chiseling (all with
manual and powered variants); torching with handheld torches (such as oxy-fuel torches or
plasma torches); and via CNC cutters (using a laser, torch, or water jet). The bending is via
hammering (manual or powered) or via press brakes and similar tools. The assembling
(joining of the pieces) is via welding, binding with adhesives, riveting, threaded fasteners, or
even yet more bending in the form of a crimped seam. Structural steel and sheet metal are the
usual starting materials for fabrication, along with the welding wire, flux, and fasteners that
will join the cut pieces. As with other manufacturing processes, both human labor and
automation are commonly used. The product resulting from (the process of) fabrication may
be called a fabrication. Shops that specialize in this type of metal work are called fab shops.
The end products of other common types of metalworking, such as machining, metal
stamping, forging, and casting, may be similar in shape and function, but those processes are
not classified as fabrication.
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Conventional machining: - It is a form of subtractive manufacturing, in which a
collection of material-working processes utilizing power-driven machine tools, such as saws,
lathes, milling machines, and drill presses, are used with a sharp cutting tool to physically
remove material to achieve a desired geometry. Machining is a part of the manufacture of
many metal products, but it can also be used on materials such as wood, plastic, ceramic, and
composites. A person who specializes in machining is called a machinist. A room, building,
or company where machining is done is called a machine shop. Machining can be a business,
a hobby, or both. Much of modern day machining is carried out by computer numerical
control (CNC). Computers are used to control the movement and operation of mills, lathes,
and variety of other cutting machines.
Numerical control (NC): - It refers to the automation of machine tools that are
operated by abstractly programmed commands encoded on a storage medium, as opposed to
controlled manually via hand wheels or levers, or mechanically automated via cams alone.
The first NC machines were built in the 1940s and 1950s, based on existing tools that were
modified with motors that moved the controls to follow points fed into the system on
punched tape. These early servomechanisms were rapidly augmented with analog and digital
computers, creating the modern computer numerical control (CNC) machine tools that have
revolutionized the machining processes. In modern CNC systems, end-to-end component
design is highly automated using computer-aided design (CAD) and computer-aided
manufacturing (CAM) programs. The programs produce a computer file that is interpreted to
extract the commands needed to operate a particular machine via a postprocessor, and then
loaded into the CNC machines for production. Since any particular component might require
the use of a number of different tools-drills, saws, etc., modern machines often combine
multiple tools into a single "cell". In other cases, a number of different machines are used
with an external controller and human or robotic operators that move the component from
machine to machine. In either case, the complex series of steps needed to produce any part is
highly automated and produces a part that closely matches the original CAD design.
Lathe: - It is a machine tool which rotates the workpiece on its axis to perform various
operations such as cutting, sanding, knurling, drilling, or deformation with tools that are
applied to the workpiece to create an object which has symmetry about an axis of rotation.
Lathes are used in woodturning, metalworking, metal spinning, and glass-working. Lathes
can be used to shape pottery, the best-known design being the potter's wheel. Most suitably
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equipped metalworking lathes can also be used to produce most solids of revolution, plane
surfaces and screw threads or helices. Ornamental lathes can produce three-dimensional
solids of incredible complexity. The material can be held in place by either one or two
centers, at least one of which can be moved horizontally to accommodate varying material
lengths. Other work-holding methods include clamping the work about the axis of rotation
using a chuck, or to a faceplate, using clamps or dogs.
Milling machine: - It is a machine tool used to machine solid materials. Milling
machines are often classed in two basic forms, horizontal and vertical, which refers to the
orientation of the main spindle. Both types range in size from small, bench-mounted devices
to room-sized machines. Unlike a drill press, which holds the workpiece stationary as the drill
moves axially to penetrate the material, milling machines also move the workpiece radially
against the rotating milling cutter, which cuts on its sides as well as its tip? Work piece and
cutter movement are precisely controlled to less than 0.001 in (0.025 mm), usually by means
of precision ground slides and lead screws or analogous technology. Milling machines may
be manually operated, mechanically automated, or digitally automated via computer
numerical control. Milling machines can perform a vast number of operations, from simple
(e.g., slot and keyway cutting, planing, drilling) to complex (e.g., contouring, die sinking).
