Hindusthan College of Engineering and Technology

An Autonomous Institution Affiliated to Anna University | Approved by AICTE, New Delhi

Accredited with ‘A’ Grade by NAAC | Accredited by NBA (ECE, MECH, EEE, IT & CSE)
Valley Campus, Pollachi Highway, Coimbatore 641 032.| www.hicet.ac.in

DEPARTMENT OF CHEMICAL ENGINEERING

INTERNSHIP PROGRAM REPORT

Travancore Cochin Chemicals Limited

NAME : ASWIN PRASOBH

REGISTER NUMBER : 720721114013
BATCH : 2021-2025
PROGRAM : B.Tech-Chemical Engineering
INTERNSHIP PERIOD : 23.01.2023 to 05.02.2023

ANNA UNIVERSITY: CHENNAI 600 025

JANUARY 2023

1
 Hindusthan College of Engineering and Technology
Coimbatore- 641032.

Certified that this is the bonafied work for the internship completed

By

ASWIN PRASOBH (Reg. No 720721114013)

in partial fulfillment for the award of the
degree of

BACHELOR OF TECHNOLOGY
IN
CHEMICAL ENGINEERING
Undergone Internship Program at Fact training and
development centre udyogamandal

 Internship Coordinator Head of the Department

Submitted during final assessment for internship presentation conducted on

…….

Internal Examiner External Examiner

2
 ACKNOWLEDGEMENT

First and foremost, I praise and thank ALMIGHTY GOD for being with me
throughout the internship.
I take this opportunity to express my gratitude towards Dr. M. Seenuvasan, Head
of the Department, and my Faculty from the Department of Chemical Engineering
for their support and help to carry out the internship in a reputed company like
Travancore Cochin Chemicals Limited.
I would like to thank the management of company for giving me the opportunity to
do the internship.
I thank Mr. P. RAMANATHAN (GENERAL MANAGER) for helping me to carry out the
internship in an effective manner.
I express my sincere thanks to all the employees who has given the guidance for
theentireperiod

3
 DECLARATION

We, hereby declare that we have uniquely prepared the presented internship report after
the completion of 15 days internship at Travancore Cochin Chemicals Ltd. We have provided
the original data and information to the best of our knowledge. Further, we declare that we
have strictly observed the reporting ethics and adequately referred to all the outsourcing of
materials used in this report.

We also confirm that the report is only prepared for our academic requirement and not for
any other purpose. We also agree not to share vital information with any other person
outside the organization

4
 ABSTRACT

Academia and industry share a symbolic relationship. Academia produces graduates who are
absorbed by industry. Research work in universities is taken up by the industry and turned
into products and services. Industry on the other hand looks to academia for solutions to
their concerns. It would like universities to tailor their courses to turn out Graduates those
skill-set are aligned to industry requirements. Often new research topics arise out of
interaction between the duos which benefit both academia and industry. The industries
neither want the sand nor the baked finished pot, but the processed soil can take any shape
they wish. The handshaking between industrial research and academic research shall lead to
the betterment of the studies and a better economy; however, there are Opportunities
produce good (related to school and learning) research that can help the industry. First, it is
extremely important to understand industry needs. It can be very hard if the industry does
not know what it wants, as is often the case, and does not understand the research process.
Even when industry members hold undergraduate degrees, there may not be a described
explained understanding of how research is produced; there may be a need to Identify
research gaps and ask the industry if they are interested to identify issues that are
Sometimes ahead of what the industry perceives to be important.

Scope of Internship:
This internship provided an insight of the working environment that we students will be
undertaking in the near future. The internship’s main scope is to bridge the gap between
academia and industry.

Learning Objectives/Internship Objectives

 Internships are generally thought to be reserved for college students looking to gain
experience in a particular field. However, a wide array of people can benefit from
training Internships in order to receive real world experience and develop their Skills.
 An objective for this position should emphasize the skills you already possess in the
area and your interest in learning more.
 Internships are utilized in a number of different career fields, including architecture,
Engineering, healthcare, economics, advertising and many more.
 Some internship is used to allow individuals to perform scientific research while
others are specifically designed to allow people to gain first-hand experience
working.

Utilizing internships is a great way to build your resume and develop skills that can be
emphasized in your resume for future jobs. When you are applying for a Training Internship,
make sure to highlight any special skills or talents that can make you stand apart from the
rest of the applicants so that you have an improved chance of landing the position.

5
 INDEX

SL.No. TITLE Page Number

1 INTRODUCTION 7

2 INDUSTRY PROFILE 8

3 COMPANY PROFILE 10

4 PRODUCT PROFILE 13

5 ORGANIZATION STRUCTURE 15

6 FUNCTIONAL AREAS 16

7 TECHNOLOGY OF PLANT/PRODUCTION 19

8 PROCESS DESCRIPTION 20

9 STAGES IN PRODUCTION 25

10 ACHIEVEMENTS 29

11 SWORT ANALYSIS 31

12 CONCLUSION 32

6
7
 THE TUVANCORE • COCHIN CHEMICALS LTD.
(A GOVERNMENT OF KERALA UNDERTAKING)
PE, No: 4. UDYOGAKWOALPO., KOCHI • 683 501. KERALA

ffRNW/ 290/2023 13.022023

CERTIFICATE Of
'This is to certify that Aswin Has06h a student OfØTech in ChemicafEngineenng

from Department Of ChemicafEngineenng at ffitufustfutn Coffege Of Engineering

and Technology, Coim6atore- 641032 has successfuCy completed an Intent-ship in

our companyfrom 23.01.2023 to 05.02.2023.

