1. GENERAL INTRODUCTION
The main aim of the organizational study is to acquire the knowledge regarding the functional as well as the management aspects of an organization It offers a unique opportunity to students to have hands on experience with industry while still in college. These are major aids in seeking employment after graduation. It exposes students to industry environment and work culture making it easier for them to transition from students to professionals. It gives a chance for the student to understand their strengths and get feedback from industry. Organizational study benefits both students and industry. Industry gets a chance to get some work done and test a student for an extended period before making them a permanent employee. This project is an organizational study at THE TRAVANCORE COCHIN CHEMICALS LIMITED, COCHIN, KERALA. The period available for the study was 31day.
1.1 OBJECTIVE OF THE STUDY
The objective of the organization study includes the following: To understand the organizational structure and the working of the various functional departments. To have an exposure to the work environment.
To understand the overall performance of the company.
To make an analysis of the organizations performance.
To study the relevance of TCC on chemical industry field in Kerala
It is an overall operation framework, which help to collect the required data. The methodology used in the study involves the collection data through primary and secondary means within the given time period. • PRIMARY DATA: It refers to the first data collected from primary sources .The primary sources of data collection were direct personal interview with managers of concerned department, official staff and workers of the company. • SECONDAY DATA: Data which are not originally collected but rather obtained from published or unpublished sources includes: 1: Company record
2: Annual records
3: Official sites of the company
1.3 SCOPE OF THE STUDY
The study was to get a general awareness of the functioning of the various departments and management of TCC Ltd. The period available for the study was one month. Since there were many departments, it was impossible to conduct a deep study on each department due to lack of time. There were many departments like operation, marketing, finance, human resource development, materials, engineering, project etc. The information from these department help to analyze the strength, weakness, opportunities and threats of the company
1.4 REASON FOR SELECTING THE COMPANY
TCC was established in 1950 through pioneering efforts of Messer’s Seshasayee Brothers Travancore Limited. The company was originally started as Travancore of Mettur Chemicals .It was the first mercury cell plant and hence happened to be the first manufactures of Rayon Grade, caustic soda in the country. TCC was the biggest NaOH manufactures in India at that time.TCC is the only caustic soda manufacture in Kerala.
TCC is a large chemical industry; as such accurate data regarding the internal affairs of the company are not easily available.
The available data is not sufficient to get the desired result.
2. INDUSTRY PROFILE
2.1 WORLD SCENARIO
In the international scene, the increased production of paper, aluminium, soap and detergent naturally leads to increased requirement of caustic soda in the world scenario. The green peace movement in seeking the phase out of chlorine usage, especially the CFC compounds. This has resulted in closing down of some of the chlorine industries in Europe and North American countries. With the drop in international production, the international price of caustic soda is steadily growing up. The caustic which was sold for 50$/ tone has grown up to the 300$/ tone now.
The international markets are opening in the context of demand supply prevailing from time to time, situation of surplus and shortage are cyclical as a result of which international prices tend to be highly volatile. Though the demand for chlorine is growing fast, the demand of caustic soda is not so promising. Hence the units in the gulf and western countries are selling caustic soda at a cheaper price. MAJOR COUNTRIES PRODUCING CAUSTIC SODA
2.2 INDIAN SCENARIO
In India caustic soda is produced by electrolytic process. The manufacture of caustic soda started during 1940 .The growth was slow during 1960 but after that the growth picked up substantially. Today there are 38 industries manufacturing caustic soda of which 40 are organized sector and the rest belong to the unorganized sector. The total installed capacity of all these units put together comes to about 17, 50,000 tones/annum. Indian Chlor-alkali industries follow membrane cell technology mostly.
This is highly beneficial because cell membrane technology is more efficient when compared to mercury cell technology. India was a net importer of chemicals in early 1990s, but has now become a net exporter due to implementation of many large scale petrochemical plants like Reliance, ONGC etc. and also because of tremendous growth of exports in sectors like bulk drugs and pharmacy, pesticides, dyes and intermediates MAJOR SOUTH INDIAN CHLORA-ALKALI UNITS
Chemfab Alkalies Ltd. Pondicherry
Southern petro Chemical Industries Corp.Ltd.Chennai
Kothari Petro Chemicals Ltd. Chennai
Sree Royal Seema Alkalies & Allied Chemicals ,Andhra Pradesh BILT, Karnataka
DCW Ltd, Mettur
TCC Ltd, Kerala
2.3 STATE SCENARIO
Caustic soda is one of the basic inorganic chemicals manufactured from common salt caustic soda; Hydrochloric acid and sodium hypochlorite are the products. In the Kerala state, TCC is the only Chlora-Alkali industrial unit and has a production capacity of 175 MT Caustic Soda per day. There are many small scale industries in the state which consumes caustic soda for the production of soap, detergents etc. Because of high transportation cost it is not possible to export caustic soda in large volume from the state. TCC is the only one chlor alkali unit in the state and it is employing environment friendly and energy efficient technology. Chlorine is a basic material required for water purification and without chlorine the water workers will not be able to supply good drinking water to the public.
