SHRI M & N VIRANI SCIENCE COLLEGE-

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B.Sc. CHEMISTRY

PROJECT REPORT ON
Chemical Industries
(CAUSTIC SODA PLANT)

SUMMER TRAINNING A
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INDIAN RAYON
(A Unit of Aditya Birla Nuvo Ltd.)
VERAVAL

SUBMITTED TO
COLLEGE OF FIRE TECHNOLOGY
IN PARTIAL FULFILLMENT FOR THE AWARD OF
B.Sc. 2nd YEAR
Guided By Submitted By
SUBMITTED BY
JAYDEEP TADA
Dr. K.D.LADVA PRATIK R. VAVAIYA
SHRI M & N VIRANI SCIENCE COLLEGE-
Dr.D.M.PUROHIT RAJKOT
CO-ORDINATOR
 ADITYA VIKRAM BIRLA

(November 14, 1943 – October 1, 1995)

A formidable force in Indian industry, Mr. Aditya Birla

dared to dream of setting up a global business empire
at the age of 24. He was the first to put Indian
business on the world map, as far back as 1969, long
before globalization became a buzzword in India. The
Aditya Birla Group, Epitomizing the philosophy of its
Legendary leader – the late Aditya Vikram Birla – one
man who Made a difference. Rooted in Indian values,
yet global in vision.

Rock solid in fundamentals. Nurturing a culture where

success does not Come in the way of the need to keep
learning afresh, to keep Innovating, to keep
experimenting. Transcending the conventional
Barriers of business to send out the message that it
cares.
A unique conglomerate

Aditya Birla Nuvo Ltd is a US$3.5 billion, diversified

conglomerate and the platform that has launched
many new businesses for India’s premier business
house, the Aditya Birla Group. Aditya Birla Nuvo has a
portfolio of manufacturing as well as service sector
businesses under its umbrella ranging from textiles to
financial services.

The razor sharp focus on each business has made it a

leading player in most segments, including viscose
filament yarn, carbon black, branded garments, agri
business, textiles and insulators. Over the past few
years, Aditya Birla Nuvo, through its subsidiaries and
joint ventures, has made successful forays into life
insurance, telecom, business process outsourcing
(BPO), IT services, asset management and financial
services.
 The idea of undertaking this project came to my mind
In chemical Industries has been carried out at INDIAN
RAYON, VERAVAL my company, recently. Since, the
project that I have chosen has very wide scope with vital
interest of my parent company as well as for the society as a
whole. A lot of information, I had tried to collect as much as
possible by regular site visit, referring of manuals
regarding chemical plants , material handling and various
other topics related to safety In chemical Industries.
Compiling of the Information, data and material started
and prepared project report during my tenure at INDIAN
RAYON, VERAVAL for short term industrial training from
1st May ,2011 to 31st May ,2011.
 DECLARATION

I Mr. JAYDEEP TADA the student of B.Sc.

CHEMISTRY from, M & N VIRANI SCIENCE
College here by declares that the project work
presented in this report entitle “CAUSTIC SODA
PLANT” Study of Indian Rayon Veraval –
Gujarat.” Submitted in partial fulfillment of the
award of the degree of B.Sc. Chemistry from
Department of Chemistry is a record of original
study done by me. This work has not been
undertaken or submitted else where in
connection with any other academic course.

Place : Veraval

Date :

JAYDEEP G. TADA
ACKNOWLEDGEMENT

Guidance and co-operation are valuable

for fulfilling and furnishing any kind work.
Similarly my project at INDIAN
RAYON(UNIT OF ADITYA BIRLA NUVO
LTD.)

I am very thankful to Shri B.B.DIXIT,

Mr.D.B.KALE (Prod.Manager). Safety
officer of Indian Rayon Mr. Kishor
Radadia and Mr. Suresh kher .I am also
thankful to Miss Shraddha Mehta Officer-
HR department to provide me this
opportunity, And Shri J.V.Dave(Librarian)
along with all staff and H.O.D. Who had
co-operated me.
Powered by:-
An intellectual capital of over 50,000 employees and
an optimum mix of revenue and profit streams, the
company is in a strong position to invest in high
growth businesses to maximise long-term
shareholder gains.

As a leading player, Aditya Birla Nuvo ranks as:

India's second largest producer of viscose filament
yarn (VFY) The country's largest premium branded
apparel company.The second largest producer of
carbon black in India

Largest manufacturer of linen fabric in India. Among

the most energy efficient fertiliser plants India’s
largest and the world’s fourth largest producer of
insulators
- INTRODUCTION

- COMPANY PROFILE

- POLICY

- ORGANAIZATION

- PRODUCTION DIPARTMENT

- PROCESS DISCRIPTION

- FLOW CHART

(CAUSTIC PLANT)

- RAW MATERIAL

- QC LAB.

- SAFTY PRECAUTION OF CI2

- AWARDS
:: INTRODUCTION:-

The Aditya Birla Group is Indian's first truly

multinational corporation. Globel in vision, rooted in
Indian values, the group is driven by performance
ethic pegged non values creation for its multiple
stakeholders. The Indian Rayon and Industries
Limited is a group company of Aditya Birla Nuvo
Limited, Situated at Veraval.

- The world's 2nd largest business group company

with turn over of 200 billion and working in 15
countries.

- IRIL has continuously offered total customer

solutions through its quality products and services. It
enjoys leadership position in key business with
strong competitive edge.