We Wish aff the bestfor fisfuture.

8
 INTRODUCTION

Travancore Cochin Chemicals (TCC) is one of the largest public sector companies in India.
TCC has the dissertation of being India's first producers of Rayon Grade Caustic soda. The
commercial production was started in the year of 1954 Wah 20 TPD w production
Production capacity increased after pioneering effort of MS Shaye h TCC is the pet for the
production of rayon grade caustic soda
AC Soda plan of 20 TPD caustic soda production capacity was started working in 1954: The
plant had comics of 6 mercury cells, which worked 12 KA. Later as a part of the fir sem
development of plaster of capacity of 10 TPD was added to the main plant, "KREBS PARIS
was behind this technology, in 1966 "KREBS SWISS launched a 30 KA cell plant. Ather
Launching 50 KA plan After the launching of this plant the capacity of TCC increased from 60
TPD 100 TPD of caustic soda. In 1976 with the collaboration of the West German Company
MUDHET, 100 TPD planes were started. The plant has a current rating of 135 KA. was
designed according to the most modern technology of that time. By this old 12 KA and 25 KA
pl was stopped. The production name of the company was fixed at 150 TPD.
In 1997 with the technical help of M/S ASAHI GLASS Company, Japan a membrane cell plan
of capacity 100 TPD was started. This new plant which completely avoided the use of
mercury was a great step in controlling the pollution. The membrane cell consumes only
two third of the current used the mercury cell by starting the plant, the 50 KA plan was
stopped and the production of ICC was fixed at 200 TPD IN 2002, Capacity of membrane cell
plant increased Brom 100 125 TPD 135 KA mercury cell was stopped operation in July 31,
2004 This was per the guidance of Central Government to convert mercury cell plant to
membrane cell plant. Now the present capacity is 175 TPD.

9
 INDUSTRY PROFILE

1. Nature of Industry
The chemical industry comprises the company that produces industrial chemicals. The
chemicals are used to make a wide variety of consumer goods as well as thousands of inputs
to agriculture, manufacturing and constructions and service industry. The chemical industry
itself consumes 26% of its own output. Major trial customers include rubber and plastic
products, textile, apparel, petroleum refining, pulp and paper and primary metals.

Specialty chemicals are a category of relatively high value, rapidly growing chemicals with
diverse and product markets. They include electronic chemicals, industrial gases, adhesives
and sealing as well as coating industrial and institutional cleaning chemicals and catalysts.
Chemicals in bulk petrochemicals and inter- chemicals are made from liquefied petroleum
(LPG), natural gas and crude oil. Typical large volume products include ethylene, propylene,
benzene, toluene, xylem, methanol, vinyl chloride monomer (VCM), styrene butadiene and
ethylene oxide.

Other derivatives and basic industries include synthetic rubber, surfactant dyes and
pigments, turpentine, resins, carbon black, explosives and rubber products contribute about
20% of basic chemical external sales. Inorganic chemicals about 2% of revenue output)
include salt, chlorine, caustic soda, soda ash, acid (such as nitric, phosphoric and sulphuric)
titanium dioxide and hydrogen peroxide fertilizers (about 6% of revenue output) include
phosphate ammonia and potash chemicals. Consumer products include direct product sale
of chemicals such as soaps, detergents and cosmetics.

2.Nature of Industry in Indian Scenario

In India, caustic soda is produced by an electrolysis process. The manufacture of caustic
soda started during 1940 in the country. The growth was slow during the time of 1960's and
later the growth was good. Today there are about 38 chlor-alkali units in India of 111 which
4 are in the organised sector and the rest belong to the unorganised sector. All these
industries follow membrane cell technology. It is more efficient compared to mercury cell
technology. It will be faced out by 2012 as per CREP voluntary commitment. Now India has
upgraded its status in this field. The total installed capacities of these units altogether were
about 1750000 tons! annum. There are many small-scale industries in the state which
consume caustic soda for the production of soap, plastics and textiles.

Major Indian chlor-alkali unit

1. TCC Ltd Kerala

2. DCW Ltd Gujarat

10
3. Chemoplast Chennai

4. Kothari petrochemicals Ltd, chennai

5. Chemical alkali Ltd, Pondicherry

6. Southern petrochemicals industries corporation Ltd chennai

7. DCM Shriram Ltd, Kota, Rajasthan

8. Lords chloro alkali Ltd, Alwar, Rajasthan

9. Punjab Alkali and Chemicals Ltd, Naya nangal, Punjab

10. SIEL Chemicals Complex Ltd, Punjab

Major countries producing caustic soda

1. USA
2. France
3. Russia
4. China
5. India
6. Germany
7. Japan

3. Nature of The Industries in Global Scenario

The nature of industry in the world scenario world chloro alkali industry is growing. The
chemical industry is growing faster in the world. The chemical industry plays an important
role in the production of manufacturing goods. The industry provides a tremendous variety
of materials to other manufacturers. Major products of the industry include detergent,
drugs, fertilizers, food, preservatives, flavouring and paper and fine chemicals. Most major
chemicals are basic chemicals used in many countries. It is used to produce fertilizers and
other basic chemicals including chlorine and sodium hypochlorite. The production has
become increasingly concentrated in multinational corporation which have plants and
offices in number of countries. To achieve a low cost of production, the company locates
their factories in developing countries where raw materials are readily available. Many basic
chemicals are produced in developing countries by factories of many multinational firms hut
chemical quiming advance production method are made it industrialised countries. Though
the demand for chlorine is growing fast, the demand for caustic soda is not so promising.
Thus, the units in gulf and western countries and selling