Cutting fluid is often pumped to the cutting site to cool and lubricate the cut and to wash
away the resulting swarf.
Grinding machine: - It is often shortened to grinder, is a machine tool used for
grinding, which is a type of machining using an abrasive wheel as the cutting tool. Each grain
of abrasive on the wheel's surface cuts a small chip from the workpiece via shear
deformation. Grinding is used to finish workpieces which must show high surface quality
(e.g., low surface roughness) and high accuracy of shape and dimension. As the accuracy in
dimensions in grinding is on the order of 0.000025mm, in most applications it tends to be a
finishing operation and removes comparatively little metal, about 0.25 to 0.50mm depth.
However, there are some roughing applications in which grinding removals high volumes of
metal quite rapidly. Thus grinding is a diverse field.
Planer: - It is a type of metalworking machine tool that uses linear relative motion
between the workpiece and a single-point cutting tool to machine a linear toolpath. Its cut is
analogous to that of a lathe, except that it is (archetypally) linear instead of helical. (Adding
axes of motion can yield helical toolpaths; see "Helical planing" below.) A planer is
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analogous to a shaper, but larger, and with the entire workpiece moving on a table beneath
the cutter, instead of the cutter riding a ram that moves above a stationary workpiece. The
table is moved back and forth on the bed beneath the cutting head either by mechanical
means, such as a rack and pinion drive or a lead screw, or by a hydraulic cylinder.
Heat treating: - It is a group of industrial and metalworking processes used to alter the
physical, and sometimes chemical, properties of a material. The most common application is
metallurgical. Heat treatments are also used in the manufacture of many other materials, such
as glass. Heat treatment involves the use of heating or chilling, normally to extreme
temperatures, to achieve a desired result such as hardening or softening of a material. Heat
treatment techniques include annealing, case hardening, precipitation strengthening,
tempering and quenching. It is noteworthy that while the term heat treatment applies only to
processes where the heating and cooling are done for the specific purpose of altering
properties intentionally, heating and cooling often occur incidentally during other
manufacturing processes such as hot forming or welding.
2.4. MAJOR PRODUCTS
The HMT Ltd Kalamassery produces a range of products. They have a strong market in
India as well as in the countries like UAE, Middle east, USA, and some African countries.
Their major products are,
Centre Lathes – NH
CNC Turning Machines – SB CNC 40/60, STC 20, STC 25, Stallion 100, Stallion
200, ECONO CNC 22/26
Sheetfed Offset Printing Machines – Single, Two, Four colour – SOM 125G, 125B,
125N, SOM 136, 136N, SOM 225, 225N, 236, SOM 425, 436
Programmable Guillotine (Paper Cutting Machine) PG 115
Reconditioning & Refurbishing
Shell Turning Lathe-SB CNC 60 4A 5M CD sub spindle
Flat Bed Lathes-CNC-AUTOMANN 26
Axle Turning Lathe AXLE TURN 40
2.5. MAJOR ACHEIVEMENTS
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1. First in the country to manufacture CNC Slant Bed Turning Center through in-house development
2. First in the country to develop flexible turning cells
3. Design, development, manufacture and commissioning of fully automated flexible turning system to manufacture heavy armor penetrator for Strategic Sector
4. Heavy duty CNC Turning Machines with gantry load/unload systems
Machines exported to Europe, America and Middle East Countries
CHAPTER 3
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THE FERTILISERS AND CHEMICALS TRAVANCORE LIMITED
FACT, a Government of India enterprise, has business interests in manufacturing and
marketing of fertilizers and caprolactum, engineering consultancy and fabrication of
equipments.
Units of FACT include the two manufacturing division, Udyogamandal complex
(UC) and Cochin division (CD), the consultancy unit FACT Engineering & Design
Organization (FEDO), the fabrication division FACT Engineering Works (FEW), and the
marketing division.
The company has also interests in petrochemicals, hydrometallurgy, chemicals and
pharmaceuticals.
3.1. UDYOGAMANDAL DIVISION
FACT commenced operation at Udyogamandal with the commissioning of 50,000
tons per annum Ammonium Sulphate Plant in 1947.