-With a 30%market share, Indian Rayon, a unit of

Aditya Birla Nuvo,is the second largest producer of
Viscous Filament Yarn(VFY)in India. With a capacity of
16,400 tones per anuum(TPA), it also accounts for
42% of VFY exports from India.
-VFY is made from natural fibers. Fabric made with
VFY feels like cotton, drapes like wool, sheaths and
clings like satin, and has the lustre and feel of silk.
VFY is used by manufactuers of apparel, saris,
upholstery, suit lining, etc.India ranks second only to
china in VFY production.

-Branded as ray one, the VFY is available in more than

400 shades. These include natural whites as well as a
wide array of color, ranging from purest tints through
medium tones to vibrant deep shades; in fine tocoarse
deniers ranging from 75 to 900.

-located at Veraval in Gujarat, the VFY plant is the first

in Aditya Birla Nuvo to be accredited with ISO 9001
and the ISO 14001 certification. It also has the OHSAS
18001 and OEKO tex certification. Technology
upgradation and quality improvements are a way of
life at Indian Rayon. AS a part of its backward
integration process, it has 82,125 tones caustic soda
plant with membrane cell technology from UHDE
GMBH (Germany).A 34.5 MW co-generation thermal
power plant supplies uninterrupted power. Recently
indian Rayon won the Top Rank award at the National
Energy Conservation Awards 2006 presented by the
Ministry of Ministry of Power, of Govt. of India.
Indian Rayon Profile:-
Profile:-

Indian Rayon, the VFY unit of Aditya Birla Nuvo, is a major

player in the Indian viscose filament yarn business. The unit
enjoys a 38 percent domestic market share, making it the
second largest producer of viscose filament yarn in India.

Branded 'Ray One', the viscose filament yarn is available in

more than 400 shades. The yarn comes in a wide array of
colours, including natural whites. It ranges from the purest
tints, through medium tones to vibrant deep shades in fine to
coarse deniers ranging from 75 to 1200.

With a capacity of 16,400 tonnes per annum (tpa), Indian

Rayon is the first in the country to adopt the most advanced
VFY technology with 88 pot spinning machines (PSY) and 17
continuous spinning machines on parallel yarn. It also
accounts for 50 per cent of VFY exports from India making it
the largest exporter of VFY from India.

Located at Veraval in Gujarat, the VFY plant is the first in

Aditya Birla Nuvo to be accredited with the ISO 9001:2000 and
the ISO 14001:2004 certification. It also has the OHSAS 18001
and OEKO Tex certification.

As a part of its backward integration process, it has a 91,250

TPA caustic soda plant with membrane cell technology from
UDHE Gmbh (Germany). A 34.5 MW cogeneration thermal
power plant supplies uninterrupted power.A slew of initiatives
are underway to improve quality, increase the share of value-
added products and lower the cost.
HISTORY OF INDIAN RAYON

- Mr. Morarjibhai Vaidya, one of the leading

industrialists of Gujarat had setup this plant with a
view to manufactured Viscose Filament Yarn in 1956.
- The foundation stone of this unit was laid by late
Prime Minister Shri Lal Bahadur Shastri
- The company was incorporated under the companies
Act 1956 on 26th September 1956 and American
Ambassador Mr. H.H.Gailbreth done the inanuguration
of the company in 1963.
- On the same day, company took its trial production.
- The company has made the technical collaboration
with the von kohorn international corporation U.S.A.
- The regular production of rayon yarn was started on
27th September 1963, while commercial production
was started on 22th Octomber 1963.
- As a result of strike and vhaos with in the unit the
present management Birla Group took over the
company in 1966.At that time the chairman was Aditya
Birla.
- Due to expansion "Indian Rayon & corporation Pvt.
Ltd." named, it becomes "Indian Rayon & Industries
Limited (IRIL)"
COMPANY POLICY
HELTH AND SAFTY POLISY
 ORGANIZATION STRUCTURE

Executive
President

Production Engineering Commercial Administrat Personal &

Department Department Department ion HRD
Department Department

Viscose Maintenance Finance Raw Time Office

Spin bath Electrical Share Legal Welfare

Spinning Instrumentati Stores and Octroi Labor Office

on Purchases

After Internal Sales Personnel

Textile HRD

Chemical Estate

Research & Security

Development

Quality
 PROCESS DESCRIPTION

PRODUCTS OF INDIAN RAYON:

Indian Rayon (A Unit Of Aditya Birla NUVO Ltd.) situated at

Veraval, Saurashtra. Indian Rayon is manufacturing Rayon,
sulphuric Acid, Carbon Di-sulphide, caustic lye & flakes, chlorine,
hypo chlorite, HCL etc. Company also produces power for their
own consumption.

Following products are manufactured on more than 100% of

their capacities.

Sr Name of product Installed capacity

no. ( Mt/Month)

1 VISCOSE FILAMENT RAYON 1650

YARN

2 SULPHURIC ACID 3600

3 CARBON DI-SULPHIDE 1000

4 ANHYDROUS SODIUM 2050

SULPHATE

5 SODIUM SULPHIDE 100

6 CAUSTIC SODA 12000

7 LIQUID CHLORINE 10560

8 HYDRO CHLORIC ACID 1800

9 SODIUM HYPO CHLORITE 3750

10 COMPRESSED HYDROGEN Nm3 650000Nm3

11 POWER PLANT 34.5 MW

 POLLUTION :

1, Liq. Effluent : 8,500 m3 /day discharged in to the sea

through marine pipeline with Diffuser System

2, Air : Gaseous Emission like SO2, Acid Mist, HS,

HCL, CL, CS, SPM, NOx, etc. are likely to
pollute
air. Adequate Air monitoring devices are
Installed and all controlling measures are
Provided to get all parameters under
Prescribed limits given by GPCB.