11
 COMPANY PROFILE

Introduction
The Travancore Cochin Chemicals, popularly known as TCC is state public sector undertaking
owned by the govt of Kerala. It is a heavy chemical industry involved in manufacture of
chlor- alkali products. TCC is the one of the leading companies in the chemical industries in
Kerala with an incredible track record of healthy industrial relations and profitable
operations. TCC is committed to supply quality chemicals at competitive prices to
customers. customer satisfaction, concern for environment, and safety are their top
priorities. The major stakeholders of the organization are government of Kerala (90.16%),
KSIDC (7.47%), FACT (1.74%), SHL trading Chennai (0.63%).

The company manufactures:

1. Caustic soda lye 32%

2. Caustic soda lye 48%
3. Caustic soda flakes
4. Liquid chlorine
5. Hydrochloric acid
6. Sodium hypochlorite

History
The Travancore- Cochin Chemicals Ltd, was established in 1950. The idea of establishing the
unit was conceived by M/s sheshasayee brothers, the then managing agents of FACT . The
venture was started as partnership concern in the name Travancore mettur chemicals with
FACT and MCIC ( mettur chemicals and industrial corporation) as partners. In 1951, the
partnership was registered as a public limited company with the state government
contributing the major share of equity and the company was then named as TRAVANCORE-
COCHIN CHEMICALS LTD. M/s sheshasayee others continue to be the managing agents for
the next 10 years commercial production of caustic soda from the first plant of 20 tpd
capacity was started in 1954 January. TCC is the first unit in India to manufacture rayon
grade caustic soda.

12
STAGES OF GROWTH

1950 Established by M/s sheshasayee

brothers Ltd joint venture of FACT
and MCIC (Mettur chemicals and
Indian corporation) in the name of
Travancore Mettur Chemicals (TMC)
for supply of HCl to FACT for making
ammonium chloride 20 tpd plant
(staff number :250)
1951 Due to financial crisis, Travancore
government gave large scale
financial assistance became a
stakeholder renamed as the
Travancore Cochin
Chemicals Ltd Regd no: 08-11-1951
1954 Commercial production started 20
TPD and 17.5 TPD chlorine
technology mercury cell ( turnover
-
24 lakhs and staffs above 1000)
1956 CCF plant 20 TPD for NaOH flakes
1958 Chlorine liquefaction plant
1960 Kerala government took over the
company when the period of
agreement expired capacity 30
TPD to 40 TPD commissioned
sodium
hydrosulphate plant capacity 3 MT
1967 Caustic soda capacity to 60 TPD, 70
TPD sodium hydrosulphate plant
1975 Caustic soda capacity enhanced
to 160 TPD water treatment plant
commissioned
1997 Started 100 TPD first membrane,
latest technology, eco friendly,
energy efficient by AGC Ltd, Japan
1998 Many old plant dismantled new CCF Plant
1999 Caustic soda, concentration and
flanking plant 100 TPD
commisioned 50% one year and 98-
99% flakes technology from M/s
13
 Bertrams,
Switzerland

14
2002 Production capacity is 125 TPD
2004 100 TPD mercury cell plant
demolished
2005-2006 Production capacity is 125 TPD to cell
membrane plant, each with 25
TPD by M/s VHDE company,
Germany
2010 Secondary brine purification method
is commissioned
2013 5 TPD sodium chlorite plant, a
venture with Vikram Sarabhai
Space
Centre (VSSC)
2013 May First customer in Kerala to purchase
electricity through open access
2015 Zero gap technology for energy
conservation
2017-2018 Company paid rupees 5 lakhs to the
government of Kerala as divident
2021 Introduction of 2 plants for caustic soda
and another plant for hydrochloric acid

15
 PRODUCT PROFILE

TCC is basically a chlor – alkali industry because it produces chlorine and alkali related
products. It is the only chlor – alkali unit in the state of Kerala. The major products of TCC is
caustic soda. It includes both lye and flake. Other products of TCC are liquid chlorine,
commercial Hydrochloric acid, Sodium hypochlorite and Sodium chlorate.

1. Caustic Soda ( NaOH )

Caustic soda is a colourless, odourless, and soapy liquid consisting of sodium ions and
hydroxide ions. NaOH is Manufactured using cell membrane technology. TCC provides two
types of NaOH lye 32% and 48%.

Uses
 For the preparation of alkali cellulose and production of viscous solution.
 For refining petroleum fractions.
 As a saponification agent.

2. Chlorine ( Cl 2 )
Chlorine is a greenish yellow in colour and has a pungent smell. It is the co – product
obtained in the manufacture of caustic soda. Chlorine is a toxic gas and it is mainly used by
water treatment plants. It is converted to liquid chlorine and transported to different
consumer industries.

Uses
 For purification of water by disinfection.
 For manufacturing of PVC and co-polymer.
 Producing insecticides like DDT,BHC and pesticides.

