my first training project

1

A Project Report

On

General Overview of Mechanical Engineering Department

In

Submitted in Partial Fulfillments of the Requirements for the Award of the Degree of

B.TECH IN MECHANICAL ENGINEERING

Prepared by

Momin Mohd. Azhruddin A.

Presidency College of Engineering

Project Duration: 14/07/2011 to 11/08/2011

2

ACKNOWLEDGEMENT

I AM GLAD TO SAY THAT I GOT A GOLDEN OPPORTUNITY TO GET TRAINING AT GUJARAT ALKALIES & CHEMICALS LIMITED (G.A.C.L) ABOUT 30 DAYS. I GOT THE TRAINING AT MECHANICAL DEPARTMENT OF COMPANY AS IT IS RELATED TO MY BRANCH. I AM GRATEFUL FOR SUPPORT & GUIDANCE OF

MR.AMIT.PATEL.MR.M.B.OZA.MR.JAYESH.PATEL.MR.DILIP.PATEL.MR.S.B.PATEL.MR.PANKAJ BHAI.MR.J.V.PATEL.MR.BRIJESH.SHAH. MR.SAAVAN.ACHARYA.

FOR THEIR ENCOURAGEMENT AND HELP DURING OUR TRAINING PERIOD DUE TO WHOM I PURSUED MY TRAINING SESSION.

3

WHAT DOES THE NEW LOGO OF GACL SAY?

Taking into the

Considerations the aspects of the global warming and the need to address to the

cleaner and greener environment,

The logo of the company Gujarat Alkalies and Chemicals Limited, Vadodara has been conceived to represent a responsible corporate. Keeping the Importance of the rising issue of the pertinent to the environment, GACL have designed a logo that would reflect the company's mission to keep earth green.

The “Green Attitude” of company addressing the aspects of global warming.

The colours Blue and Yellow reflect the rising temperatures can adversely affect some regions with excessive rainfall while some others with heat waves and drought.

4

INDEX

1 History

2 Company Profile

3 Board of Directors

4 Awards Received by G.A.C.L.

5 Corporate profile

6 Organization Structure

7 Products of G.A.C.L.

8 Milestone of G.A.C.L.

9 Manpower Strength

10 Policies

5

11 Overview of CLM Plant

12 Pump

13 Compressor

14 Vales

15 Blowers

16 Boilers

17 Cooling

towers

6

HISTORY OF GACL

Gujarat Alkalies and Chemicals Limited (GACL) was incorporated on 29th March, 1973 in the

State of Gujarat by Gujarat Industrial Investment Corporation Limited (GIIC), a wholly owned company of Govt. of Gujarat, as a Core

Promoter.

GACL has two units located at Vadodara and Dahej, both in the State of Gujarat. It has

integrated manufacturing facilities for Caustic Soda, Chlorine, Hydrogen Gas,

Hydrochloric Acid, Chloromethane, Hydrogen Peroxide, Phosphoric Acid, Potassium

Hydroxide, Potassium Carbonate, Sodium Cyanide, Sodium Ferro cyanide. The Dahej unit also has 90 MW Captive Power Plant (CPP) for regular and economical power

supply.

The Company commenced its operations in 1976 with 37,425 Metric Tons Per Annum (MTPA) Caustic Soda Plant based on the

then, state-of-the-art Mercury Cell process at its Plant which is situated 16 km North of Vadodara near Village Ranoli on the main Railway track route between Ahmadabad

7

and Mumbai.

Right from the inception, GACL has been following the strategy of continuous capacity

expansion in core areas. The first stage expansion of the Caustic Soda Plant raising

the capacity to 70,425 MTPA was undertaken in October, 1981 followed by a diversification

program to produce 2000 MTPA of Sodium Cyanide in December, 1982.

In 1984, the second stage expansion to increase the capacity of Caustic Soda Plant

to 103,425 MTPA was undertaken. Simultaneously, the Company undertook the

diversification project for manufacture of 10,560 MTPA of Chloromethane using

Chlorine, a co-product of the Company and in 1991, the capacity of Chloromethane

production was doubled.

As power is the major input for production of Caustic Soda and constitutes about 65% -

70% of the cost of production, the Company along with other Corporations like, M/s.

GSFC, Petrochemicals Co-operative Ltd. and Gujarat Electricity Board promoted a gas based power unit in Vadodara under the

name of Gujarat Industrial Power Company Ltd. (GIPCL) during the year 1985. As a promoter of GIPCL, the Company gets low

cost power, as the plant is gas based and is depreciated.

Since production of Caustic Soda is highly power intensive, in order to reduce power

cost and to eliminate mercury pollution, the Company during the year 1989 converted one of its Cell Houses producing Caustic

8

Soda from Mercury Cell Technology to environment friendly Membrane Cell

Technology, thereby eliminating the use of mercury. The Capacity of Caustic Soda was

also increased to 132000 MTA.

The conversion of second Mercury Cell to Membrane Cell was carried out during March,

1994, thereby eliminating the total use of mercury from the Complex for production of Caustic Soda and increasing the capacity of plant along with this conversion to 170000 MTA including Potassium Hydroxide facility.