GENERAL RISKS

1. Leakage of Acids & Alkalis.

2. CARBON DI-SULPHIDE Leakages & Fire.

3. Liquid CHLORINE leakages.

4. Explosion in Boilers.

5. Fire in Hydrogen
INTRODUCTION
The manufacture of Caustic Soda is based on the Membrane Cell
Technology. Caustic soda lye, chlorine gas and hydrogen gas are
simultaneously produced from bipolar membrane cells. The various
stages in the manufacture of Caustic Soda are explained in further
paragraphs.

RAW MATERIAL
The main raw materials for the manufacturing of Caustic Soda are given
below:-
Sr.No Name Consumption / MT Source of raw material

1. Salt 1.7 tones Local Manufactures

2. Electricity 2360 KWH. Own Power Plant

AUXILARY RAW MATERIAL:-

Sr.No Name Consumption / MT Source of raw material

1. Na2CO3 9.5 KG Purchase

2. NaOH 8.5KG Own Product

3. Sodium Bi 0.20 KG Purchase
Sulphite

4. Alpha 0.02KG Purchase

Cellulose
5.0 Megna Flock 0.01KG Purchase

6.0 H2SO4 19.0KG/ Tone of Rayon Plant

Chlorine
 FLOW CHART:-

Na0H IONEXCHANGE
SALT
WATER Na2C03 COLUMNS
BaC03

ANTHRACITE FILTER

POLISHING FILTER
SETTLER OVERHEAD MEMBRANE
PURIFIER BRINETANK
HYDROGEN
SATURATOR
CAUSTICSODA
CLARIFIED
BRINETANK DILUTE
BRINE
DILUTED BRINE SLUDGETOFILTER

IMPURECELL GAS DE-

BRINE DILUTECAUSTIC
CHLORI-
ELECTROLYSER
NATION CHLORATE
HCL
DESTRUCTION
CHILLED STEAM
CWS
WATERIN CONC.H2S04 NaOH
RECEIVER
COOLERII MOIST
COOLER FILTERER DRYING CAUSTIC
I SNIFF GAS
TOWER
FILTER Rayon
COMPRESSOR Evpn.
CWR
CHLORINEFILLING
CONDENSATE DIL.H2S04 LIQUEFIER
C.H.W. LIQUID
OUTLET
OUT CHLORINE
STORAGE Flaking
WASTESNIFF GASES
H2 H2 Bottling
CH.W. OUT
COOLINGWATER
IN OUT SODIUMHYPO
HYDROGEN

GAS
COOLER

H2 GAS ABSORPTION TOFILLING

ABSORBER
WATER
BUFFER HCL
VESSEL
ABSORBER
HCL

FURNACE HCL
STORAGE
HCL
RECEIVER
HCL FILLING
CH.W.IN

EXHAUST

Na0H SOIUMHYPO
CIRCULATION
TANK
TANK
PLATE PUMP
COOLER PUMP

BLOWER

FLOWSHEET FORMANUFACTURE OF CAUSTICSODA

:: Caustic Soda Plant
-Process Description ::

INTRODUCTION:-
The manufacture of Caustic Soda is based on the
Membrane Cell Technology. Caustic soda lye, chlorine
gas and hydrogen gas are simultaneously produced
from bipolar membrane cells. The various stages in
the manufacture of Caustic Soda are explained in
further paragraphs.

RAW MATERIAL:-
Name Consumption/MT Source of raw
Material

Salt 1.7 tones Local

Manufactured

Electricity 2400 KWh Own Power

Plant
A) BRINE SATURATION:-
The starting step is to staurate brine solution (NaCl
solution) and this is carried out in vertical saturator.
There are two saturators 02D01 A/B, one inline & one
standby. Salt is charged into the saturator by means
of bucket elevators.

Depleted (return) brine from the process having a

concentration of approximately 190-220 gpl NaCl is
fed by means charged with salt. The brine rises up
through the salt bed, getting saturated in the process
and overflows out. The brine leaving the sturator is at
a temperature of about 60 C and as a concentration of
approximately 310-320 gpl NaCl.

B) CHEMICAL PRECIPITATION:-
Saturated brine overflows from the saturator into the
precipitation tank where it is treated chemically to
precipitate the impurities, which are primarily
chlorides of calcium and magnesium and sodium
sulphate.

The precipitation reaction taking place are as follows:

Na2SO4 + BaCo3 = BaSO4 + Na2CO3

(BaCO3 eliminated at Indian Rayon by brine
purging)
CaCl2 + Na2CO3 = CaCO3 + 2NaCl
MgCl2 + 2NaOH = Mg(OH)2 + 2NaCl
C) CLARIFICATION:-
The impurities precipited out in the precipitetion stage
are settled in the clarifier 04A01 which is a large tank
providing adquate setting time. A small quantity of
flocculant in the range of 1-3 PPM is dosed into the
inlet to aid the setting. Clear brine overflowing from
the cleaner contains approximately 10 PPM
suspended solids and is led into the clarified brine
tank 04D03.

Under flow sludge is taken to decanter to recover

brine.

D) FILTRATION:-
The supplied solids in clarified brine is removed by
passing through a bed of anthracite filters tear 05F01
A/B/C/D/E/. Special quality antharite is employed to
avoid any contamination of brine. All filters are in line
at all time except for back wash operation. The
suspended solid level is reduced approximately less
than 1 NTU in the filtered brine which is collected in
the filtered brine tank 05D01

1. SECONDARY BRINE PURIFICATION:-

The secondary brine purification stage comprises

of two steps:

i) Polishing Filtration

ii) Ion Exchange

and to achieve the objective of producing the ultra
pure brine required for membrane cell operation.
POLISHING FILTRATION:-

The suspended solids are removed by passing brine

through polishing filters which are precoat type carbo
candle filters. There are five polishing filters 05F02
A/B/C/D/E. All five are in line at any time. Alpha
cellulose is used as the precoat material.