3. Hydrochloric acid ( HCl )

TCC produce high purity HCl . They played an important role in the extraction of rare earth
element. It is an aqueous solution of hydrogen chloride gas. It is a yellowish green colour
fluid and as a strong acid. HCl is widely used by variety of industries for fertilizers ,mineral
processing etc.

Uses
 For hydrolysing starch into sugar.
 For the production of ammonium chloride.

16
  For the manufacture of phosphoric acid.

4. Sodium hypochlorite ( NaOCl )

It is an inorganic compound consisting of sodium and hypochlorite ions. It is also known as
soda bleach. It is an alkaline compound with a pale yellowish green colour.

Uses
 Used for sterilization.
 Used as a bleaching agent.
 Used as a germicide and cleaning agent.

5. Caustic soda Flakes

Caustic soda flakes are solid form of sodium hydroxide. The product is widely used in textile
soaps and detergents and in alumina industries. It has a concentration of 98.99%.

Uses
 Used in cosmetics industry.
 Used in the production of soap, detergents etc.
 Used as a drain pipe cleaner.

6) Sodium chlorate
It is a white crystalline inorganic compound which is soluble in water. It is hygroscopic and
decomposes above 300°C to release oxygen and leaves sodium chloride. TCC produces
sodium chlorate in collaboration with ISRO because it is used to produce ammonium
perchlorate which is oxidising agent in rocket fuel .

Uses
 Used for making explosives.
 Used for making dyes .
 Used for making paper and leather.

17
 ORGANIZATIONAL STRUCTURE

An organizational structure is a system that outlines how certain activities are directed in
order to achieve the goals of an organization. These activities can be include rules, roles, and
responsibilities. The organizational structure also determines how information flows
between levels within the company. An organizational structure outlines how certain
activities are directed to achieve the goals of an organization. Successful organizational
structure defines each employees job and how it fits within the overall system. A centralized
structure has a defined chain of command while decentralized structures give almost every
employee receiving a high level of personal agency. Types of organizational structures
include functional, divisional, flatarchy and matrix structures. Senior leaders should consider
a variety of factors before deciding which type of organization is best for their business,
including the business goals industry and culture of the company. An organizational
structure defines how activities such as task allocation, coordination and supervision are
directed toward the achievement of organizational aims.

Organizational structure developed from the ancient times of hunters and collectors in tribal
organizations through highly royal and clerical power structures to industrial structures and
today’s post industrial structures. The present organization Structure of the company has
proven to be effective in conducting operations at its optimum level.

The staff structure encourages teamwork and good internal relationships. Unity of
command is maintained throughout the organization. MD – Managing Director, GMT –
General Manager technical, DGM (P) – Deputy General Manager (project). MD – Managing
Director

GMT - General Manager Technical

DGM(PJ) - Deputy General Manager (project)
DFC - Deputy Finance controller
CS&IA – Company Secretary and Internal Auditor
AGM(op) – Assistant General Manager
(operation) AGM(E)- Assistant General Manager
(Engineering)
AGM(E&I) – Assistant General Manager (Electrical and Instrumentation)
AGM(M) – Assistant General Manager (Marketing)
AGM( HR) – Assistant General Manager (Human Resource)
AGM (MT) – Assistant General Manager (material)
AGM (PJ) – Assistant General Manager (project)
AGM( T) – Assistant General Manager (Technical)
18
 FUNCTIONAL AREAS

TCC

ADMINISTRATION PRODUCTION

MATERIALS ENGINEERING
HR & TRAINING TECHNICAL & SERVICE
MARKETING ELECTRICAL &
FINANCE INSTRUMENTATION
PROJECT & SYSTEM

19
 PLANTS IN TCC

There are mainly 3 plants involved in the production.

1. AGC PLANT

It is designed by AHASI GLASS COMPANY, Tokyo, Japan. The plant was commissioned on 29
may 1997. The products are NaOH, HCl and liquefied chlorine. The plant consists of 20
electrolytes.

2. UDHE 1 PLANT

It’s designed by UDHE infrastructure Ltd, Germany. The plant was commissioned on 30
October 2001. The plant has the production capacity of 25 TPD of 12% NaOH Lye. It consists
of 1 electrolyte.

3. UDHE 2 PLANT

It’s designed by the same company that designed UDHE 1 PLANT. The plant commissioned
on 15th August 2006. This has the production capacity of 25 TPD of 32% NaOH lye. It
consists of one electrolyte.

The technology used: MEMBRANE CELL TECHNOLOGY

The process used: ELECTROLYSIS

20
Raw materials
The primary raw materials used for the production are:

1. Salt:

The salt here used is the compound Sodium chloride which composed of 39.337% sodium
and 60.633% chlorine by weight. The salt is brought on tender base from Kutch (Gujarat)
and Thoothukudi (Tamil Nadu)

2. Water:

Purified water is used on the decomposers as well as the cell for washing the feed box and
the end box, soft water is converted into process water for this purpose

3. Electricity:

The electricity supplied is maintained by KSEB, TCC is its largest customer. Now open access
is also introduced, acquiring current from private companies. At present, most of the plant
use contact rectifiers for converting AC to desired voltage with an overall efficiency of 95%.

4. Chemicals:

Small quantities of sulphuric acid, sodium carbonate, sodium bisulphate and barium
carbonate are used.