As part of this Membrane Cell Conversion Project, a new facility for manufacture of 16500 MTA of Potassium Hydroxide Lye

based on Membrane Cell was also set up. The Company has further set up facility for converting part of this Caustic Potash Lye

into Potassium Carbonate with a capacity of 13200 MTA. In order to add further value to

its products, the company had set up manufacturing facility for production of

11000 MTA Hydrogen Peroxide (100%) at Vadodara Complex during the year 1996 to utilize Hydrogen gas, which is a co-product

from Caustic Soda Process.

In 1995, as a part of diversification program and to meet the growing demand of its

products in the State of Gujarat and nearby areas, the Company had set up a plant for

manufacture of Technical Grade Phosphoric Acid with capacity of 26400 MTA (85%

Phosphoric Acid) at a new location at Dahej, District Bharuch. The Company also set up Membrane Cell based grass root Caustic-

Chlorine Unit with a capacity of 100000 MTA

9

at Dahej. Along with this, a captive 90 MW co-generation Power Plant was set up so as to ensure uninterrupted and low cost power

for its captive operations.

COMPANY PROFILE

Name of the Company

GUJARAT ALKALIES AND CHEMICALS LIMITED (GACL)

Registered Office / Vadodara Complex

P.O. Petrochemicals-391 346Dist. Vadodara, Gujarat, India.Phone-+91-265-2232681-2Fax-+91-265-2232130

Dahej Complex

P.O. Dahej-392 130Taluka- Vagra, Dist. Bharuch, Gujarat, India. Phone-+91-2641-256315-6-7Fax-+91-2641-256220

URL

www.gacl.com

www.gujaratalkalies.com

Size of the Organization

http://www.gujaratalkalies.com/

10

Large Organization

Solicitors

Messer’s Amarchand & Mangaldas & Suresh A. Shroff & Co. Mumbai.

Cost Auditors Messer’s Diwanji & Associate

Cost Accountants Vadodara.

BOARDS OF DIRECTORS:

Shri. A.K.JOTI (I.A.S)…………… Chairman

Shri. G.C.Murmu (I.A.S)

Shri. M.M.Srivastava (I.A.S)

Shri. D J Pandian (I.A.S)

Shri. G.M.Yadwadkar

Dr. Sukh Dev

Shri. J N Godbole

Shri. Guruprasad Mohapatra (I.A.S.)……………. Managing Director

11

AWARDS & RECOGNITION

The Company is a proud recipient of the following recognitions and

awards:

Sr. No.

Name of the Award Purpose of the Award Name of the Organization

Date of receiving the Award

Year 2009-101) Excellent achiever

Award.For valuable

contribution in chemical industry

Gujarat Chemicals

Association, Ahmadabad

February, 2010

2) Award for Excellence – 2009.

Certificate of Meritin the field of Export

Promotion

Federation of Gujarat

Industries, Vadodara

May, 2010.

3) NSCI safety Award -2009.

Appreciation letter by National Safety

Council

National Safety Council established by

Ministry of Labour &

Rehabilitation, Government

of India

October, 2010.

4) Excellence Certificate for

‘Securing Participation Position

in Good House Keeping Contest

2009-10’.

Baroda Productivity

Council, Vadodara

For the year 2009-10.

5) CHEMEXCIL Award For Outstanding Export Performance

Export Promotion Council,

Government of India

For the year 2008-09 & 2009-10.

Year 20081) Amity Corporate

Excellence Award, 2008

For one of the best and the most

admired business

Amity International

Business

20th

February, 2008

12

organizations for its unparallel

performance.

School

Year 20071) 3rd National Award for

Excellence in Cost Management - 2006

for the manufacturing unit in the Public

sector.

For efficient management in cost

works of the manufacturing unit.

Institute of Cost & Works Accountants

of India (ICWAI).

2nd July, 2007.

2) National Energy Conservation Award - 2007 : Second Prize in the Chlor-Alkali

Sector

For consistent performance on

energy conservation.

Bureau of Energy

Efficiency (BEE),Min. of Power, Govt.

of India

14 December

2007

Year 20062.) AIOE Industrial

Relations Award 2005-2006

Corporate initiative in the field of industrial

relations, social security and

promoting Bi-partism

All India Organization of Employers

05 January 2007

13

3.) Safety Innovation Award -2006

In the field of Safety Excellence

Institute of Engineers, New Delhi

06 September

20064.) Indian Society for

Training & Development (ISTD) Certificate of merit

2005-06

For Innovative Training Practices: 2005-06 National

Level

Indian Society for Training & Development (ISTD), New

Delhi

01 July 2006

5.) SCOPE Meritorious Award 2004-05

In the field of Good Corporate

Governance

Standing Conference of

Public Enterprises (SCOPE),

Delhi

26 June 2006

6.) TERI's Certificate of Appreciation for Environmental

Excellence award – 2005

For case study of Recovery of Calcium Chloride project at

Dahej which uses the waste effluent to

make useful product reducing pollution in

sea.