In the decades that followed multi stage expansion programs were undertaken
bringing in the latest technologies of the day which were quickly mastered and successfully
implemented. Today the division is a mostly mix of 35 year old small capacity plants and 2
year old state of the art technology plants.
The latest addition to this unit is 900 tons per day ammonia complex set up with an
investment of RS 642 corers. FACT Udyogamandal division is 14001 certified.
Udyogamandal Division
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3.2. COCHIN DIVISION
FACT Cochin Division has set up in the 1970's at Ambalamedu 30 km from
Udyogamandal and adjacent to the Cochin Refineries. Phase-I of the division saw the setting
up of an integrated Ammonia urea complex utilizing Indian Engineering skills. A large scale
complex fertilizer plant of 485,000 TPA was set up as phase-II of Cochin Division and
sulphuric acid and phosphoric acid plant of marketing capacity.
Cochin Division
3.3. PETROCHEMICAL DIVISION
FACT diversified into petrochemicals in 1990 with the production of caprolactam.
This versatile petrochemical is the raw material in the manufacture of nylone-6, which finds
extensive application in textiles, tyre cord and engineering products. Thanks to its high
quality the products have been acknowledge as among the best in the world.
The division is located adjacent to the Udyogamandal division. Co-product
ammonium sulphate is transferred for processing to the fertilizer plant of udyogamandal
division. Petrochemical Division is ISO 9002 and 14001 certified.
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3.4. CAPROLACTAM
FACT Petrochemical Division is one of the only two manufacturers of Caprolactam in
India. For FACT customer satisfaction through excellence in quality of products and services
comes first. This is why we have strictly adhered to documented quality systems. In February
1996, FACT Petrochemical Division was certified to ISO 9002 (1994) and ISO 14001
(1996). This prestigious certification was conferred by RWTUV, the reputed German Quality
Audit firm.
FACT Caprolactam plant was built with licence and know-how from the world
leaders in Caprolactam technology - M/s Stamicarbon, the engineering subsidiary of DSM of
Netherlands. Sourcing of technology from a single source ensured unified package and
excellent consistent quality right from the time of commissioning. Detailed engineering of the
plant was undertaken by Chiyoda Corporation of Japan in association with FACT
Engineering and Design Organisation (FEDO), a subsidiary unit of FACT.The plant can
produce 50,000 TPA of Caprolactam and 2,25,000 TPA of Ammonium Sulphate as co-
product.
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3.4.1. Caprolactam Process
CYCLOHEXANONE, the main intermediate, is produced from benzene by
hydrogenation to cyclohexane and subsequent oxidation.
HYDROXYLAMINE, the second intermediate, is obtained in the form of its stable
sulphate salt, from ammonia, sulphur-di-oxide and ammonium nitrite by the proven, easy-to-
operate and efficient Raschig route.
CAPROLACTAM is produced by the Beckmann rearrangement of the OXIME in the
presence of oleum. The subsequent neutralisation step yields ammonium sulphate as co-
product. The crude CAPROLACTAM is purified by solvent extraction, ion-exchange,
hydrogenation, evaporation and vacuum distillation to obtain products of extremely high
purity and consistent quality.
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3.4.2. Packing Of Caprolactam
FACT Caprolactam is available in 25 Kilograms packed in a multilayer bag.
Inner Bag - Transparent LDPE loose bag, 150 microns thick, heat sealed at the top and
bottom.
Outer Bag - Brown kraft paper bag laminated with HDPE woven fabric.
Middle Paper Layer - Brown loose craft paper 60 gsm, separating outer and inner bag.
Caprolactam is filled in the inner LDPE bag and heat sealed at top.
The middle paper layer and the outer bag are stitched with Rayon thread and crepe paper
tape.
For export, Caprolactam bags will be loose stuffed in 20'(T.E.U) containers each of which
will contain 16.5 / 17 MT of Caprolactam.