The Travancore Cochin Chemicals Limited, Udyogamandal is a State Public Sector Undertaking owned by Government of Kerala. Reflecting the quality policy of commitment and excellence.TCC has a good track record of profitable operation and healthy industrial relations. A heavy chemical industry engaged in the manufacture and marketing of Caustic Soda, Chlorine and allied chemicals, TCC is accredited with ISO 9001: 2008certification.TCC is hence a mother company. The installed capacity of TCC is 175tons per day caustic soda and the products are used in manufacturing of soaps, textiles, plastics etc:
3. COMPANY PROFILE
The Travancore Cochin Chemicals Limited popularly known as TCC Ltd is a state public sector undertaking owned by the Govt of Kerala. It is situated at udyogamandal in Cochin industrial belt incorporated in 1951.TCC is one of the oldest chlor-alkali units in the sub continent.TCC is a heavy chemical industry engaged in the manufacture and marketing of caustic soda, chlorine and allied chemicals.TCC is an ISO 9001:2000 certified company.
TCC is one of the oldest chlor alkali units in India. It was the first mercury cell plant for manufacturing caustic soda in the country and hence it was the pioneer producer of rayon grade caustic soda in India. TCC is the only chlor alkali unit in the state of Kerala and also the only one chlor alkali unit in the public sector in the country. Countrywide it has about 37 competitors. Today TCC has a production capacity of 57750tones of caustic soda per annum. The company supports a large number of industrial units of strategic importance by supplying basic chemicals.
With continuous efforts for up gradation of technology and professional management the company has a good track record of operation and healthy industrial relations. TCC was bestowed with various awards for excellent performance with regard to production, productivity energy conservation and environmental protection which is considered as an award for commitment rather than for efficiency. The company has a good production plant TCC is conscious about its social responsibility and is dedicated to maintain the quality of product.
3.1 A BRIEF HISTORY OF TCC LTD
The company was registered under the name Travancore Mettur Chemicals (TMC) in 1950 as a joint venture between the FACT and METTUR Chemicals. The idea was to supply hydrogen chloride gas to FACT for making ammonium chloride for their newly set up ammonia plant. As it was post second world war period, the TMC could not raise sufficient fund to take delivery of equipment arrived in Cochin port knowing that chlor alkali industry is being set up to other companies. (M/S Hindustan Insecticides LTD and other companies and M/S Indian rax Earth LTD ) have started setting up the their plants at udyogamandal with the hope to get chlor alkali product for further processing.
The financial problem of TMC was taken up by then Travancore Cochin State Government .As the problem of TMC could affect three other companies, Travancore State Government gave massive financial statements to TML and with that company was renamed as Travancore Cochin chemicals LTD in 1951 commercial production started in 1954 with 20 tons per day caustic soda production capacity. The technology employed was mercury cell technology. The installed capacity was increased stage wise to 160 TPD employing mercury cell technology .In 1997 TCC commission a 100TPD caustic soda plant employing membrane cell technology from Asahi glass company, Japan. In 2002the capacity of AGC plant was enhanced to 125 TPD. In 2004 the last mercury cell plant was decommission .In 2005 and 2006 a 25 TPD capacity membrane cell plant each were installed and plants were supplied by M/S uhde company Germany. The total installed capacity at present is 175 TPD caustic soda.TCC also has a 100 TPD continuous caustic fusion plant flakes production plant and 45 TPD soda bleach plant.