ION EXCHANGE:-

Before the polishing brine is passed through on

exchange column it is sent through the chlorin
recuperator 21EO1 and the brain recuperator 07E01 to
recover the heat content of chlorin and depleted brain
leavin the electrolyser. Next passees through two nos.
of ion exchange coloumns 06CO1 A/B connected in
series. The coloumns are filled with a special cation
exchange rasin (lewatite tp 208) which provide active
site for adsorption in the brain. The brain leaving the
ion exchange columns is less then 20 ppb, which is
within the limit stiputed for the membrane.

ELECTROLYSIS:-

The brine from the head tank flows into the anode
chamber of the electrolyser cells. There are five no. of
electrolysers 11A01 A/B/C/D/E and each electrolysers
consist of 120 elements. The cathode chamber of the
electrolytic cells similarly receive the weak caustic
from the catholyte head tank.

The anode and cathode chamber of the cells are

isolated from each other by the membrane which is
selective to the migration of Na+ ions.
Chlorine is liberated at the anodic surface and the
brine in the anode compartment is depleted to about
210-225 gpl NaCl. The two phase mixture of depleted
brine and chlorine over flows from the anode
chambers via insert pipe into the anolyte header.As a
result of electrochemical reactions taking place in the
cathode chamber, hydrogen is generated at time
cathode surface and OH- ions combine with the Na+
ions diffusing through the membrane. A two thase
mixture of 33% NaOH and hydrogen overflows from
the cathode chamber into the catholyte header.

NaCl + H2O = NaOH + 1/2H2 +1/2Cl2

The product caustic is taped off hot as above and fed
to the caustic evaporation unit for further
concentration. A part of the product is directly sent to
rayon plant (without concentrating 33%) through
product cooler as and when required.
ANOLYTE DECHLORINATION:-

The depleted brine coming out of the cells is at a

temperature of 88 C and has a concentration of 210-
225 gpl NaCl and also contains 250-350 MGPL
dissolved chlorine. Thus the depleted brine is
dechlorinated is in two stages i) VACCUM
DECHLORINATION ii) CHEMICAL DECHLORINATION.

The fully dechlorinated brine then comes to brine

saturator.

CHLORINE TREATMENT:-

A) Chlorine leaving the cells is at a pressure of 2000

MMWC and a temperature of 88 C, is saturated with
water vapour. The chlorine gas is first cooled in the
chlorine recuperator 21E01 with pure brine. Next
cooled in cooler-I 21E02 to a temperature of 40 c using
cooling water. The gas leaving from cooler No.1 is
finally cooled to a temperature of 15 C in cooler-II:
21E03 using chilled water. Then passed through the
moist chlorine filter 21F01 to remove the brine arosol.
B) DRYING:-

The gas leaving from moist chlorine filter is dryed by

using 98% H2SO4 in a drying tower 21C01 A/B/C. The
drying tower consist tonnel tray section and a packed
column section. 98% H2SO4 is fed to the top most tray
by means of metering pump. The acid gets diluted to
78% and 78% H2SO4 is continuously circulated over the
packed column section. The heat of dilution is
Dessipated using chilled water in a cooler 21E04
installed in the recirculation line. The chlorine gas
leaving the tower as a moisture content of 10-12 PPM
The gas leaving tower is passed through H2SO4
separator, which is a part of drying tower.

COMPRESSION, LIQUEFACATION,

STORAGE & FILLING:-

The dried chorine gas is compressed to a pressure of
2.5 to 3.0 kg.cm2G using liquid ring compressor
22u01/K01 A/B/C The compressor uses 98% H2SO4 as
sealing liquid. The compressed gas is remove
entrained H2SO4. then the compressed chorine gas is
sent to the liquefier 23E01 working in the Freon
Refrigerator system 23U01 A/B. Liquid chlorine from
the liquefier is sent to liquid chlorine storage tanks
from 24T01 A/B/C/D/E. Unliquified chlorine gas is sent
to the HCl synthesis for making HCl or wast air
dechlorination system for neutralisation.
Liquid chlorine from chlorine storage is filled in
chlorine cylinder which are sent to market.
EFFLUENT TREATMENT:

BRIEF PROCESS DESCRIPTION OF EFFLUENT

HANDLING / TREATMENT PLANT
The Effluent from the various sections of industry is led to
the Effluent Treatment Plant (ETP). The acidic effluent
flow through the overhead drain 2 & 3 are neutralized by
the addition of lime slurry. The lime dosing valves are
pneumatically operated and receive signals from pH
sensor located on the overhead channel. The neutralized
effluent is then led to two zinc clarifiers (old and new) for
effective removal of Zinc. The overflow from the clarifier is
led to the mixing chamber where effluents from the other
two drains also join. Lime slurry is also added in drain 1
prior to mixing chamber whenever required. Addition is
carried out through a pneumatically operated valve, which
receives signals from pH sensor located in drain No.1.
Polyelectrolyte is added to the mixing chamber. The mixed
effluent is then pumped to 2 Nos. suspended solids
clarifier. The overflow flows into a holding tank from where
it is disposed off into the sea through pipeline with diffuser
system. The addition of acid is carried out to adjust the pH
before final disposal of effluent.
The primary treatment facility for wastewater generated by
caustic plant consists of collection and neutralization units,
subsequent to which wastewater is sent to ETP.
The Sludge from clarifiers are drained and taken to
Thickener. From thickener, sludge is taken to Centrifuge
where solid is separated.
The Treated Effluent from the Effluent Treatment Plant is
disposed of into the sea through pipeline with diffuser
system as per the standards stipulated by Gujarat
Pollution Control Board.
The sewage is disposed off into Main effluent treatment
plant (METP) through septic tank / soak pit system.
HYDROGEN TREATMENT:-