Major countries producing caustic soda

1. USA

2. France

3. Russia

4. China

5. India

Major indian chlor- alkali units

1. TCC Ltd, Kerala

2. DCW Ltd, Mettur

3. Chemplast, Tamilnadu

4. BILT, Karnataka

5. Kothari petrochemicals Ltd, Chennai

21
 TECHNOLOGY OF PLANT/PRODUCTION:

There are three methods for electrolysis of resolution

1. cell electrolysis

2. Diaphragm cell electrolysis

3. Membrane cell electrolysis

At present TCC utilizes membrane cell electrolysis as it provides improved power

consumption and its environmentally friendly compared to the previous two technology

MEMBRANE CELL ELECTROLYSIS TECHNOLOGY

In membrane cell technology, the process makes use of brine and a membrane cell with
positive and negatively charged electrodes The anode (negative charge) oxidizes the
chloride ion, which loses an electron to become free chlorine gas. The hydrogen ions are
pulled at the cathode and form hydrogen gas. The semi- permeable membrane of the cell
allows for the sodium ions to travel to a second chamber, where they react with water to
produce sodium hydroxide, because of the corrosive nature chlorine production, the anode
(where chlorine is formed) must be made from a non-reactive metal such as titanium
whereas the cathode (Where hydroxide is formed) can be made from easily oxidizable metal
such as nickel.

ELECTROLYSIS PLANT PRESENT:

TCC has four plants for electrolysis of brine, the latest plant was opened at 2020 and is fully
automated.

The other three plants are AGC, UHDE 1 and UHDE 2 the plants are named after the
companies they are bought from

AGC ELECTROLYSER

AGC has 20 cells containing 15 anode and 18 cathodes

Gross current required is 51.7KA

No of electrolysis is 30 Mesh type electrode is red

Membrane material is made of nafione Anode is made from Titanium

Cathode is made from copper

UDHE 1 AND UDHE 2 ELECTROLYSERS

22
 PROCESS DESCRIPTION

Preparations are done in brine (solution of raw salt and water) purification process are
common for AGC, UDHE 1, UDHE 2 plants.

Advantages of Membrane Cell Process

 Flexibility in operation.
 High purity product.
 Reduce power consumption of membrane to 2750KW per hour compared to
4000KW per hour mercury cell.
 Lower cost and higher tolerance for power fluctuations.
 Elimination of environment pollution through the avoidance of use of mercury.

The process of manufacture involves several steps. The parameters that are measured in the
process is pressure level, flow level, temperature, impurity level and pH.

1. Brine preparation

Salt is fed into the saturator using pocketed elevators where it gets mixed with water. Here
saturated brine of 310GPL is prepared.

2. Primary Purification

It consists of three stages.

2.1) Saturation

Saturation process takes place in horizontal saturators. There are two saturators. One and
operation another in the standby by the raw sak from salt storage area is fed to the
saturator capacity 45m3 from the top using bucket elevators. Payloader and feed hopper
process water is added to the saturator at a rate of 5 to 6m3/hr. Then brine is fed to the
bottom of saturator through drip pipe for removal of macro size suspended impurities. This
brine solution then flows to the precipitated tank for precipitation process.

2.2) Precipitation

Hot Na2CO3 are fed to the precipitation tank. In petition in the plain the bone solution is
precipitated as CaCO3.The outlet from peption task fed to the tank where caustic soda lye is
added in order to precipitate gum as M2. 90% of the precipitate is settled as clodge and is
removed from bottom.

2.3) Filtration

The brine from clarifier is pumped to the four filters connected in series. When the two
filters are in service, the other two are kept is standby.

23
3. Secondary Purification

It consists of four Ion exchange filters; the primary purified brine is passed through the ion
exchanger filter where it undergoes ion exchange process. Ion exchange materials are
insoluble in acids and bases which when converted to salt remain insoluble. This ion
exchange materials are used in columns in which the solution contain ionic impurities like Ca
and Mg are in contact with resin bed.

4. Electrolysis

The 2° purified brine is passed through and the heat exchanger, the brine is fed to the head
tank and is admitted to anode compartment of electrolysis. Demineralized water is also
admitted to the cathode compartment of the electrolysis, direct current supply is connected
to the anode and during electrolysis caustic soda lye is produced. Hydrogen gas is also
formed at cathode chamber. Chlorine is formed at anode where depleted brine solution
comes out and the caustic soda is pumped into the storage tank and hydrogen and chlorine
gas go to their respective treatment section.

5. Chlorine treatment and liquefaction

Chlorine treatment and liquefaction involve cooling, washing, drying, compression,

liquefaction storage and liquid chlorine filling in cylinders. The chlorine from anode chamber
of electrolysis is first cooled at 30°C with cooling tower water, here final traces of salt are
removed by using wet chlorine filter. The chlorine gas is divided into 2 streams one for HCl
synthesis another for chlorine liquefaction. It is dried using 98% H2SO4 in drying tower.

6. Hydrogen treatment and HCl analysis

Hydrogen gas from electrolytic cell is washed with water in washing chamber and then
cooled using tower water is later admitted directly to hydrogen tower after separating the
condensate. The hydrogen gasted for synthesis of HCl and also used as a fuel in CCF plant.
The resulting HCl gas is absorbed by water flowing down the oven to produce 31%
commercial HCl acid.