3.2 PRESENT SITUATION
TCC is the only chlor alkali unit in Kerala. In India, there are about 37 chlor alkali units as the company’s competitors. Now TCC owns 109 acres of land and around 778 people are working in three shifts .This year TCC expects to achieve a record sales turnover of 145 crores. Previous year it was 126 crores. Now plants are functioning by utilizing full capacity. At present the company having the installed capacity of 175 TPD of caustic soda, 125TPD from M/S ASAHI Glass Company, Japan commissioned in 1997. 25 tons per day bipolar membrane cell caustic soda plant supplied by M/S uhde Germany were commissioned in July 2005 and another 25 TPD membrane cell plant from UHDE, Germany was commissioned in August 2006. The registered office and the factory of the company is situated at Eloor Udyogamandal. 683501 Ernakulum district, Kerala company was obtained ISO certification 9001-2001 in the year 2006. TRADE UNIONS
Recognized trade union
TCC Employee Association
Unrecognized trade union
TCC Employee union(INTUC)
3.3 THE PRESENT CAPITAL INFORMATION
INVESTOR AMOUNT SHARES Govt of Kerala
Vinyi investment LTD Chennai
3.4 INDUSTRIAL INFRASTRUCTURE
The company is situated at udyogamandal industrial area in Kerala state on the bank of river periyar. Out of the 109areas of land the company owns include 20 acres leased out M/S BSES Kerala power limited on which company receives lease rent .In addition to the plant and building it has a fully fledged housing colony for accommodation of the employees .The company is having a water treatment plant which draws water from periyar river and the plant has a capacity of 5mgd.Also TCC is having a 110KV electrical substation
3.5 QUALITY POLICY
The company is committed to enhance customer satisfaction by providing products and related services complying with a continually improving quality management system.
3.6 MISSION AND VISION
TCC is committed to supply quality chemicals at competitive price to customers. Customer satisfaction concern for environment and the safety are
their priorities VISION
Utmost level of conversion of all resources including energy Cost effectiveness in all operations
Regular up gradation of technologies used in processing
Compliance with laws and statutory regulation
State Bank of Travancore
State Bank of Hyderabad
Union Bank of India
Indian Overseas Bank
3.8 MANAGEMENT OF THE COMPANY
There are 10 directors for the company. As the major shareholders, Govt of Kerala nominates the BOD professionals as well as bureaucrats are being nominated to the board. The managing Director is the only full time director in the board. The principal secretary of industrial department is the chairman.
3.9 CORPORATE OBJECTIVES
To produce and market chemicals such as caustic soda, liquid chlorine, hydrochloric acid carefully and in environmentally sound manner. To make maximum profit from projects taken up
To continuously upgrade the quality of human resource of the company and promote organizational development To continuously improve the plant and operational safety and abide by the statutory pollution control standards. To ensure expansion and diversification through corporate growth To care the environment around
To maintain option level of efficiency and productivity and optimum level of investment
3.10 OBJECTIVES AND PHILOSOPHY
TCC believes that a public sector unit has to work effectively and profitably. It has no right to exist on the basis of continuous governmental aids to cover defects. Profits are required for contributing to the governmental treasury as a reasonable return on investment for use by the government for economic development purposes. Profits are also required for healthy continuity modernization and growth. The company also believes in healthy relations and human satisfaction as essential for survival and thus strives to be reliable supplies of quality products attending promptly to customer complaints.
3.11 GROWTH OF TCC
1956- A continuous caustic fusion plant with a capacity to upgrade up to 20 tones of caustic soda per day was set up 1958- A chlorine Liquefied plant was added mainly to meet demand from the newly set up DDT plant of Hindustan Insecticides limited, Ernakulum
1960- Production of caustic soda was raised to 30 tons per day.
1963- The caustic soda capacity was raised to new level of 40 TPD. The company established a new unit for the manufacture of sodium hydrosulphate with rated capacity of 30TPD.
1967- The capacity of caustic soda plant was raised to 60TPD as per third stage of expansion
1970A 60 TPD caustic soda CCF plant was set up along with its own water treatment plant.
1975- As the fourth stage expansion, a 100 TPD caustic soda plant was set up. This employed Mercury Cell Technology.
1976- The company set its own water plumbing and purification station.
1980- Export of commercial hydrochloric acid to Gulf countries 1980- Export of commercial hydrochloric acid to Gulf countries
1983- Installed and indigenously developed plant to cover mercury from effluents
1987- Installed hydrogen- firing system in continuous caustic fusion plant
1990- Brine Decolonization units commissioned
1992- A Research &Development section was set up
1997- The company planned to setup a technology for the production of caustic soda in collaboration with ASAHI GLASS of Japan, with a capacity of 100 TPD ,using Membrane Cell technology.