3.4.3. Caprolactam Export
10,000 to 12,000 Metric tons per year of Caprolactam is earmarked for
meeting Export orders. FACT Caprolactam is currently being exported to USA, China,
Korea, Taiwan, Philippines, Australia, Slovenia and Sri Lanka. Response from our buyers
indicate that they consider FACT Caprolactam at par with the best available anywhere in the
world. They are also appreciative of the high consistency in the quality parameters that we
maintain and the strict adherence to committed schedules and trade terms.
3.4.4. Application of Caprolactam
Caprolactam is the popular monomer for the versatile Nylon-6 polyamide.
Nylon 6 offers excellent properties like high strength-to-weight ratio, good chemical and
thermal stability and durability. Textile yarn manufactured from Nylon-6 exhibits fine drape,
resistance to abrasion, high flexibility, chemical and biological stability etc. Nylon-6 is
widely used in manufacture of fishing nets, tyre yarns, sewing threads, industrial drive-belts
etc. As an engineering plastic, it finds wide application in castings, injection moulding and
extrusion. Items manufactured using Nylon-6 offer excellent engineering properties.
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3.5. FACT ENGINEERING & DESIGN ORGANISATION (FEDO)
FACT Engineering & Design Organization (FEDO) was established in 1965 for
utilizing the considerable indigenous plant building expertise accumulated by FACT in its
process of nurturing the nascent chemical fertilizer industry.
FEDO is today one of India's premier project engineering organization, catering to a
wide spectrum of industries like petrochemicals, refining, pharmaceuticals, hydrometallurgy
etc as well as petroleum storage, environmental engineering, offsite facilities etc.
The division undertakes project execution on consultancy and turnkey basis, handling
the intricacies of the technology sourcing, design and engineering, hardware procurement and
construction with practiced ease. FEDO is ISO 9001 certified.
3.5.1. Functional setup of FEDO
Multi-dimensional services and vital experience gathered over the past four decades,
attract clients from all spheres of industry to this engineering consultancy. And FEDO offers
them an entire gamut of services at every stage of a project, delivered through the co-
ordinated functioning of the various specialist groups,as indicated in the graphic.
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3.6. FACT ENGINEERING WORKS (FEW)
Established in 1966, FACT Engineering Works was originally conceived as a unit to
fabricate and erect equipment for fertilizer plants. Over the years, it developed capabilities in
the manufacture of Class I Pressure Vessels, Heat Exchangers, Columns, Towers etc.
required for the fertilizer, petrochemical and petroleum industries. FEW received ISO 9002
Certification in 1998.
3.7. RESEARCH & DEVELOPMENT
FACT's well equipped R & D section has advanced facilities with pilot plants,
modern equipment and accessories. The division is backed by a team of highly motivated
research scientists.
Various processes have been developed and patented by FACT R & D division of
which several have been commercialized successfully. A 150 TPA Bio Fertilizer Plant is set
up at R&D centre.
3.8. MARKETING
FACT has been a pacesetter in fertilizer marketing. The marketing network of FACT
is spread over the southern states of Kerala, Tamilnadu, Pondichery, Karnataka and Andhra
Pradesh. The distribution netwrok consists of 100 Agro Service Centres, 50 field storage
points and over 7900 retail selling points in these states, and serves the farmers by supply of
fertilizers and agronomy advice. Through innovative farmer education and fertilizer
promotion programmes, FACT has created awareness about scientific cultivation and
fertilizer use.
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3.8.1. MARKETING OPERATIONS:
Agro Service Centres 100
SWC / CWC Points 43
Soil Testing Laboratories 3
Area & Regional Offices 20
Field Sales Offices 100
Dealer Points 7759
3.9. COMPUTER SERVICE CENTRE
FACT is a pioneer in the industry for adopting information technology and has the
unique distinction of having implemented IT enabled enterprise business systems way back in
1965 to meet the growing need for management information, engineering and commercial
applications. IT systems have since then been kept constantly upgraded so as to keep pace
with the rapid technological advancements.
The latest in the chain of enhancements is the FACT>>FORWARD enterprise
resource planning system (ERP) implemented in November, 2009 by in-house core group
along with implementation partners M/s SAP, the world leader in ERP segment.