Hydrogen gas leaving the cells is at a pressure of

about 2200 MMWC and a temperature of 88 C. The gas
is saturated with water vapour at this condition and is
cooled in two stages. In first stage heat exchanger
41E01 the gas is cooled to the brine system thereby
recovering the heat into the brine system thereby
recovering cooled to 40 C using cooling water in the
cooler 41E02. The cooled gas is passed throudh a
filter 41F01 to remove the NaOH erosols. The gas is
sent to the HCl synthesis system as per requirment.
Main part of the hydrogen gas is utilised in flaking
plant furnace as a fuel. A facility ia available for filling
hydrogen in hydrogen cylinder at 150 Kg/CM2G as per
market requirement.
HCl SYNTHESIS:

THE HCl IS PRODUCED BY BURING HYDROGEN AND

CHLORINE AND ABSORBING THE RESULTING
COMBUSTION GASES IN WATER TO YIELD A 30-32%
HYDROCHLORIC ACID SOLUTION. THE HCl
PRODUCED IS COLLECTED IN THE HCl RECEIVER
51D01 FROM WHERE IT IS PUMPED TO MAIN
STORAGE.

WASTE AIR DECHLORINATION

SYSTEM:

THE CHLONE BEARING WATE STREAM FROM THE

PLANT ARE LED TO THE WASTE AIR
DECHLORINATION SYSTEM, WHERE IT IS RENDERED
FREE OF CHLORINE BY SCRUBBING WITH 18%
CAUSTIC SOLUTION TO PRODUCE CAUSTIC HYPO.
THE SYSTEM CONSISTS OF THREE ABSORBERS
26C01 A/B/C AND A FINAL ABSORBER 26C02. EACH
PROVIDED WITH CIRCULATING PUMP AND A
COOLER INSTALLED IN THE RECIRCULATING LINE.
18% CAUSTIC IS PREPARED BY DILUTING 32%
CAUSTIC IN A MIXING JET 26J01. SODIUM HYPO
SOLUTION IS WITHDRAWN FROM THE FIRST
ABSORBER INTO BLEACH LYE DAY TANK 26D04
FROM WHERE IT IS PUMPED TO STORAGE TANK
27T01 AND FROM THERE IT IS LOADED INTO
TANKERS OR PUMPED TO AFTER TREATMENT
PLANT OF RAYON DIVISION AS PER THE
REQUIREMENT.
AN EXCESS OF 10 GPL Na0H IS MAINTAINED IN THE
CIRCULATING SODIUM HYPO SOLUTION.
CAUSTIC EVAPORATION:

33% Na0H PRODUCED FORM MEMBRANE CELLS IS

CONCENTRATED TO 48% IN TRIPLE EFFECT
EVAPORATOR. THE EVAPORATORS ARE OF
FALLING FILM TYPE. THE FIRST STAGE
EVAPORATOR USES THE VAPOUR GENERATED IN
THE 2ND STAGE AND THE 2ND STAGE EVAPORATOR
USES THE VAPOUR GENERATED IN 3RD STAGE
EVAPORATOR. STEAM IS USED AS HEATING
RD
MEDIUM IN THE 3 STAGE ONLY.
THE VAPOUR CONDENSATE FROM THE
EVAPORATION UNIT IS RECYCLED TO THE BRINE
SYSTEM OF THE MEMBRANE CELL PLANT. THE
MAIN PART OF THE 50% Na0H IS SENT TO CAUSTIC
FLAKING PLANT FOR FURTHER CONCENTRATION
AND REMAINING IS PASSED THROUGH PRODUCT
COOLER AND SENT TO 50% CAUSTIC STORAGE
TANK 33T01 A/B WHERE IT IS LOADED INTO ROAD
TANKERS.
CAUSTIC FLAKING UNIT
48% lye is converted to Caustic Flakes (98.5%):
48 % CAUSTIC LYE IS CONVERTED INTO FLAKES BY
TWO STAGE FALLING FILM EVAPORATORS AND
FLAKER DRUM.
THE FEED CAUSTIC (48%) IS PUMPED TO PRE-
CONCENTRATOR EITHER FROM STORAGE TANK BY
33 P02 A/B OR DIRECTLY FROM EVAPORATION UNIT.
LEVEL OF 34EV-1 IS CONTROLLED BY 34LIC-3411
FROM DCS (CONTROL ROOM). 48% CAUSTIC IS
CONCENTRATED UP TO 57% BY USING THE VAPORS
FROM FINAL CONCENTRATOR. MAINTAIN THE
VACCUM OF PRECONCENTRATOR UP TO 0.93
KG/CM2 WITH THE HELP OF VACUUM PUMP IN THE
TUBE SIDE. WATER VAPORS EVAPORATED IN
PRECONCENTRATOR IS CONDENSED IN SURFACE
INERT GASES ARE SUCKED OFF BY
WATER-RING VACUUM PUMP. :-
34EV-1 CONCENTRATES THE CAUSTIC UP TO 57 TO 60
%. THIS CAUSTIC IS FED VIA 34-P-2-A/B TO FINAL
CONCENTRATOR, 57% CAUSTIC FLOW TO 34EV-2 IS
CONTROLLED BY A CONTROLLER 34FIC-3411 FROM DCS.
57% CAUSTIC IS HEATED BY THE HEATED MOLTEN SALT IN
FINAL CONCENTRATOR (FALLING FILM EVAPORATOR). THE
57 % CAUSTIC IS EVAPORATED UNDER NORMAL PRESSURE
TO APPROX. (96% TO 98.5%) NAOH. THE VAPORS OF FINAL
CONCENTRATOR ARE USED TO HEAT PRE-
CONCENTRATOR. THE CONDENSED VAPOR IN SURFACE
CONDENSER AND PRE-CONCENTRATOR ARE COLLECTED
IN CONDENSATE TANK. WHICH IS INTERCONNECTED WITH
EVAPORATION PLANT CONDENSATE TANK.