2000- The company set up a Brine purification plant.
2003- The company commissioned a new continuous Caustic Fusion plant and increased the membrane cell capacity to 125 TPD.
2005- The company commissioned a new caustic soda plant with a plant capacity of 25 TPD- M/s UHDE
2006- The company commissioned a new caustic soda plant with a plant capacity of 25 TPD
2012- Joint venture with ISRO- installed sodium sulphate plant
3.13 COMPETITORS OF TCC LTD
TCC is the only chlor-alkali unit under public sector in India and it is the only chlor-alkali unit in kerala. Some of the major competitors are: 1. Atul ltd, Ahmadabad
2. Bilt chemicals, New Delhi
3. Century rayon, New Delhi.
4. Chem., Fab alkalis, Pondicherry.
5. Chemplat sanmat ltd, Mumbai.
6. PCW ltd, Mumbai.
7. Grassing industries, Nagda, Madhya Pradesh.
8. Gujarat alkalis and chemicals, Gujarat.
9. Gujarat heavy chemicals, Ahmadabad.
3.14 POLICIES FOLLOWED BY TCC QUALITY POLICY We are committed to enhance customer satisfaction by providing products and related services complying with a continually improving quality management system. ENERGY POLICY
Travancore-Cochin Chemicals is always committed towards the conservation of energy by all possible means. They strive for: Technological up gradation to reduce specific energy consumption. Using renewable energy sources to the extent possible
Disseminating knowledge and information on energy conservation to our Employees. Low energy fuels also to be tried depending upon feasibility HEALTH AND SAFETY POLICY
The company will provide a work environment in which identified hazards are controlled, if elimination is not feasible and will provide personal protective equipments wherever necessary. Accident prevention is the direct responsibility of the Line Management and will be an important criterion for performance appraisal. Line Management will ensure that all safety measures are incorporated in the operating and maintenance procedures as well as in any process technology changes in the plant/infrastructure. Consideration of health and safety will be given proper weight age in selection and deployment of the personnel.
4. PRODUCT PROFILE
TCC produces wide varieties of products from Caustic soda to sodium hypochlorite. Various product of TCC are; 1. CAUSTIC SODA (NaoH)
2. CHLORINE (Cl2)
3. HYDRO CHLORIC ACID (Hcl)
4. CAUSTIC SODA FLAKES
5. SODIUM HYPOCHLORITE
1. CAUSTIC SODA (NaoH) Caustic soda is a basic alkali. It came into being in the latter half of 19thcentury with the development of electrolysis. Caustic soda lye, obtained from membrane cell is a clear colourless, odourless and soapy liquid. TCC is producing two types of caustic lye of concentration 32% and 50% USES
A chemical for dissolving out extraneous matter from wood
For preparing pure cellulose and for the preparation of alkalie cellulose and for the production of viscose solution As specification agent
In bleaching,dyeing and mercerzing for processing monazite and refining of bauxite A purification agent and absorbent for acidic gases
A clearing agent
For clearing petroleum fractions
Reagent for production of various organic chemicals
Fig. 4.1 Caustic Soda
2. CHLORINE ( Cl2)Chlorine, a co-product obtained in the manufacturing process of caustic soda is anequally important basic chemical. It is a renowned water purifying chemical. It is a greenish yellow gas. Chlorine is sold after liquefying. Chlorine has got a pungentsmell and liquid chlorine is amber in colour. USES
Providing insecticides(DDT,BHC) and pesticides like Aldrin
In purifying drinking water
For manufacturing pvc and allied co-polymers
As a bleaching agent
For producing chloramines and its organic derivatives
For upgrading titanium content in limonite.