7. Continuous Caustic Fusion

The process is done in CCF plant. CCF plant is mainly for concentrating 32% NaOH Lye to 50%
NaOH Lye and later to 98-99% NaOH melts which are converted into flakes. The 32% NaOH
lye is stored in Evaporator 1 is then drawn by a vacuum pump through a condenser, the
evaporator is working at 70-80°C this is converted to 42% lye. The 42% lye is converted to
48% lye in evaporator 2. This is fed to evaporator 3 where it is heated to 400°C with the
helpof HTS and converted to 98-99% concentrated caustic soda melt which is converted to
causticsoda flakes in flakers drum.

8. Soda Bleach Preparation

24
Excess of waste chlorine is diluted with caustic soda lye to produce soda bleach thus the
soda bleach plant serves as a pollution control system. The excess chlorine at the time of
plant shut down or start up and also from cylinder filling station goes for soda bleach
preparation. Here 32% caustic soda lye is diluted in demineralized water and passed through
two absorbing towers, where it reacts with chlorine gas so as to produce soda bleach.

25
 PRODUCTION PROCESS FLOW DIADRAM

RAW SALT

BRINE
SOLUTIO
N

BRINE
PURIFICATIO
N

ELECTROLYSIS

CHLORINE HYDROGEN 32% CAUSTIC DECHLORINAT

SODA ION

CHLORINE HYDROGEN SALE CCF PLANT

TREATMENT TREATMENT

CHLORINE
LIQUIFACTION HCL
SYNTHESIS

CHLORINE
LIQUIFIED
26
COM
M
E
R
C
I
A
L

H
C
L

27
 LAB ACTIVITIES

The systematic Analysis of products obtained from plants is done periodically. Quantitative
Analysis used for product analysis. The concentration of each product is analysed in lab.

VOLUMETRIC ANALYSIS

10 ml of sample is pipetted out to a conical flask. So in conical flask contains brine water.
Add some nitric acid and indicator. Indicator used for this analysis is nitroprusside. In burette
Mercury Nitrate is taken. Conduct the titration. At the end point, turbidity appears.

Analysis Of ClO-

10 ml of acetic acid is added with 10 ml of KI and some demineralized water is taken in a

conical flask. This is then titrated against sodium thiosulfate. Red colour changes to pale
yellow colour . Then add 25 ml of brine solution sample and little amount of starch to the
conical flask. After titration decolourisation occur.

NaCl + KI KCl + I2

Iodine and the added starch will form a complex to break the bond.

Analysis Of NaoH and Carbonate in Primary Filtrate ( Double Titration )

100 ml of sample is taken in a conical flask and phenolphthalein indicator is added. It is

titrated against HCl . At end point decolourisation occurs. Then add a little amount of
methyl orange and titrate until Pink colour appears.

Estimation Of Hardness (Complexometric Titration)

100 ml of sample is taken and brine solution is added to it. Brine solution is added to sample
to maintain the Ph. EBT is added as the indicator and it is titrated against EDTA. At the end
point, the colour changes from wine red to blue.

28
 STAGES IN PRODUCTION

In operation (1), be supplied to the concentration of the feed hydrogen aqueous solution of
sodium oxide in reactive tank, be generally 30-60 quality %, be preferably 35-55 quality %,
be more preferably 40-50 quality %. If the concentration of feed hydrogen aqueous solution
of sodium oxide is lower than described scope, then the aqueous sodium hypochlorite
solution manufacturing the low salt concentration expected is had to become the tendency
of difficulty. On the other hand, if the concentration of feed hydrogen aqueous solution of
sodium oxide is higher than described scope, then in order to adjust the aqueous sodium
hydroxide solution of normality, sometimes need numerous and diverse operation of
distillation etc. Temperature of reaction in the chlorination reaction of operation (2), is
generally 20 DEG C 50 DEG C, is preferably 30 DEG C sim 50 DEG (is more preferably 30 DEG
C sim 40 DEC C. If temperature of reaction is lower than described scope, then easily
produce the fouling of cooling coil pipe. On the other hand, if temperature of reaction is
higher than described scope, then what have the decomposition of clorox carries out speed
soon, the tendency that unit consumption resources reduce.

In reaction times in the chlorination reaction of operation (2), be preferably 10-200 minutes,
be more preferably 50 150 minutes, be particularly preferably 70 sim130 minutes. In the
chlorination reaction of operation (2), the sodium hydroxide of importing and the mol ratio
(NaOH/Cl of chlorine 2), be preferably 2 sim2.5. be more preferably 2.01 sim2.30, more
preferably 2.02 sim 2.2 * 0.1f the mol ratio of sodium hydroxide and chlorine is lower than
described scope, then easily carry out superchlorination, on the other hand, if higher than
described scope, then NaOH concentration remaining in obtained aqueous sodium
hypochlorite solution increases, therefore improper in quality.

In operation (2), by importing chlorine to aqueous sodium hydroxide solution, carrying out

2NaCl+Cl2→NaClO+NaCl+H2O

the reaction of following formula, generating clorox.

In this chlorination reaction, generate and the equimolar sodium-chloride of clorox (salt),
but when using the aqueous sodium hydroxide solution of above-mentioned concentration
as raw material, the crystal of the sodium-chloride that solubleness is low is separated out.
The low salt concentration high-concentrated sodium hypochlorite aqueous solution can be
obtained by being removed.