IN ORDER TO PREVENT CORROSION OF THE NI-

EQUIPMENT 10% SUGAR SOLUTION IS ADDED IN 34-P-2 A/B
DISCHARGE LINE. THIS 10% SUGAR SOLUTION IS
PREPARED WT/WT IN SUGAR TANK AND DOSED BY A
SUGAR METERING PUMP 34-P-3 A/B

THE HIGH TEMP. HEAT TRANSFER SALT SYSTEM

CONSISTS OF A SALT HEATER 34-H-1 WITH COMBUSTION
AIR PRE HEATER 34-HE-1 TO HEAT THE MOLTEN SALT,
WHICH IS CIRCULATED IN CLOSED SYSTEM BY SALT PUMP
34-P-6 MOUNTED ON THE SALT TANK 34-T-1.

THE AUTOMATICALLY OPERATING FURNACE F.O. AND

/OR HYDROGEN BURNER UNIT 34-B-2 IS MOUNTED ON TOP
OF THE SALT HEATER 34-H-1 AND TEMP. OF SALT IS
MAINTAINED BY TIC-3401 FROM D.C.S / PLC

THE FLUE GASES ARE VENTED AFTER PASSING

COMBUSTION AIR PRE-HEATER 34-HE-1 VIA STACK 34-D-6 IN
TO THE ATMOSPHERE.
 THE CAUSTIC MELT NAOH (96% MINIMUM) IS FED VIA
TO THE SEAL POT 34-T-5 TO THE FLAKER 34-F-1. TEMP. OF
MELT CAUSTIC IS MONITORED BY TE-3471 AND TE-3472
FROM D.C.S.

THE NAOH FLAKES PRODUCED IN 34-F-1 REACH VIA

FLAKE CHUTE TO THE BAGGING SCALE 34 -W-1; THE
FLAKES ARE FILLED IN 50 KGS BAGS, WHICH ARE
CONVEYED ON BELT CONVEYER 34-N-1 TO THE BAGS
STITCHING MACHINE.

DURING STARTING OF FLAKING PLANT FIRST 5 - 7

BAGS OF FLAKES SEGREGATED DUE TO HIGH NI & IT IS
USED IN INTERNAL CONSUMPTION. (VISUAL
OBSERVATION/SUBSEQUENT TESTING IN LAB.)

AFTER STITCHING BAGS ARE KEPT FOR NATURAL

COOLING OF MINIMUM 4 HR. AND THEN STACKED IN GO
DOWN BY DATE VICE PRODUCTION WHICH IS DISPATCH BY
MARKETING DEPT.
 FLOW DIAGRAM OF CAUSTIC FLAKING

CW

CR
OIL H2 47% CAUSTIC LYE

G SCALE
BAGGIN
STACK

57% CAUSTIC
FLUE
BURNER
CONDENSOR
34-B-2
GAS 34-C-1

CONCENTRATOR
PREHEATER
COMB AIR
34-HE-1

34-EV-1
PRE-
CONCENTRATOTOR
34-EV-2
FINAL
SALT-HEATER

COOLIN
34--H-1

G
COMBUSTIO

FLUE
NAIR

GAS FLAKER CR

34-F-1
CW
SALT
TANK BAGGING
SCALE

FLAKE

CAUSTIC LINE :
SALT LINE :
VAPOR LINE :
COMBUSTION AIR LINE :
AIR MANAGEMENT – CAUSTIC SODA
PLANT:

For Sodium Hypochlorite Plant:–

The waste chlorine gas from the manufacturing of caustic
soda is de-chlorinated by the three stage scrubbing system.

All the waste chlorine gases emitted are stripped in chilled
circulating caustic in three tower system wherein even traces
of chlorine gases are absorbed.

The industry is getting sodium hypochlorite as a co-product
from this system.
For Hydrochloric Acid Plant:–

Bubble cap tray followed by packed bed scrubber with DM
water as media to scrub HCl gas mist & Vapor.