3. HYDROCHLORIC ACID (Hcl)Hydro chloric acid produced by TCC is of high
purity and finds application in number of chemical industries and it is yellowish green in colour. The Hcl produced have concentration 30.33% and 50% USES
For the production of ammonium chloride and in the manufacture of phosphoricacid. 2.In monazite processing for the separation of rare earths as Chlorides from thorium. 3.As cleaning agent in galvanizing
Fig.4.3 .Hydrochloric Acid
4.SODIUM HYPOCHLORITE (NaClO)Sodium Hypochlorite, known as soda bleach,find its application in bleaching and disinfectant and also in the extraction of rare earth chemicals.It is a pale yellowish green colour liquid.Soda bleach is the only branded product that company producing ,brand name is “EKOCLEAN”
As a bleaching agent
As germicide and cleaning agent
Fig.4.4 Sodium Hypochlorite
5.CAUSTIC SODA FLAKES Caustic soda lye is fused to produce caustic soda flakes.This is a continuos caustic fusion plant that produces caustic soda flakes
5. DEPARTMENTAL ANALYSIS
5.1 HRD/TRAINING DEPARTMENT
Human resources is considered as the most vital asset of an organization. TCC hasa well defined employee power which helps the organization to perform well in themarkets. Human resource department is headed by manager (HRD). He isresponsible only for training and development M (HRD) id reporting to AssistantGeneral Manager (HR)
MAIN FUNCTIONS OF HR / TRAINING DEPARTMENT
a. Identifying training needs.
b. Arrangement requirement training.
c. Maintaining the training record.
The details are handed over to the training department by respective departmenthead. Training department does compilation of the identified training needs of theemployees. Necessary training programs are arranged by training department tolater the identified training needs of the employees.Training department organizetraining programs using internal faculty or engaging faculty from reputedorganization. The training department in consultation with concerned departmentheads organizes in house training programs on special requirements.
Whenemployees attend training programs conducted in house. A feedback about theusefulness of the training is obtained and consolidated. The concerned departmenthad evaluates the feedback from the participants after a period of 2-3 months toascertain the effectiveness of the training program. Employees are also sent for training to other reputed institutors nominations for sending employees for training insuch institutions outside the company are put up for approval of the appropriateauthority as per the guidelines outside programs submits a feed back on the traineeundergone the training department.
The achievement against annual trainingcalendar is reviewed half yearly by department helps for the number of programsheld, number of employees participated for each programs the highlights of training effectiveness, feedbacks…..etc. The training department maintains a register on thetraining program attended by the employees. Training department maintains theformat received from participants after getting it evaluated by the concerndepartment head regarding the effectiveness of training.
Every month three day training program is held for workers. The workers educationcenter,under the central labour industry conducts it. These programs are conductedon a contract basisand are recorded annually 20-25 workers from various sectionsare selected every month and 4-5 officers from WEC conduct the training programs. The topics covered include personality,management development, inter personnelrelations, impact of globalization effective communication…etc.
Other in house programs are conducted by agencies like Kerala state productivity council. Insuchprograms company can decide upon faculties and topics for training. During theinstallation of membrane cell plant, officers were sent to Japan for training. So on the job training is prevalent in all sections of the company.
EXTERNAL TRAINING PROGRAM
These programs are provided for workers conducted mainly inside Kerala and a fewnumbers outside Kerala also. The management does not keep aside a budget for training need. On anaverage TCC spends more than 11 lakh rupees on the training needs every year.
OBSERVATION OF HRD
HRD Department organizes training programs using internal faculty or engineeringfaculties from reputed organization. TCC should see to it that training needs of theworks, supervisors and executives are recognized and separate training programshould be developed for each groups
In order to provide this type of training, one has to determine what is the trainees growth potential, up to what level to be done and requires evaluation of his presentperformance.
NEED BASED TRAINING
Need based training will be done on the basis of determining the level of knowledgeand skill one requires for a job. Next is to find out how many employees have to begiven this training. On the basis of these needs training is given to the employees.
CUSTOMER TRAININ Customers are given training on handling of chlorine and other products in various situations. INDUCTION TRAINING
It is the training provided to the newly recruited employees to familiarize them with the activities, rules and policies of the organization. It is also done to introduce the new employees to the other employees of the organization.
Company provides advanced training for workers to cope up technological changes.Feedback is obtained from employees and effectiveness of the training program is ascertained after a period of 2-3 months
5.2 TECHNICAL DEPARTMENT
There are two main sections in this department:
1.The Technical Service section
The technical service department is concern with the monitoring of productionprocess. This includes making a comparative analysis if any deviations are found.Reports are maintained on daily as well as monthly basis and internal as well asexternal basis. The reports are sent to all other departments.
I. Daily report includes the following:
Daily production details
Material consumption details
Over time reporting etc.
II. Monthly internal reports include the following:
Production process report
Raw salt analysis etc.
III. Monthly external report includes reports to various Government department andother agencies, production calculation and reporting.Computerization & IT development.