FACT Computer Services Centre (CSC), the in-house IT department performed a key
role in implementation of FACT>>FORWARD system including feasibility analysis,
securing management approval, selecting/ managing core group members from different
functional groups, coordinating project management during project preparation, blueprinting,
realization, final preparation and go-live.
CSC is equipped with around 25 numbers of centrally located virtualized servers for
hosting SAP system and the corporate IT network, FACTNET encompasses around 600
connected PCs, a Citrix based virtual private network (VPN) that connects via Internet
around 150 sales points spread across the 4 southern states, 2 Mbps leased line from CSC to
FACT Cochin division, 4 Mbps Internet leased line for hosting Citrix VPN, 64 Kbps leased
lines from CSC to FACT Engineering Works & FACT offices in Willingdon Island and
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around 15 km of optical fibre network that links FACT offices in Udyogamandal complex &
nearby locations.
Functional modules of ERP system including Finance, Costing, Materials
management, Sales & distribution, Production planning, Quality management, Plant
maintenance, Project systems, Human capital management, Supplier relationship
management are maintained by the in-house Centre of Excellence consisting of members
from functional groups. Technical modules including Enterprise portal, Business intelligence
and ABAP based custom software are maintained by the in-house IT team.
Besides functioning as a central hub for IT support in the organisation, CSC has an
important role to play in ensuring compliance to enterprise wide standards, business rules and
best practices, keeping management abreast of fast paced technological changes and
recommending timely enhancements of IT resources in the enterprise.
CSC is geared up to augment its infrastructure with state-of-the-art data centre,
disaster recovery site, optic fibre network for FACT Cochin division, access control system
for sensitive areas, e-kiosks for extending enterprise portal to employee work-spots and to
explore IT enabled sectors such as mobile computing, e-commerce/ e-payment/ payment
gateway, B2B systems and so on.
3.10. FACT MANAGEMENT DEVELOPMENT CENTRE
The FACT Management Development Centre (MDC) was established in April 1978
and is engaged in the training and development of managerial personnel. The training
philosophy springs from the conviction that there exists a compelling need to continuously
prepare mangers for meeting tomorrow's challenges. The Centre has adequate facilities for
conducting management training programs.
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3.11. PERSONAL WELFARE
There are 2000 managerial and 5350 non managerial employed on the rolls of FACT
on 31/9/2000. At FACT, employees are the most valuable assets. Their welfare and well
being is paramount. FACT has always devised a range of appropriate welfare amenities
specially for their benefit.
The facilities at FACT comprise of planned townships with well designed residences,
support services like hospitals, dispensaries, schools, sports stadiums, auditorium, banks, post
offices, telephone exchange, shopping centres, cooperative societies and entertainment
facilities. Apart from these, they enjoy personal benefits like health schemes, incentives and
subsidy schemes.
3.12. COMMUNITY DEVELOPMENT
FACT is always in the forefront of service to socially and economically weaker
section of the society. The company constantly undertakes multitudinous welfare projects.
Under FACT's village adoption programs, various necessary public amenities like water
tanks, sanitation, bus shelters, safe drinking water distribution systems etc are constructed.
Free medical camps at regular intervals are conducted and books and television sets are
donated to village libraries and reading rooms. Financial assistance is also made to the
weaker section of the society.
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CHAPTER 4
TRAVANCORE TITANIUM PRODUCTS Ltd, TVM
4.1. TRAVANCORE TITANIUM PRODUCTS Ltd
Travancore Titanium Products Ltd (TTP), is the leading manufacturer of anatase
grade titanium dioxide in India. The company was incorporated in 1946 at
Thiruvananthapuram, the capital of Kerala, India on the initiative of Sir C.P.Ramaswamy
Iyer. The main product is pigment grade titanium dioxide which is extracted from ilmenite,
which is abundantly available as placer deposits on beaches near Kollam, 65 km north of
Thiruvananthapuram. Ilmenite, a mixture of titanium dioxide and iron in the form of
ferric/ferrous oxide, is treated with Sulphuric Acid to get Titanium dioxide and ferrous
sulphate.
The company was promoted by His Highness Chithira Tirunal Balaramavarma Maharaja, the
then ruler of the State of Travancore (now Kerala State in India) with the technical
collaboration of British Titan Products, (now Ti-oxide Group). Though the company was
registered in 1946, actual production was started only in 1952 with a small capacity of 5 t.p.a.