The industry has installed total 20 on line chlorine monitors
at 20 locations hooked up with DCS within caustic soda plant
to indicate the ambient concentration of Chlorine gas and on
line hydrogen monitors at 2 locations hooked up with DCS
within caustic soda plant

Brine Sludge (Non-Hazardous)

The inorganic solid waste is generated during to salt
purification in caustic plant. The solid waste sent will be sent to
ETP which is in three pits having impervious lining for leachate
collection and any liquid collected is/ will be sent back to the ETP.
The sludge is being stored and utilized for low-lying area filling
within the factory premises and also used for growing Plantation.
Under Cleaner Production activities briquette formed by Process
Sludge, Cellulose waste, charcoal churry, coal ash & binder in
uniform composition The GCV (Gross calorific Value) of sludge
briquettes is in the range of 3800 to 4400 KCal/Kg, which is
equivalent to lignite. Briquettes are using in our boilers and co
incineration in our Group plant Ultra Tech Rajul

When Empty Tonner Recived form
Party :-

Following steps followed by Supervisor :

Physically check by Supervisor

Checked for presence of any process liquid inside/defect of

cylinder at the time of unloading and marked (Ok / Not Ok)

Cylinders which are having negative pressure, zero pressure &

weighing more than tare weight , not taking for refilling unless
other wise proper internal inspection carried out.

If pressure is negative or zero than compressed air given through

upper valve and checked with ammonia torch by opening lower
valve, if chlorine gas is coming cylinder is ok can be refilling other
wise cylinder is checked internally.

Valve, spindle checked, if found damage then after degassing the

cylinder same is
replaced with new one

Hydraulic Testing Procedure for Chlorine

Cylinder :-
Purpose : To Certify the Fitness of Cl2 cylinders for Liquid
Cl2 filling after
every 2 years.

Description: Degas Testing due Empty cylinders through

Degassing Header up 0.0 Kg/Cm2 pressure. Shift
the cylinders to Testing Station, Rinse the Cylinder
with caustic for neutralization then wash the
Cylinder with plenty of water by removing
accessories fitting. Again fit the Accessories Keep
the Cylinder Slightly inclined valve position should
be perpendicular. Fill the Cylinder with water
remove air at the top.
1, Set Burette level 90 Cm - TAKE - Reading ( L-1 )

2, Start Hydraulic pump, Pressurise the Cylinder up to

35.5 Kg / Cm2 keep the Cyl
30 sec.& ensure the leakages.TAKE -Reading( L-2 )

3, Release the pressure slowly through release valve up to

0.0Kg Cm2 TAKE - Reading ( L-3)

Drain the water start steam heating of Cylinder, heat up to

120°C. Flush with padding air and ensure complete
cleaning & drying. Allow to cool the Cylinder for internal
inspection.Fix valves and Plugs ,Take the weight of
Cylinder.

Calculation:

% weight loss = (Original Wt – Act.Wt ) * 100

Original Wt

% Expansion = Permanent Exp. * 100

Temporary Exp.

Basis of Rejection : Weight loss more than 5 %

% Expansion more than 10
DIAGRAM OF LIQUID CHORINE TANK:-
Chlorine Tonner Filling Procedure :-

Check following points before Giving Chlorine

Cylinder for filling:

Check Hydraulic Test date

Check the documents.

Check valves and physical condition of Cylinders.

Check positive pressure of Chlorine in side the cylinder
( with Ammonia solution.)

Check Hypo suction.

Check E.O.T.Crane Operation.

After checking all the above points:

Take clearance from control room .

Place the cylinder on weighing scale and connect liquid
coil to the bottom and vent coil on top valves.

Open cylinder valves after connection & ensure the
chlorine leakage.

Open coil mouth and liquid Cl2 control valves then start
filling with bottom coil .

Hypo degassing control valve should be close before
opening interconnection valve for double coil filling .

After filling the cylinder ensure liquid Control valve,
Cylinder valve & coil valve should be close and then
degas the coil to hypo.

Disconnect the cylinder and place the cylinder at its
proper place.
 QUALITY CONTROL

“Quality is an asset which may be offered to the

potential customer of a product or a service.”

It mainly depends upon two factors:

1. Product-Service Design
2. Operating System makes a product/provides a
service

Quality policy

We are committed to:

 Meet customer’s expectation of quality and services in

premium segment.
 Maintain high morale of employee.
 Use eco-friendly technology and maintain pollution free
environment.
SAFTY PRECAUTION TO BE TAKEN IN
CASE OF CHOLORINE STORAGE FILLING
AND LEAKAGE:-

CHLORINE LEAKAGE.

Properties of Chlorine (Greenish Yellow Colour)

Threshold limit value = 1 ppm
Fatal dose = 1000 ppm
Boiling point = (-) 34.90 Deg.C
Melting point = 101 Deg.C
Liquid density = 1.43 gm/cc
Filling ratio = 1.19
Non-flammable but highly toxic. Chlorine behaves as an
explosive when temperature is more that 70 Deg.C
Chlorine storage & installation is governed by The Gas
Cylinder Rules, 1981 framed under the Indian Explosive
Act, 1884.

HOW TO IDENTIFY CHLORINE?

• Chlorine is a greenish yellow coloured gas which can

be seen clearly. It is heavier than air. It has irritating
odour.

• Chlorine settles in low lying areas as it is heavier than

air.

• Chlorine is irritating to nose, eyes and throat.

SELF PROTECTION DURING CHLORINE
LEAKAGE:-
• Cover your nose and mouth with wet cloth or
handkerchief

• Check wind direction and move either left or right side

of the direction of wind.

• Do not run. Walk fast and get away from leakage area
by using any means of available transport.

• Untie cattle, pets, etc.

• Wash the eyes with plenty of water.

SAFETY FEATURES FOR CHLORINE

STORAGE & INSTALLATION :-

• We have 250 TPD caustic-soda plant (Backward

integration) where from chlorine is generated as a by-
product. The technology adopted is membrane cell.

• There are five chlorine storage vessels so called bullets

(Capacity 65 M3 water capacity each). The total
operation of chlorine storage vessels i.e. starting, filling,
isolation and transfer is auto-sequential controls by
DCS with necessary safety interlocks.