2. Safety & Pollution control systemThe safety policy of the company states that: • TCC is committed to provide every one of its employees &the related public anaccident free and healthy environment in its efforts to manufacture high qualityproducts with all stationary requirements in this regard. • The company will provide a work environment in which identified hazards &controlled if eliminations not feasible and will provide personal protectionrequirements like gloves, file mask welding shield, safety shoes, helmets, safety belt,skin protective ointments…etc .whenever necessary. • Accident prevention is the direct responsibility of the line management and will bean important criterion for performance appraisal.
Line management will ensure thatall safety measures are incorporated in the operating and maintenance procedure aswell as in any process technology changes in the plant. • The company will ensure that health & safety aspects are given due considerationin decision regarding purchase of plant equipments machinery & materials.
• All contract job will be carried only through the laid down procedures with appropriate supervision • Employee, consumers & public awareness where necessary, will be imparted withthe required education, training & retraining safety and health aspects related to theprocess and products.
• Contractors, sub-contractors, workers, transports & visitors entering the factory shall be required to observe health and safety practices of the company in all their activities. • The company will include a resume of its health and safety performance in its annual reports
5.3 MARKETING DEPARTMENT
TCC is the only chlor-alkali unit in Kerala and hence it is more or less a monopoly in Kerala market. However, nationwide there are around 40 competitors. TCC giveshigh importance for customer satisfaction. They maintain close contact products.Type of market is buyer market. Marketing department consists of two sections:
Office sectionb. Issue section All documentation works come under office section and all the work relating to salescome under issue section. TCC adopts marketing strategy according to the productnature, market situation, demand for the product etc. TCC currently has about 80%of the total market share in the state. Of the total production, 60% of the goods aresold outside Kerala and 40% within the state. MAIN FUNCTIONS OF OFFICE SECTION
Preparation of sales quotation, letters, amendments etc, maintenance of salesofficers register books and other necessary information Preparation of sales budget, sales plan, monthly allotments etc,correspondence with parties and follow up of routine and regular matters Preparation of sales order, dispatch and delivery notes
Up keeping of all files up to date
MAIN FUNCTIONS OF ISSUE SECTION
Preparation of schedule of dispatch and actual dispatch
Execution of sales offers
Advising parties about the dispatch effected
Maintenance of daily stock registers
DUTIES OF MARKETING MANAGER (SALES)
Concerned with the office section of the department
Responsible for tender issue process
ACTIVITIES OF MARKETING DEPARTMENT
Whenever a company places an advertisement regarding the requirement of chemicals like caustic soda lye or flakes with the specification for the chemicalpayment terms, quantity required, validity required, the companies
that are ready tosupply viz., TCC, will send tenders to the required company. This is known as atender document. In a tender document mainly two documents are specified
a. Technical bid
This is the specification about the quality aspect of the product, how much quantitycan be given within a period as specified by the customer company etc. These termsare well explained in the technical bid
b. Price bid
This is a part of the tender document which specifies the basic prices of thecompany products. The document rate is given for bulk purchaser, payment termsare also experienced. Along with the tender to the customer company, an attractiveEarnest Money Deposit (EMD) is also offered. This deposit is for the purpose of assuring the customer company that if they accept TCCs offer, certainly the product will be supplied to the customer.
The deposit will be refunded by the customer company after the purchase is made. The EMD is attached only in the case of bulkpurchase. After accepting the offer placed by TCC, the customer company will placea purchase order. The purchase order explains the details of the product, quantity,price etc. Sales order is placed and will be verified by Deputy Marketing Manager.He makes arrangement in respect of supplying product to the customer. The acceptance offer is usually by selecting the lowest price
DUTIES & RESPONSIBILITIES OF ASSISTANT GENETAL MANAGER
• Head of the operations department.
• He fixes the monthly target of the product based on the market requirement .• He is responsible for modification in the production process and responsible for the affluent discharge.
• He is the designated emergency controller during any hazardous incident of leakage & emission of toxic gasses/ fluid etc.
DUTIES & RESPONSIBILITIES OF PLANT MANAGER
• Custodian of plant
.• He will plan production activities to meet the production of target set by the AGM (OP).
• He is responsible for the material consumption.