TERI - The Energy & Resources

Institute, New Delhi

26 June 2006

7.) Greentech Safety Silver Award 2006

Safety Excellence at Dahej Complex

Greentech. Foundation, New Delhi

08 April 2006

8.) Greentech Safety Gold Award 2006

Safety Excellence at Vadodara Complex

Greentech. Foundation, New Delhi

08 April 2006

9.) FGI (Federation of Gujarat) award for

Excellence in Environment – 2005

(Dahej)

For Environment Preservation &

Pollution Control at Dahej Complex

FGI (Federation of

Gujarat), Vadodara

03 April 2006

10.)

IMC Ramakrishna Bajaj National Quality

Certificate of Merit 2005 Award in Manufacturing

Category at National level

For Quality Management

Systems adopted at GACL (as per quality

criteria of management

systems of Malcolm Bald ridge, (USA)

Indian Merchants' Chamber, Mumbai

06 March 2006

11.)

Appreciation Prize for the case study on

"Economics of Quality"

For "Economics of Quality" for the

systems at GACL

Quality Council of

India, Ministry of Commerce & Industry,

Govt. of India

03 March 2006

12.)

Jamnalal Bajaj Uchit Vyavahar Puraskar

2005

For Fair & Ethical Business Practices

Council for Fair Business

Practices (CFBP), Mumbai

24 February

2006

13.)

Recognition by ICSI (Institute of Company Secretaries of India) considering GACL in

the list of Top 25 Companies for the

year 2005

For National Excellence in

compliance of law, ethics and best management

practices in the field of Corporate Governance

Institute of Company

Secretaries of India (ICSI), New Delhi

13 January 2006

Year 2005

14

14.)

First Prize Winner In Category - C for

Chemical Process Industries for " House

Keeping "

House Keeping Baroda Productivity

Council, Vadodara

28 December

2005

15.)

Certificates of Appreciation & Honor

for Safety Performance (Vadodara) &

Certificate of Honor (Dahej)

Safety Performance Gujarat Safety Council & Factory

Inspectorate, Govt. of Gujarat

16 December

2005

16.)

National Energy Conservation Award 2005: National Level (Chlor-Alkali Sector) 1st prize (Vadodara Complex) & Merit Certificate (Dahej

Complex)

Energy Conservation at Vadodara Complex

Bureau of Energy


of India

14 December 2005 by His Excellency

the President of India.

17.)

IMEA-2005 Award India Manufacturing Excellence Award for

Housekeeping & Effective Deployment

of QMS

Excellence in Housekeeping &

Effective Deployment of QMS

Frost & Sullivan,

Mumbai,(USA based

organization)

09 December

2005

18.)

Green Tech Environment

Excellence Award - 2004-05 (Silver)

Environment Excellence at

Vadodara Complex

Greentech Foundation, New Delhi

22 October 2005

19.)

Green Tech Environment

Excellence Award - 2004-05 (Gold)

Environment Excellence at Dahej

Complex


22 October 2005

20.)

AMA-Metro chem. Outstanding Manager

of the Year Award 2005 (Declared for

MD, GACL)

Outstanding Manager of the Year

AMA (Ahmadabad Management) Association)- Metro chem., Ahmadabad

17 July 2005

21.)

Greentech Safety Excellence (Silver)


Greentech Foundation,

12 May 2005

15

New Delhi22.)

Greentech Safety Excellence (Gold)

Safety Excellence at Vadodara Complex


12 May 2005

23.)

Merit Award for ICWAI (Vadodara)

National Merit Award for Excellence in Cost Management - 2004

Institute of Cost & Works Accountants

of India (ICWAI)

12 March 2005

24.)

Certificate of Appreciation for

Safety Performance

Safety Performance at Vadodara Complex

Gujarat Safety Council & Factory


18 January 2005

25.)

Certificate of Honor for Safety

Performance

Safety Performance at Dahej Complex

Gujarat Safety Council & Factory


18 January 2005

Year 200426.)

National Energy Conservation Award

2004 1st prize (Chlor-Alkali Sector)

Energy Conservation at Dahej Complex

Bureau of Energy


of India

14 December

2004 awarded by

Hon'ble Prime

Minister of India

16

27.)

Greentech Environment

Excellence (Silver)

Environment Excellence at

Vadodara Complex


04 November

200428.)

Greentech Environment

Excellence (Gold)

Environment Excellence at Dahej

Complex


04 November

200429.)

Greentech Safety Excellence Award

(Silver)



21 June 2004

30.)

Dr. H.C. Srivastava Memorial Award 2003

Developing Eco-Friendly cold

bleaching process using Hydrogen

Peroxide of GACL for Hand Processing Sector of Textile

industry

ATIRA: Ahmadabad

26 February 2004 at National

Conference of Textile Research

Association, Mumbai

17

CORPORATE PROFILE

GACL is a forward-looking company, set up in the year 1973. 30 years is a long time. Long enough to test the character of any organization. Be it recession, inflation, increased competition or changing governments, we've lived it all. And for sure, all the turbulences have made GACL a stronger and a progressive company. Our stern resolve to manufacture quality chemicals and trek customer satisfaction to a new height has yielded unbelievable results.