Later subsequent expansions were made in 1962 and 1973 and now TTP can produce about
20000 tones of titanium dioxide per annum.
In 1960 Government of Kerala took over the management of the Company. Now the
administrative control is vested with the Department of Industries, Government of Kerala.
The company also possesses a modern sulphuric acid plant which was commissioned in 1996,
for utilizing the tail gas recycling DCDA (Double Catalysis Double Absorption) technology.
An alkali scrubbing system is incorporated in the plant, and this in turn helps to keep sulphur
dioxide emissions from the factory well within permissible limits.
For about 50 years, TTP was one of the profit making Public Sector Undertaking of
Government of Kerala. Every year company declares a dividend of around 20 per cent. TTP
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is contributing crores of rupees to the State exchqeuer by way of Sales Tax, other duties and
levies. Welfare amenities, salary and perquisites, working environment etc. are comparatively
satisfactory. TTP has a good library with around 25000 books in stock. During the 70s,
TItanium Football team was one of the most acclaimed Football Clubs in Kerala, winning so
many covetable tropies. Players like Sankarankutty, Abdul Hameed, Najumuddin, Thomas
Sebastian were members of Titanium Football team. In 1980 Titanium Volleyball Team was
formed with national and international players like Cyril C. Velloor, K. Udayakumar,Abdul
Razak,N.C.Chacko,P.S.Mohammed Ali, Sebastian George etc. Subsequently Danikutty
David, Binu Jose ,Tomy and others joined the team .Volleyball team won the Federation Cup
in 1993.
TTP has a strength of around 1300 employees now.
4.2. TECHNOLOGY/PROCESS
Travancore Titanium Products Limited is currently producing TiO2, antase grade,
through the sulphate route. Ilmenite, a mixed oxide of titanium, ferrous iron and ferric iron is
the main raw material for the production of titanium dioxide pigment. Ilmenite is reacted with
sulfuric acid in reinforced cement concrete tanks called Digesters, lined with lead and acid
resistant bricks. Exothermic reaction is initiated by the heat of dilution of the acid with water
and a porous cake is formed. The mass in the solid form is dissolved in dilute sulphuric acid
to get titanium in solution as titanium oxy sulphate (TiOSO4) along with other metallic
ingradients in ilmenite as their sulphate. The liquor is reduced using scrap iron, when the
ferric iron gets completely reduced to the ferrous state.
The resulting black liquor is clarified, concentrated and boiled by injecting steam to
precipitate the titanium content as hydrated titania. The hydrated titania is filtered over drum
type rotary vacuum filters. Any ferric iron still present is reduced to ferrous iron by leaching
the pulp with dilute sulphuric acid. It is washed free of iron and other impurities and calcined
in a rotary kiln is cooled in rotating coolers and de-agglomerated in pendulum mills to very
fine particles. The fine white powder is packed in 25kg HDPE bags.
Ilmenite + Sulphuric Acid => Titanyl Sulphate => Hydrated Titanium Dioxide
=> Titanium Dioxide
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B.Tech Mech Engg., University of Kerala
4.3. PRODUCTS
Titanium Dioxide is the whitest of white pigments and has replaced other less
effective pigments such as Zinc Oxide, Lithopone etc. This is because of the unique
combination of its superior properties of a high refractive index, low specific gravity, high
hiding power and opacity,and non-toxicity. It also has high tinting strength and dispersion
properties as well as chemical stability. Titanium Dioxide is produced in TTP in the
ANATASE form and marketed as AJANTOX Anatase grade possesses excellent water
dispersion properties and gives a clear tone in all ranges of application.
Travancore Titanium Products Limited has recently launched a Rutile Grade Titanium
dioxide pigment viz., TTP RD-01. This product was developed in the year 2002 indigenously
through the Sulphate route. TTP markets this product without surface treatment at a very
competitive price.