At this, in water law from the beginning, as the impurity of aqueous sodium hypochlorite
solution, not only above-mentioned sodium-chloride, the tendency of chloric acid also
restricted reinforcement. In order to make this chloric acid reduce, such as, as described in
Patent Document 1, need temperature of reaction to remain on 26 sim 29 DEGC. is owing to

29
thinking that the reason generating chloric acid is "natural decomposition" and "side
reaction as described below.

Described " natural decomposition" is the phenomenon of clorox natural decomposition,

particularly carries out sharp decomposing (with reference to non-patent literature 1) more
than 40 DEG C. This decomposition is represented by following reaction, generates sodium
chlorate (NaClO thus 3).

NaClO→NaCl+O

2NaClO→NaCl+NaClO2

NaClO+NaClO2→NaCl+NaClO3

Described side reaction", the side reaction occurred when being and sodium hydroxide and
chlorine are reacted, the secondary generation sodium chlorate by following shown reaction

6NaOH+3Cl2→NaClO3+5NaCl+3H2O

Such natural decomposition and side reaction, in arbitrary reactive system, all make the unit
consumption resources relative with the chlorine of clorox reduce. That is, the generation of
sodium chlorate makes unit consumption resources reduce, and suppresses the generation
of sodium chlorate to mean and unit consumption resources is increased. These two kinds of
phenomenon’s are all inevitable reactions, under particularly favourable in cost and in the
maintenance of equipment condition of high temperature, because natural decomposition is
carried out sharp, therefore think suppress the generation of chloric acid, to obtain aqueous
sodium hypochlorite solution be well very difficult to yield.

But present inventor has performed and conscientiously discuss, specify that in aqueous
sodium hydroxide solution while carry out stirring while be blown in the method for chlorine
with agitating vane," natural decomposition " and " side reaction" is not generation chloric
acid and makes the major cause of unit consumption resources reduction. That is, think
except "natural decomposition " and " side reaction", there occurs and cause the reaction
that chloric acid generates and unit consumption resources reduces.

Therefore, the present inventor is conceived to "superchlorination “. Described "

superchlorination", according to non-patent literature 1, is if chlorination reaction
terminates and do not have caustic soda, then the chain generation of following
decomposition reaction, the phenomenon that all clorox sharply decompose.

NaClO+Cl2+H2O→NaCl+2HClO

NaClO+2HClO→NaClO3+2HCl

NaClO+2HCl→NaCl+H2O+Cl2

30
Think that this superchlorination is to sodium hydroxide for the uncontrolled reaction that
occurs when giving the chlorine exceeding needs, but the present inventor is not limited to
such condition, thinks and there occurs superchlorination partly near the mouth blown of
chlorine. That is, think that NaOH concentration declines and the rising of clorox
concentration near the mouth blown of chlorine, chlorine and sodium hypochlorite reaction
thus. Like this, by above-mentioned reaction formula, clorox decomposed and generate
sodium chlorate, and by superchlorination, chlorine being reproduced. Moreover beyond
near the mouth blown of chlorine, because NaOH concentration is sufficient, the chlorine
therefore reproduced is consumed. Therefore, although all clorox can not be made to
decompose sharp, the clorox near mouth blown is decomposed by chlorine and causes the
reduction of unit consumption resources.

The concentration of the chlorine by inert gas dilution, as el conen, is preferably 5-95 volume
%, is more preferably 20-80 volume %, is particularly preferably 30-70 volume %. If the
concentration of diluted chlorine gas is higher than described scope, then sometimes cannot
obtain sufficient superchlorination inhibition. On the other hand, if the concentration of
diluted chlorine gas is lower than described scope, then there is the tendency that the
efficiency of chlorination reaction reduces, and uneconomical, and sometimes reaction
solution can be made to disperse in reactive tank by the blowout of rare gas element. In
operation (3), use the equipment for separating liquid from solid of such as centrifuge
separator, strainer etc., the byproduct sodium chloride of separating out in operation (2) is
that clorox concentration is preferably 30-40 quality %, is more preferably 32 sim38 quality%
is obtained The sodium chloride concentration of the aqueous sodium hypochlorite solution
obtained in operation (3), is preferably below 5.0 quality %, is more preferably 1.0-5.0
quality
%, is 3 sim4.8 particularly preferably quality % In addition, the chloranion concentration of
the aqueous sodium hypochlorite solution obtained in operation (3), is preferably below 1.5
quality %, is more preferably 0.01 sim1.2 quality %, is particularly preferably 0.05 sim1.0
quality %. Like this, adopt the less salt aqueous sodium hypochlorite solution that
manufacture method of the present invention obtains, the chloric acid concentration as
impurity is low, therefore has sufficient value of the product as low chloric acid aqueous
sodium hypochlorite solution.

One cell contains 27 anode and 27 cathodes

current required is 13.7KA

Number of electrolysis required is 1

Membrane material is made from nafione 982 Anode is made from titanium

Cathode is made from nickel

31
ADDITIONAL PLANTS:
1. Plant-cooling, drying compression and liquefaction of chlorine is done here, capacity of
the plant is 90 TPD.
2. Continuous caustic fusion plant: This plant is used for the manufacture of NaOH Flakes
with 150 TPD capacity. The feed solution the containing not less than 30% NaOH is
evaporated 40% and then to 47-49% in evaporator Evaporator 1 steam and evaporator 2
with steam and atmospheric pressure of 9 kg/cm2. The 47-49% caustic soda is then
turned into 97-99% concentration caustic in a third evaporator, third evaporator with
molten salt as heating element which is melted in furnace with hydrogen/furnace oil as
fuel. The waste steam evolved from third evaporator is utilized in the first evaporator
operated at vacuum for concentrating the 32% molten caustic soda solution from the
third evaporator it is then flaked in flaking device.