From an initial capacity of 37,425 TPA Caustic Soda, GACL have grown to be the largest producer in India, with a capacity of 3, 58,760 TPA. Spread over 2 complexes at Vadodara and Dahej.

Knowing that the time ahead may prop-up newer hurdles, GACL has already started to diversify and expand its existing infrastructure to consolidate its supremacy in Chlor-Alkali and other integrated downstream products.

World Class Technology :

Technology moulds generations. GACL’s endeavor to continually upgrade technology has allowed GACL to optimize resources, thus bringing down the cost of production and increasing revenues. Acquired through the best and prestigious collaborations means that they meet international specifications for our products. Besides, GACL’s manufacturing plants are eco-friendly, which ensure that the environment is well looked after.

The location of both the plants 'Vadodara' and 'Dahej' has

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dual advantage of proximity to the raw material suppliers and the end users.

While the capacity utilization is about 70% in the Caustic Soda Industry, GACL's plants are working at almost 100% capacity.... thereby utilizing the assets to the fullest extent.

Self-Reliance:

Various factors that influence the success of any corporation, the self-sufficiency ranks the foremost. We at GACL understand this all too well. Power, being a major input to the electrolytic Caustic Soda process, we promoted a joint captive power plant, Gujarat Industries Power Company Limited to meet our energy requirements for Vadodara Complex. Our complex at Dahej is also integrated with a captive co-generation plant of capacity of 90 MW.

Cost effective natural gas was substituted as fuel in place of Naphtha for Captive Power Plant. The plant load factor has increased and surplus power is supplied to State grid. This has helped achieve economies of operations.

Green all the way:

Nature bestows human race with umpteen benefits. Clean air, Lush green trees, GACL's commitment towards the environment is undying. Safe and unadulterated nature is high on our list of priorities; we are an organization with Green Attitude.

19

A dedicated senior executive heads a Safety and Environment Department to maintain high standards of safety and a harmonious relationship between environment and technology. The company has planted more than 1, 00,000 plants and it keeps maintaining the same. With tree plantation being a regular feature, it plants 1000 sapling every year.

As a matter of strategy, the company has placed sensors at strategic locations in and around the complex to monitor ambient air quality.

For disposal of solid waste, GACL has secured dedicated landfill site conforming to the hazardous Waste Management Act. Being a member of Effluent Channel Project, it releases its liquid effluent in this channel and adheres to the necessary parameters of the Gujarat Pollution Control Board before discharging it into the channel.

People: Our Valued Assets :

World-class technology and self-reliance are baseless without brains that work ardently to produce high quality chemicals. People are our real assets, whom we nurture and harness to get the very best out of them.

Our conviction is:

People make the organization. A sense of belonging is a must for dedication and

loyalty. Employees give their best when the company cares for

them.

20

Excellent labour relationship helped the company in achieving very high manpower production turnover per employee per annum. This is also a result of a thin and lean workforce, which is lead by the professional management.

Spreading Our Wings:

The unshakeable desire to deliver quality products to our customers means that our products are well accepted, both in India and the world over. Domestic customers are assured of prompt delivery of quality products at their doorsteps through our well-established network of dealers and consignment stockiest. Overseas customers are serviced directly or through agents.

Caustic-Chlorine being its prime product, the company has diversified into value added products like Sodium Cyanide, Chloromethane, Hydrogen Peroxide, Potassium Carbonate, Phosphoric Acid, etc. These value added products provide dual benefit to the organization by hedging against cyclical fluctuations in the Chlor-Alkali Industry. GACL sells 26 products today, maintaining its leadership in Caustic-Chlorine industry with 18% market share and has emerged as a major player in the segment of value added products.

VISION, MISSION &

21

GROWTH STRATEGY

VISION

To continue to be identified & recognized as dynamic, modem & ecofriendly chemicals company with enduring ethics & values.

MISSION

To manage our business responsibility & sensitivity in order to address the needs of our customers & stakeholders.

To strive for continuous improvement performance, measuring results precisely & ensuring GACL's growth & profitability through innovations.

To demand from ourselves & others the highest ethical standards and to ensure products & processes to be of the highest quality.

GROWTH STRATEGY

To remain the largest producer. To maintain highest quality & be the first choice of

customer. To have downstream value added products & product mix

for better margins. To ultimate good to remain leader in the Chlor alkalis.

22

DEPARTMENTS AT GACL

1)Technical Department:

Development DepartmentProduction DepartmentEngineering DepartmentQuality Control DepartmentSafety & Environmental Department

2)Non- Technical Department:

Marketing DepartmentPurchase DepartmentExport DepartmentDispatch DepartmentFinance DepartmentHR DepartmentPersonnel DepartmentSecurity DepartmentAdministration DepartmentTime Keeping DepartmentSecretary DepartmentMS Department (Management System)

23

ORGANISATION STRUCTURE

Mm

GM(HR&A)

CS&GM(Legal)

GM(MM)&CIO

CFO Sr. ED(Commercial)

Sr. ED(Tech.)