• All important in/out on / off valves are provided with

limit switches to physically verify the opening / closing
of on / off valves. All these valves are bellow sealed
type and are remote operated. If Cl2 pressure valve
remains open for more than 10 minutes, then rectifier
will trip.
• Each storage vessel is provided with double safety
valves, set at 13.5 kg/cm2g having common isolation
valve and individual rupture disc at the up stream of
safety valve. The safety valves are tested once in six
months.

• As an additional safety feature, there is a pressure

switch mounted between rupture disc and safety valve
which gives an alarm in case rupture disc fails.

• There are three level measurement devices on each

storage vessels. Out of which two devices are based on
level trolls, one is level transmitter and other is level
switch to give low and high level alarm. The third device
works on load cell and gives hold-up of chlorine in
vessel in tones. All the three devices are independent of
each other.

• The safety valve outlets are connected to waste air unit

where chlorine is absorbed in lean caustic solution.

• Each vessel is mounted with pressure gauge and

pressure transmitter. The pressure transmitter gives
indication and high pressure alarm in DCS.

• Twenty (21) chlorine detectors are mounted in chlorine

leakage area which detects chlorine leakage and gives
alarm in DCS.

• Hard wired emergency switches are provided in control

room for closing on / off valves mounted on vessels,
one switch for each vessel. This can be operated in
emergency for complete isolation of vessel.

• The total storage area is isolated and entry is restricted

by wire link maintaining required safety distances.
• All vessels are insulated with cold insulation and kept
under approved shed by CCE, Govt. of India, Nagpur.

• One bullet is always kept under reserve for emergency

dumping. This is also taken care of in operation
sequence by DCS.

• The sufficient number of fire monitors, hydrants are

provided around the installation.

• Emergency exits are provided on both sides of the

working platform on the storage vessels.

• Enough number of chlorine kits, air line respirator &

SCBA are provided for emergency purpose.

• Sufficient numbers of personal protective equipment are

made available.
• Sufficient number of wind socks are installed in the
plant to know wind direction from any corner of the
plant.

• Regular safety training, practical demonstration are

imparted to the employees.

• In addition to above, we have got well proven work

permit system, fire fighting squad and safety
department to maintain high standard of safety in the
plant.
Awards and Recognition
Performance & recognition received in the
last year:-

• Greentech Gold Award in Chemical Sector for

outstanding achievement in Environment
Management in year 2010
• ICC Award for Excellence in Energy
Conservation & Management in year 2010 (
Indian Chemical council )
• The Ministry of Environment & Forests
(Government of India), has given accolades to
Indian Rayon, Veraval (A division of Aditya Birla
Nuvo) for its unrelenting endeavours towards
environmental conservation and development of
clean technologies. The Ministry chose Indian
Rayon, for the coveted National Award for
Prevention of Pollution titled - The Rajiv Gandhi
Environment Award for Prevention of Pollution
2008-2009.

Integrated Management System:-

• ISO-9001 2000 ( Quality Management System )

• Recertified for ISO 14001:2004 (Environment
Management System) in April, 2008.
• Recertified for OHSAS 18001:2007 (Health &
Safety Management System) in May, 2007.
• Unit has been certified for SA-8000 (Social
Accountability) in the year 2007.
• Unit has been certified for RC- 14001
(Responsible Care and Environment
Management System) in the year 2008.
 LOCATION

Location is very essential and important part of the

industries. When deciding the location we should
identifies the key factor which is directly affected the
industry.

Indian Rayon units is located at veraval, in district

junagadh. It is approximately 185 km. away from
Rajkot. 85 km away from Junagadh towards south
east and 125 km. away from Porbandar in west north.
The place is 1 meter above sea level. Location is
nearest to Railway Station and state Bus Station. State
roadways operate round the clock towards Baroda,
Ahmedabad and Porbandar including its night
services.
WORLD CLASS MANUFACTURING

The economy is integrated to the global economy and

industry is facing global competition. It is therefore,
necessary to improve performance so IR & IL co.
adopt WCM model to improve performance and fitting
with global competition.

The following characteristics of WCM are used

to fulfill the customer expectations.
(1) Products of high quality.
(2) Products at the right price.
(3) Product with the enhanced features.
(4) Product in a wide variety.
(5) Products delivered in time, in fact short time.
(6) Products delivered with shorter lead times.
(7) Flexibility in fulfilling the demand for the product.

The above listed performance measures are external

to the manufacturing system but are vital for the
success of the organization. Indian Rayon Co. follows
WCM excellence model for competitive advantage as
we seen in above diagram.

WCM POLICY followed by company

To maximize equipment effectiveness,
Achieve zero breakdowns, zero defects, and zero
accident and eco-friendly environment through
innovative methods with total involvement of our
employees and b continuous up gradation of
technology. This will lead us to excellence and
perfection in all spheres of management, to be
globally. Competitive and preferred choice of
customers.
WCM Excellence Model for

Competitive Advantage
ACKNOWLEDGEMENT

Guidance and co-operation are valuable

for fulfilling and furnishing any kind work.
Similarly my project at INDIAN
RAYON(UNIT OF ADITYA BIRLA NUVO
LTD.)

I am very thankful to Shri B.B.DIXIT,

Mr.D.B.KALE (Prod.Manager). Safety
officer of Indian Rayon Mr. Kishor
Radadia and Mr. Suresh kher .I am also
thankful to Miss Shraddha Mehta Officer-
HR department to provide me this
opportunity, And Shri J.V.Dave(Librarian)
along with all staff and H.O.D. Who had
co-operated me.