32
 ACHIEVEMENTS

With the times, TCC keeps up its technology regularly updated and continue to be the
competitive strength in the chlor- alkali industry. Over the years, we have achieved
recognitions and rewards for the remarkable performance in industry with regard to the
production, productivity, energy conservation and environment protection. Some of them
are:

 1981: Best performance award in safety in the state from directories of factories and
boilers, government of Kerala.
 1988-89: best pollution control award under group “heavy inorganic industries in
Kerala” from Kerala state pollution control board
 1989: Award for best performance in safety in India under “chemical industries
“group from national safety council
 1989-90: prize for productivity from Kerala state productivity council
 1993: Best performance award for energy conservation in the state of Kerala under
group “chemical & fertilizers- above 3000 KVA” from government of Kerala
 1994-95: Best performance award for the productivity in the state of Kerala under
group “large industries” from Kerala state productivity council.
 1995-96: Best performance award for the productivity in the state of Kerala under
group “large industries” from Kerala state productivity council.
 1998: Best performance award for energy conservation in the state of Kerala under
group “major industries” from energy Management centre, govt of Kerala.
 1998: performance Award for energy conservation under group “chlor-alkali sector”,
ministry of Power, govt of Kerala
 2003: Kerala state energy conservation award (2000) in the category of large-scale
industry
 2005: National energy conservation award “chlor-alkali sector”
 2008: Kerala state pollution award among large scale industries
 2009: outstanding achievement award in pollution abatement by department of
industries and commerce, government of Kerala
 2014: FACT M.K.K Nayar memorial productivity award for the year 2013-2014
 2015: certificate for merit in the category of large-scale industries by Kerala state
pollution control board
 2015: Kerala state energy conservation award
 2016: second best productivity performance award
 2018: Kerala state productivity award for the year 2016-2017
 2020-21: Kerala state energy award in the category of large-scale energy consumers
considering the efforts in energy conservation for HCl synthesis unit for steam

33
 cogeneration, zero gap conversion of UDHE II plant, plant wise energy norms fixed
and regularly monitored using SCADA for any deviation in consumption, installed 20
KW grid interacting solar power plant
 2022: Gold award for 5 th National convention on innovative QC teams, organized by
alumni society of AOTS Kerala and ABK-AOTS DOSOKAI Tamil Nadu centre.

34
 SWOT ANALYSIS

STRENGTH
TCC is the only chlor alkali unit in the state. It has the best record of physical and financial
performance in the past. TCC has got the best work force, engineers, manager and skilled
workers. The main thing is that the company has got 80%of the share for there products in
Kerala. At present no other competitors nearby so the company is running successfully.
Great availability of water due to the river side location of the company. It also has the best
road ways, river ways and railway line. They also produce the best caustic soda.

WEAKNESS
The major decision in the company is approved by the government thus the implementation
takes delay in time. The infrastructure of the company is old-fashioned compared to others.
Main problem faced by the company is the large consumption of electricity. The company
not much take part in marketing activities.

OPPORTUNITIES
Economic development in the country may result in higher demand for the product
especially for chlorine. Kerala Mineral and Metals in Ltd going for expansion. Expansion plan
of cochin Refineries and Hindustan Newsprint Ltd.

THREATS
Competition from foreign countries. High cost of production and increase in the cost of
electricity is also a threat.

35
 CONCLUSION

In conclusion, this internship has give us substantial amounts of practical and theoretical
knowledge in various fields. The internship has helped us immensely in understanding the
industrial environment and giving a clear perspective of what the challenges are and how to
overcome those challenges. It can be said that this experience is critical in our pursuit of
knowledge and will help us adapt to the ever changing professional landscape Also the
professional work environment provided a nice exposure of how the industry works. Our
knowledge in the field of sensors and Instrumentation has vastly improved allowing us to
put them to use effectively.

36
OUTCOME

1. Acquired knowledge about the functional and managerial aspects of Travancore Cochin
Chemicals Limited .

2. Familiarization with the production processes in Travancore Cochin Chemicals Limited.

3. Able to analyze the functions of Materials department and Inventory control of

Travancore Cochin Chemicals Limited.

4. Brief study of the processes undergone for the production of Titanium Dioxide Pigment.

5. Processes and machinery required for production of Titanium Sponge.

6. Able to relate theory with hand-on practical learning.

37
 DEPARTMENT OF CHEMICAL ENGINEERING

STUDENTS FEED BACK FORM

NAME ASWIN PRASOBH

REGISTER NUMBER 720721114013
NAME OF THE INTERNSHIP Travancore Cochin
ORGANISATION. Chemicals Limited
CITY KOCHI, KERALA
LOCATION. ELOOR

Not
SN Excelle V.Go Avera Satisfa
Parameters satisf
o nt od ge ctory
a
ctory
Learning benefits during
1. 4
the internship period

Facilities available in the

2. 5
industry in working condition.

Learning on problem
3. identification and 4
designing solutions
development.
Ability to work as team and also
4. 4
showing individual skills.

Support received from

5. the company on 5
internship identification.

6. Placement opportunities 4
Recommend the company for
7. 4
the following batch of
students.

Date: Signature of the student

38