DGM(MM)

CGM &CMO

Addnl. GM(Mktg.)

CM(Engg.

Service)

MD

CM (MS)

GM(Operatio

ns)

GM(Engg.

Service)

CM(Security & Vigilance)

GM(Operations)

ED(Ranoli)

ED(Dahej)

ED(CPP)

24

PRODUCTS OF GACL

As per the classification and the differentiation of the products, the products are classified in to SEVEN (7) different Groups.

The Groups are Listed and described as below.

1) Caustic Soda Group

Caustic Soda Flakes (NaOH)

Caustic Soda Lye

Caustic Soda Pills

Sodium hypo chloride (NaOCl)

Liquid Chlorine (Cl2)

Compressed hydrogen Gas (H2)

Hydrochloric Acid (HCl)

2) Caustic Potash Group

Caustic Potash Flakes (KOH)

Caustic Potash Lye

Potassium Carbonate

3) Chloromethane Group

Methyl Chloride (CH3Cl)

Methylene Chloride (CH2Cl2)

Carbon Tetrachloride (CCl3)

Chloroform (CHCl3)

25

4) Sodium Group

Sodium Cyanide (NaCN)

Sodium Ferro cyanide [Na4Fe(CN)6 :10H2O]

5) Phosphoric Acid Group

Phosphoric Acid (H3PO4)

Calcium Chloride Flakes (CaCl2)

Calcium Chloride Powder

6) Hydrogen Peroxide Group

Hydrogen Peroxide (H2O2)

Bleach win

7) Other products

Dilute Sulphuric Acid (H2SO4)

Scale win (Water treatment chemical)

Aluminum Chloride Anhydrous (AlCl3)

Poly Aluminum Chloride (The New Product)

26

MILESTONES OF GACL

Government of Gujarat promoted GACL in 1973. It's first Caustic Soda, Liquid Chlorine and Hydrochloric Acid Plants went on stream in 1976.

Year

Achievements

1982 Commissioned Sodium Cyanide plant with a capacity of 2000 TPA.

1986GACL went in for a diversification project to manufacture

Chloromethane.1987 Commissioned Caustic Soda Flaking unit with a capacity of 26400 TPA

1989First revamp to energy efficient and environment friendly Membrane

Cell technology.

1992 Commissioned Sodium Ferro cyanide plant (100 TPA) based on in-house Research & Development.

1994

Converted balance manufacturing facilities to Membrane Cell & expanded its Caustic Soda capacity to 153500 TPA.

Expanded caustic flaking unit to 53000 TPA.

Commissioned caustic potash plant with a capacity of 16500 TPA.

1995 First certification IS/ISO 9002:1994.

Phosphoric Acid Plant started production at Dahej.

1996 Hydrogen Peroxide plant commissioned.

1998 Commissioning of 300 TPD of Caustic Soda & 90 MW power plants at Dahej.

2000 Commissioning of Caustic Potash/Flakes, Vadodara.

2001 Increase in H2O2 Capacity to 12540 MTA.

2003 Up gradation of ISO Certificate from 9002:1994 to 9001:2000.

27

2004

ISO 14001:1996 Certificate for Vadodara Complex and Dahej Complex.

Commissioning of Calcium Chloride plant at Dahej.

2005 ISO 18001:2000 Certificate for Vadodara Complex and Dahej Complex.

2006 Commissioning of Poly Aluminum Chloride Plant at Dahej Complex

2007

Commissioning of Poly Aluminum Chloride at Vadodra with same capacity.

Commissioning of Hydrogen Peroxide at Dahej with capacity of 12540 TPA.

Commissioning of Anhydrous Aluminum chloride with capacity of 16500 TPA.

2008 Commissioning of wind power project at Moti Sindhodi, Kutch with 23.75 MW (1.25MW*19Nos.) rs 122.02 crores.

2009

Commissioning of second phase wind mill project of 39 MW at Gandhidham started on 12.01.2009. In the month of February 2009 all

WTG have been commissioned.RA-10 commissioned in the month of October in MC-2 2009

Dr. M filter commissioned on 20.11.2009.G-5B electrolysers(E-1,2,8 and partly 7) are commissioned on 15.12.2009

One more electrolysers commissioned for 50 TPD production of CSL stated at Dahej CSL plant.

2010 21 MW wind mill project commissioned on 22.03.2010.

2011 25 TPD CaCL2 plant at sodium Cyanide complex of Baroda has been commissioned on 20.01.2011.

2011 25 TPD stable Bleaching powder plant at Dahej is commissioned on 2nd

march 2011.

2011 42 TPD Hydrogen Peroxide plant (phase-2) is commissioned.At Dahej on 27.06.2011

28

MANPOWER STRENGTH

Manpower is the real strength of any organization & that is

so in GACL also. The total manpower strength at GACL

includes both management & Non- Management Category.