• He plans the shutdown activities and carries out maintenance work of the plant .• He co-ordinates the operational functions with the manager of other departmentsfor the smooth functioning of the plant. OBJECTIVES OF OPERATIONS DEPARTMENT
• Maximize production confirming to production specification .• Optimizing the consumption of electricity and purification of chemicals .• Maximize the production overheads
.• Maximize the availability of electrolysis for operations
PLANTS IN TCC
There are three plants involved in the electrolytic production process of thecompany. 1. AGC Plant
This plant is designed by ASAHII GLASS COMPANYLIMITED,TOKYO, JAPAN. The plant was commissioned on 29thmay 1997. Theproductsare Caustic Soda , commercial Hydrocloric Acid, liquid Chlorine andSodableach. The plant consists of 20 electrolyzes. The plant has 125 TPDCausticSoda production capacities.
2. UHDE 1 Plant
The plant is designed by UHDE, Germany. Theplantwascommissioned in 2005. The plant has a production capacity of 25 TPD of Caustic Soda. It consists of one electrolyze with 54 elements. 3. UHDE 2 Plant
This plant is also designed by UHDE, Germany. The plant wascommissioned in 2006. The plant has a production capacity of 25 TPD of CausticSoda. It consists of one electrolyze with 54 elements. RAW MATERIALS USED
Raw materials used in the production process in TCC are
1. Common Salt (raw salt)
TECHNOLOGY USED FOR PRODUCTION
The technology used by TCC is Membrane Cell Technology which is environment friendly and energy efficient technology.
The process followed in production by TCC is electrolysis of Brine.PROCESS DESCRIPTIONBrine (solution of raw salt & water) saturation & purification process are common for AGC,UHDE 1 and UHDE 2 plants.
STAYS IN THE PRODUCTION PROCESS
1. Brine saturation and primary purification
Sodium Chloride or row salt is fed intothe saturator using the bucket elevator, where it set mixed with the Chlorinedecomposed,depleted Brine. This saturated Brine from the saturator goes toprecipitation tanks A & B and a mixer tank where Barium Carbonate Soda Ash andCaustic Soda are added respectively to remove Sulphates, Calcium and Magnesium.
Impurities as precipitates.the Brine along with the precipitates then goes to theclarifier where 90% of the precepts are allowed to settle. Theclarified Brine is passedthrough Anthracite filters where the remaining 10% precepts areseparated.HCL isadded to the filtered Brine tank to convert impurities to ionic form. Brine is tobeadmitted to the secondary purification system only after the desired purity level isattained.
2. Secondary brine purification
The secondary Brine purification systemconsists of our ion exchange filters. The primary purified Brine is passed through theIon exchange filters where it undergoes Ion exchange process. Ion exchangematerials are insoluble acids & bases, which when converted to salt remaininsoluble.These ion exchange materials are used in columns in which the solutionscontaining ionic impurities like Calcium and Magnesium are in contact with the resin bed. The saturated resin is then regenerated to its original state by acid alkalisolution
The secondary purified Brine is passed through a heat exchange, fedto Brine head tank and is admitted to the anode compartments of the electrolysis.Dematerialized water is also admitted to the cathode compartment of theelectrolysis. Direct current (DC) supply is connected to the anode and cathode.During electrolysis Caustic Soda Lye is produced at cathode which is 32%concentration. Hydrogen gas is also formed at the cathode chamber. Chlorine isformed in the anode where the depleted Brine solution comes out.Caustic Soda ispumped into storage tank and Hydrogen and Chlorine gas goes to their respective treatment section
4. Chlorine treatment & liquefaction
Chlorine treatment and liquefaction involvescooling,washing filtration, drying, compression liquefaction, storage and liquidChlorine filling in the cylinders, the Chlorine from anode chamber of the electrolysisis first cooled at 30 degree celcious with the cooling tower water. Final traces of saltis removed by using a wet Chlorine filter, it is then again cooked using chilled water. After this the Chlorine gas is divided into two streams for the HCL synthesis and for liquefying. The Chlorine for liquefaction is dried using 98% Hydrochloric acid indrying tower. The dried Chlorine is compressed using acid ring compressors. Thecompressed Chlorine gas turns into liquid Chlorine storage tanks.Chlorine for the HCL synthesis unit is fed by using chlorine blower
5. H2 treatment and HCL analysis
Hydrogen gas from the electrolyser is washedwith water in washing chamber, cooled using tower water and admitted directly toHydrogen blower,after separating the condensate. The Hydrogen gas is used for theHCL synthesis and also as a fuel in the CCF plant. Hydrogen for HCL synthesis isfed to the oven using Hydrogen blowers. Here it is burned in the presence of Chlorine. The resulting HCL gas is absorbed in the water flowing down the oven to produce 31% commercial HCL gas
6. Continuous Caustic fusion
It is done in CCF (continuous caustic fusion) plant.CCF plant is mainly for concentrating 32% NaOH lye to 50% NaOH lye and then to98%-99% NaOH melts which is converted as flakes. The 32% NaOH lye is stored in generated in Ev1 is then drawn by a vaccum pump through a condenser and thusEv1 is working under vaccum and at 70-80 degree celcious. The outlet from Ev1 is40% Caustic Soda lye which is passed through Ev2 where it is evaporated to 50%Caustic Soda lye using 9 kg/-cm steam from boiler. A portion of 50% Caustic Sodalye cooled and sold. The remaining portion of 50% Caustic Soda lye is pumped toEv3 where it is heated using heat transfer salt which is a mixture of 53% PotassiumNitrate, 40% Sodium Nitrate and 7% Sodium Nitrate. In Ev3 the 50% Caustic Sodalye is concentrated to 98%-99% Caustic Soda melt which is converted as CausticSoda flakes in a flakers drum.