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B.Tech Mech Engg., University of Kerala
CHAPTER 5
TRAVANCORE COCHIN CHEMICALS Ltd, KOCHI
5.1. TCC Ltd, KOCHI
The Travancore-Cochin Chemicals Ltd., popularly knows as TCC was established in
1950. The idea of establishing the unit was conceived by M/s Sheshasayee Brothers the then
Managing Agents of FACT. The venture was started as partnership concern in the name
Travancore Mettur Chemicals with FACT and MCIC (Mettur Chemicals and Industrial
Corporation) as partners. In 1951 the partnership was registered as a Public Limited
Company, with the State Government contributing the major share of equity and the company
was then named as TRAVANCORE-COCHIN CHEMICALS LTD. M/s Sheshasayee
Brothers continued to be the managing agents for the next 10 years.
Commercial production of Caustic Soda from the first plant of 20 tpd capacity was started in
1954 January. TCC is the first unit in India to manufacture Rayon grade Caustic Soda.
5.2. STAGES OF GROWTH
1956 - A continuous Caustic Fusion Plant 20 tpd for producing Caustic Soda flakes.
1958 - Chlorine Liquefaction Plant
1960 - Capacity enhanced to 30 tpd further to 40 tpd.
Established new plant for manufacture of Sodium Hydrosulphate 3 tpd capacity
1967 - 7 tpd Sodium Hydrosulphate, 60 tpd Caustic Fusion Plant
4 tpd Iron free Sodium Sulphate
1975 Added another 100 tpd Caustic Soda Membrane Unit thereby increased the
production capacity 200 tpd own Water Treatment Plant.
(by 1988, many of the old unit were dismantled)
1997 - 100 TPD Caustic Soda manufacturing unit using Membarane technology
capacity 125 tpd.
1998- New CCF Plant in place of existing 60 tpd.
2005 -Addition 25 tpd
2006 Addition 25 tpd
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B.Tech Mech Engg., University of Kerala
At present total installed capacity is 175 tpd Caustic Fusion plant for 100 tpd. The company
produces Rayon grade caustic soda using Membrane cell Technology. The main raw
materials are common salt (NaCl) electricity and water. Company has three running plants
which are membrane plant, CCF plant and Soda bleach plant.
5.3. TECHNOLOGY/PROCESS DESCRIPTION
5.3.1. Membrane cell technology
It employs Ion exchange membrane placed between coated Titanium
anode and coated Copper cathode. It requires lower current consumption and is an
environment friendly technology. However the caustic soda lye thus produces is of low
concentration-(32%) compares to the Caustic Soda production in mercury, and the major part
of it is to be further concentrated to 48-50% for use of consuming industries.
The membrane cell technology use the following steps to produce the caustic soda they are
described below
Brine saturation and purification
Electrolysis
Lean brine dechlorination
HCl Synthesis
Chlorine liquefaction
The chloralkali process is an industrial process for the electrolysis of sodium chloride
solution (brine). Depending on the method several products beside hydrogen can be
produced. If the products are separated, chlorine and sodium hydroxide (caustic soda) are the
products; by mixing, sodium hypochlorite or sodium chlorates are produced, depending on
the temperature. Higher temperatures are needed for the production of sodium chlorate
instead of sodium hypochlorite. Industrial scale production began in 1892.
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B.Tech Mech Engg., University of Kerala
When using calcium chloride or potassium chloride, the products contain calcium or
potassium instead of sodium.
The process has a high energy consumption, for example over 4 billion kWh per year in West
Germany 1985, and produces equal (molar) amounts of chlorine and sodium hydroxide,
which makes it necessary to find a use for the product for which there is less demand, usually
the chlorine.
There are three production methods in use. While the mercury cell method produces chlorine-
free sodium hydroxide, the use of several tonnes of mercury leads to serious environmental
problems. In normal production cycle a few hundred pounds of mercury per year are emitted
which accumulate in the environment. Additionally, the chlorine and sodium hydroxide
produced via the mercury-cell chloralkali process are themselves contaminated with trace
amounts of mercury. The membrane and diaphragm method use no mercury, but the sodium
hydroxide contains chlorine which has to be removed.
The most common chloralkali process involves the electrolysis of aqueous sodium
chloride brine) in a membrane cell.