As on 31/5/2011 details Ranoli Dahej Total

Management 424 218 831

Non Management 366 465 831

Trainee Management 7 2 9

Trainee Non Management 21 10 31

Contractual Management 6 2 8

Contractual Non Management 44 34 78

Apprentice Management 10 11 21

Apprentice Non Management 56 41 97

Total 934 783 1717

Thus, the total manpower strength at GACL

has 1717 employees

29

POLICIES AT GACL

35

OVERVIEW OF CLM PLANT

SECTION 100

(THERMAL CHLORINATION)

Thermal chlorination of methane is carried out in four

cylindrical reactors simultaneously.

Gases like methane, chlorine, nitrogen, recycle gases are

passed in these cylinders.

There are basic four reactions involved in production of

chloromethane by thermal chlorination of methane gas.

CH4+CL2 = CH3CL+HCL

CH3CL+CL2=CH2CL2+HCL

CH2CL2+CL2=CHCL3+HCL

CHCL3+CL2=CCL4+HCL

36

SECTION 300-400

(HCL ABSORPTION AND DEHUMIDIFICATION)

The product mixture coming from section 100 contains HCL along

with product which must be removed as it is highly corrosive in nature, so

if there is HCL along with product it would be difficult to handle the

process fluid. This product mixture enters in to six columns & where in

HCL is removed by the process of absorption, there after another

processes are carried out in these columns like de-acidification,

neutralization, dehumidification & drying is carried out. Dehumidification &

Drying columns are provided to get moisture level in the product gas

mixture below 50 ppm.

SECTION 500

(COMPRESSION AND LIQUIFICATION)

The process gas from last column is taken to section 500 where

the gas is being compressed & cooled so that the product will liquefy

under these conditions.

37

SECTION 800

(DISTILLATION)

In this section the liquefied & pressurized mixture is taken for

distillation to get pure product. There are total ten columns

provided to separate four products from impurities. First two are

provided for Cl separation, then two for C2, three for C3 & last

three for C4 separation from low boilers & other impurities.

Cl-Methyl Chloride

C2 - Methylene Chloride

C3 - Chloroform

C4 - Carbon Tetra Chloride

SECTION 200

(PHOTOCHLORINATION)

This section is provided to raise the higher derivatives of

methane as a product keeping market demand in mind, feed for

photo chlorination can be adjusted in such a way that either

production of C29 C3 & C4 can be optimized as per market

requirement.

38

SECTION 700

(CRUDE PRODUCTION HANDLING)

Crude product from almost each section is dumped in

TK-701 tank plus HCL formed in liquid phase is also dumped in

this tank. Product after purification in this section is taken to 800

sections for distillation.

SECTION 900

(PRODUCT HANDLING AND STORAGE)

Product handling & storage is the last section of CLM

plant. As all four products have their properties differing from

each other so their storage conditions are also different.

39

CLASSIFICATION OF PUMPS

Pumps are classified o n the basis of the

principle by which the energy is added to the fluid

and their design feature.

PUMPS

(1) Dynamic Pressure (2) Positive Displacement

Pumps Pumps

a) Centrifugal pump (a) Reciprocating pumpb)Turbine pump (b) Rotary pumpc) Propeller pump

CENTRIFUGAL PUMP

(PRINCIPLE OF OPERATION)

The centrifugal pump works on the principle of forced vortex flow which means the certain mass of

liquid rotated by an external torque. The rise in pressure head of the rotating liquid takes place.

40

MAIN COMPONENTS OF C.P.

The main components of C.P. are shown in

figure,

The main components are....

(1) Casing

(2) Impeller

(3) Wear-Ring

(4) Shaft

(5) Shaft-sleeve

(6) Bearing

(7) Bearing Frame

(8) Breather

(9) Cir-Clip

(10) Seals etc....

42

Wear Rings Pump Case Shaft Sealing Shaft Bearing Bracket

Front and back renewable wear rings arc furnished in order to

achieve the best pump performance and ease the

maintenance

The pump case is of rigid design with a generous wall thickness, giving good protection against

erosion and corrosion

SCP pumps can be fitted with most scaling arrangements;

- Soft packing

The heavy duty console with incorporated assure silent and

reliable operation

Front and back renewable fully endorsed. Single-piece casting gives reliability, long trouble-free operation and high efficiency

For high temperature applications (90-160 C) an arrangement foot hot water is provided. This modification includes a cooling chamber for introduction of the cooling medium

■ Vertical arrangement is mainly used in systems for water-supply, miming, civil engineering, waste water applications, irrigation systems etc.

Ample dimensioned single and double row ball bearings improve

the stiffness and infinite shaft deflection

STCP

VSCP

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The shaft is protected by a replaceable shaft sleeve stainless sled

CENTRIFUGAL PUMP PARTS

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(1)CASING

The basic function of casing is to provide support to the

components. The casing has to contain the impeller attached to

the shaft and allow them to rotate smoothly inside thus activating

the process. The casing is usually made of C.I. because it has

excellent cast ability coupled with machine ability and low cost.