7. Soda Bleach preparation
Excess of waste Chlorine can‟t be disposed as a wastegas. But it has to be absorbed in dilute Caustic Soda lye to produce Soda bleach.Thus the Soda bleach plant serves also as a pollution control system.A part of 32%Caustic Soda lye, chlorine is used for the preparation of Soda bleach. The excessChlorine at the time of plant shutdown or startup and also from cylinder fillingstationgoes for Soda bleach preparation, 32% Caustic soda lye is diluted using de-mineralized water. The solution is passed through two absorbing towers, where itreacts with Chlorine gas so as to produce Soda bleach.
5.5 MATERIALS DEPARTMENT
Manager Materials is the head of the department. He is responsible for all functionsrelated to purchase, stores and inventory control. Materials department is dividedinto three sections.1. Purchase section2. Stores section3. Inventory Control section PURCHASE SECTION
Purchase procedure:- Receiving MPR.- Evaluation of the MPR.- Inviting tender from various organization.- Evaluation of the tenders and prepare a comparative statement Send tenders to the originator of MPR for recommendation.- Issue purchase order as per the recommendation of the originator.Purchase section deals with:- Purchase of stock items as required by inventory control.- Purchase of maintenance items as required by the maintenance planning and plantsections.- Purchasing of raw materials required for the process.- Purchase of bulk consumable for the process.- Purchase of demanded item.s- Payment against delivery through bank.STORES SECTIONStore section deals with:- Maintaining a minimum stock of items required by various departments.- Issuing of stock items required by various departments according to the materialsrequest.(MR).- Preparation of various reports like
• Receiving report
.• Inspection reports
.• Evaluation of MPR for purchase of new items
.• Preparation of materials code system (10-digit system)
INVENTORY CONTROL SECTION
Inventory control is an essential function of stores department. It helps to reduce costand increase profit of the organization. Codification of material is done by manager inventory control. For controlling the inventory, certain levels of inventory such asmaximum, minimum and re-order level is prepared. When the stock reaches the re-order level, purchase request is made. INVENTORY CONTROL
The purpose of inventory control is to avoid surplus and security of materials. Theinventories items are classified based on value contributed by each items dependingon the cost of and turnover of materials. OBJECTIVES OF INVENTORY CONTROL- Avoid unwanted pilling up of inventory- Material identification to avoid duplication- To maintain records- To dispose scrapped items- To determine which and how much to replenish
FUNCTIONS OF INVENTORY CONTROL
Maintaining a minimum stock of items required by various departments. Preparationsof various reports regarding inventory such as: • Receiving reports
• Inventory ledger
• Inspection report
• Evaluation of MPR
• Preparation of material code system to verify items and for easy handling
• Fix various levels such as minimum level, maximum level, re-order level,damages level etc. of each items • Calculate and minimize lead time
• Separate materials into Indian/import
The major type of customer deal with TCC is pharmaceuticals, soapindustries,insecticides, pesticides, paper industries and rayon industries.
No major environment pollution has been reported for the past 50% years of operation.
The strength of TCC is the quality of their products services and the delivery.
Location preference, reference and quality are the major criteria for selectingmanufacture.
The company is depending heavily on electricity and around 60%of their product price is for this.
Annual Report -Travancore Cochin ChemicalsLTD.