Saturated brine is passed into the first chamber of the cell where the chloride ions are
oxidised at the anode to chlorine:
2Cl– → Cl2 + 2e–
At the cathode, hydrogen in the water is reduced to hydrogen gas, releasing hydroxide ions
into the solution (C in figure):
2H2O + 2e– → H2 + 2OH–
The non-permeable ion exchange membrane at the center of the cell allows the sodium ions
(Na+) to pass to the second chamber where they react with the hydroxide ions to produce
caustic soda (NaOH) (B in figure). The overall reaction for the electrolysis of brine is thus:
2NaCl + 2H2O → Cl2 + H2 + 2NaOH
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B.Tech Mech Engg., University of Kerala
A membrane cell is used to prevent the reaction between the chlorine and hydroxide ions. If
this reaction were to occur the chlorine would be disproportionated to form chloride and
hypochlorite ions:
Cl2 + 2OH– → Cl– + ClO– + H2O
Above about 60°C, chlorate can be formed:
3Cl2 + 6OH– → 5Cl– + ClO3– + 3H2O
Because of the corrosive nature of chlorine production, the anode has to be made from a non-
reactive metal such as titanium, whereas the cathode can be made from Nickel.
In the membrane cell, the anode and cathode are separated by an ion-permeable membrane.
Saturated brine is fed to the compartment with the anode (the anolyte). A DC current is
passed through the cell and the NaCl splits into its constituent components. The membrane
passes Na+ ions to the cathode compartment (catholyte), where it forms sodium hydroxide in
solution. The membrane allows only positive ions to pass through to prevent the chlorine
from mixing with the sodium hydroxide. The chloride ions are oxidised to chlorine gas at the
anode, which is collected, purified and stored. Hydrogen gas and Hydroxide ions are formed
at the cathode.
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B.Tech Mech Engg., University of Kerala
Fig. 5.3.1 PROCESS DIAGRAM
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B.Tech Mech Engg., University of Kerala
Fig 5.3.2. ION EXCHANGE MEMBRANE
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B.Tech Mech Engg., University of Kerala
5.4. PRODUCTS
1: Caustic Soda
Caustic Soda is a basic alkali entering into the manufacturing of a host of
articles of daily use like soap, paper, and textiles. There are various concentrations available
which are used by different industries. Using this technology brings about 30% reduction in
electrical power requirements. This is free from pollution hazards of mercury.
2: Chlorine
Chlorine, a co-product obtained in the process of manufacturing of Caustic
soda is an equally important basic chemical, inevitable for the manufacture of plastics,
textiles & paper, insecticides, pharmaceuticals etc. It is also renowned water purification
chemical
3: Hydrochloric acid and sodium hypochlorite
TCC also produces high-purity Hydrochloric Acid used for manufacture of ossein,
which is exported for edible pharmaceutical application. Another by-product, sodium
hypochlorite, finds its use in bleaching and disinfectant applications and also for extraction of
rare earth materials.
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B.Tech Mech Engg., University of Kerala
5.5. MAJOR ACHEIVEMENTS
Moving with the times, TCC keeps up its technology regularly updated and continue
to be the competitive strength in the Chlor-alkali industry. With expanded plants and higher
production capacity, TCC has come out to be the profitable public sector undertaking. Over
the years we have achieved recognition and awards for the remarkable performance in the
industry with regard to production, productivity, energy conservation and environmental
protection.
1981 - 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 - Best Performance award for Energy Conservation in the State of Kerala under
group "Chemical & Fertilizers – above 3000 KVA" from Government of Kerala.
1994-95 - 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.
2003 - Kerala State Energy Conservation Award
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B.Tech Mech Engg., University of Kerala
CHAPTER 6
CONCLUSION
This seminar includes all the Industrial Visits and Industrial Training I had undergone
during this course. These industrial visits were done as a part of curricular activities. The
selection of apt industries was a difficult task and more over availing there permission was a
tedious job also.
Industrial visits and training enabled the familiarization of real working environment.
The industrial visits were a kind of stepping out from a theoretical world of books to the
practical world. These visits also enabled to create awareness to the need of harmony at work.
The essence of industrial morale and other disciplines in industries were also understood.
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