The following three types of casing are used for general

purpose:-

Volute casingVortex casing,Casing with guide blades.

(2) IMPELLER

The impeller is rotating device in the pump that draws

and delivers out the fluid in a specified direction under pressure .

There are two types of impellers.

Linear Axial Impeller

Francis Impeller

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(3)WEAR RINGS

Wear rings are attachment given to soft areas to prevent

erosion and wear. These are made of hard and wear resistant

materials. Wear rings provide an easy and economically

replaceable leakage proof Joint between impeller and casing.

(4)SHAFT

The basic function of shaft is to transmit the torque

or power.

(5)THE SHAFT SLEEVE

The shaft sleeve covers the shaft tightly and protects it

from corrosion erosion and wear , it must have a close tolerance

in order to have a close running fit. It should have the same

thermal expansion similar to the shaft material have. A sleeve

material used in G.A.C.L. is S

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SFA LS AND STUFFING B

The seal blocks the fluid that is being circulated through

casing from escaping to rear Part of the pump through the

contact between shaft and casing. There are two types of seal:-

Mechanical Type Seal.Packing Type Seal.

BEARINGS

The main function of the bearing is to support the

rotating assembly by taking load and guide the shaft in order to

avoid the vibrations. The most common bearing is ball bearing.

Bearings are usually made of A1SI -52100 STEEL.

BEARING FRAME

The bearing frame is usually made of steel. For absolute

corrosion resistance and good appearance stainless steel

housing or frame can be used.

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CIR CLIP & STAR LOCK WASHER

Cir clip & Star lock Washer is provided for locking the Bearing.

PREATHER

To provide inlet & outlet of air for bearing frame.

VARIOUS TERMS DEFINITIONS

USED FOR C.P.

SUCTION HEAD

It is the vertical height of the centerline of the c.p. above the

liquid surface in the tank of pump from which the liquid is to be

lifted.

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The vertical distance between the centre line of the pump and

the liquid surface of the tank to which liquid is to be delivered is

known is delivery head.

STATIC HEAD

It is the sum of suction head and delivery head

MANOMATRIC HEAD

The manomatric head is defined against which a C.P. has to

work.

PRIMING

Priming of a c.p. is defined as the operation in which the

suction pipe casing of the pump and a portion of delivery pipe

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up to delivery valve is completely filled up from out-side source

with the liquid to be raised by the pump before starting a pump.

By this way the air from those parts of pump will be removed

and these parts are filled with the liquid to be pumped.

CAVITATION

Cavitation is defined as the phenomena of formation of vapour

bubbles of flowing liquid in a region where the pressure of liquid

falls below its vapour pressure and sudden collapsing of these

vapour bubbles in a region of higher pressure.

The metallic surface above which these vapour bubbles

collapse is subjected to the high pressure which cause pitting

thus cavities is formed on the metallic surface and also

considerable noise and vibration is produced due to the

cavitation, the efficiency of C.P. is decreased.

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PREAUTIONS FOR CAVITATION

The following precautions should be taken against cavitation….

The pressure of the flowing liquid in any part of the

hydraulic system should not allow falling below its vapour

pressure.

The special materials or coatings such as

Aluminum-bronze and stainless steel which are cavitation

resistant should be used

CAVITATION IN C.P.

In C.P. the cavitation may occur at the inlet of the Impeller of

the Pump or at the suction of the Pump where the pressure is

considerably reduced.

The cavitation in a pump can be noted by a sudden drop of

efficiency and head.

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NET POSITIVE SUCTION HEAD

The term NPSH is very commonly used in

the pump Industry. Actually the minimum suction

conditions are more frequently specified in terms

of NPSH.

NPSH means the total head required to

make the liquid flow through the suction pipe to

the pump impeller.

USES OF THIS TYPE OF PUMPS IN GACL

For handling alkaline fluids,

For anti corrosive application,

For handling HCL

RECIPROCATING PUMP

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In reciprocating pump liquid is drawn

through an Inlet check valve into the

cylinder by the withdrawal of piston &

forced out of discharge check valve on

the return stroke. They are also called

piston pumps, plunger pumps &

diaphragm pump.

MAIN PARTS

Piston

Piston rod

Bearing frame

Mechanical seal

Grand inlet

Coupling

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Outlet valve

Connecting rod

Crankshaft

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-

Most of piston pumps are double acting. Two or more cylinders are used in parallel with common Suction & discharge headers adjusted

to minimize the fluctuation in discharge rate.It is independent of the speed with normal operating limits &

decreases slightly with increase in discharge pressure because of added friction & leakage.

USES OF THIS TYPE OF PUMP

For brine separation,

For chemical dosing in boiler feed pump.

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COMPRESSORS

RECIPROCATING COMPRESSOR

CENTRIFUGAL COMPRESSOR

SCREW COMPRESSOR

RECIPROCATING COMPRESSOR

There are 14 reciprocating

compressors of different kinds in C.L.M

plant of G.A.C.L.

There are 8 RG compressors, 4

Instrument air compressors and 2

Nitrogen compressors we find in C.L.M

plant.

Main parts used in reciprocating

compressor are piston, piston rod, cross

head, crank shaft, connecting rod,

cylinders, flywheel, Intercooler, after

cooler, pulley, motor, suction valve,

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discharge valve, etc.

In reciprocating air compressor, air is

compressed by the movement of the piston

in the cylinder. Piston is reciprocated by

flywheel and crank shaft. The rotary motion

of flywheel and crank shaft is transferred to

reciprocating motion of piston by crosshead.

Piston rod moves the piston in the cylinder

and compresses the air in the cylinder.

In G.A.CL the

reciprocati

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ng compressors are two stage compressors. In

two stage compressors two cylinders are used.

L.P. cylinders are larger in volume than H.P.

Cylinders. In two stage compressors the gases

first compressed into L.P. Cylinder and after that

it is cooled in intercooler. Intercooler cools the

gases to the temperature which is equivalent to

the temperature desired at the suction side of

the H.P. cylinder. If the gases are not cooled than

in the second stage the temperature of the gases

will so high that it can damage the compressor.

After the gases cooled in intercooler, it is entered

in H.P. cylinder and it compressed to desired

pressure.

Reciprocating Compressors are also of two types:

Lubricating and Non-lubricating compressors.

In non-lubricating compressors the parts

are lubricated accept piston and piston ring. In

non-lubricating compressor the Non lubricating

parts are made of Carbon Filled Teflon (CFT). Non

Lubricating parts are used to avoid

contamination of lubricating oil with Process Gas.

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V-TYPE COMPRESSOR

V-type compressor is special type of

reciprocating compressor. Its L.P. and H.P.

cylinders which form V shape. In v- type

compressor the compression of nature gas take

place, it is a two stage double acting and non

lubricating compressor. In v type compressor at

the suction side of L.P. cylinder natural gas

enters and compressed and its temperature and

pressure increases, after that the compressed

natural gas enters intercooler and its

temperature is reduced.

Then low temperature compressed natural gas

enters into the H.P. cylinder and is compressed

to desired pressure. Then highly compressed

natural gas enters into the after cooler and cools

down and fed to the process.

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In centrifugal compressor, centrifugal force is

exerted over the fluid. Here energy is transferred

by dynamic means from the rotating impeller.

When the impeller rotates at high speed, suction

is created at the impeller eye and air is drawn

from the accelerating nozzle. Due to this the

velocity of air is increased and the pressure,

temperature is decreased.


Air Thrown at

rim of impeller

Housing

Air out

ImpellerAir enters

in a center

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The diffuser is provided with impeller.Diffuser converts velocity of air into pressure and

the air is compressed, Impeller is used to increase the energy of the fluid by whirling it

outwards and increasing the angular momentum of the fluid.

In G.A.C.L. these compressors are used at Hydrogen Peroxide unit. In H202 plant, two stageCentrifugal compressors are used to compress the air.

In this inter cooling is done by the cooling water which surrounds the tubes through which

compressed air is passed.

SCREW COMPRESSOR

Screw compressor is positive displacement type

compressor. In screw compressor the

compression is accomplished by the enmeshing

two matins helical grooved rotors which are

housed in a cylinder.

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FIG: SCREW COMPRESSOR

The male rotor is usually a driving

element with series of grooves along the length

of the rotor. Male rotor grooves mesh with

similarly formed helical flutes on the female

rotor which is usually driven element.

The entrapped gas is compressed as it

passes through the two rotors. Here a narrowing

Passage is formed as the gas will pass through

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the gap of two rotors. The gas is passed due to

rotating motion of the two rotors. The gases will

be passed due to rotating motion of rotors and

will be discharged at outlet. Gas will come from

the bottom of the screw compressor and it will

get compressed between the two rotors.

VALVES

At G.A.C.L various plants contain thousands

of valves of different size and shapes with variety

of designs. Basically all valves serve a common

purpose to slow down or to stop the flow of the

fluid. Other types of valves are designed to

throttle or to reduce the pressure and the flow

rate of the fluid.

They will permit flow In One direction only

under certain condition of temperature and

pressure. This is done by placing an obstruction

that can be moved along inside with little or no

leakage of the fluid.

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Various types of valves used in G.A.C.L are....

Sate valve

Ball valve

Butterfly valve

Globe valve

Check valve

N.R.V valve

Gate valve

Needle valve

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BLOWERS

Various types of blowers used in GACL are

Centrifugal blower

Lobe blower.

BOILERS

In G.A.C.L. mainly gas fired boilers are used for the purpose of steam

production. This steam is used in various plants of G.A.C.L. in CLM plant it is used

in distillation tower.

COOLING TOWERS

In G.A.C.L. there are 5 cooling towers, all are induced draft cross flow and having different cooling capacities. There are

baffles provided for better contact between cold air & hot water. Cold water is collected in tank at the base of tower

& from there it is sent to cooling systems through pump.

my first training project

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