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Industries in Palamu

BIHAR CAUSTIC & CHEMICALS LIMITED
( A joint venture company of Aditya Birla Group)
GARHWA ROAD,P.O - REHLA
PALAMAU (JHARKHAND)

Phone – (06584) 22211, 22221, 22488
Fax – (06584) 22205
E-Mail – bccl@adityabirla.com
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Bihar Caustic & Chemicals Ltd

Caustic plays a vital role in various field in day to day life. Bihar Caustic & Chemicals limited has been a pioneer in the field of manufacturing Caustic as well as chlorine in India and caters to most of the usage segments of the markets in the eastern region of the country.

Bihar Caustic & Chemicals Ltd. is a profit making, joint venture Company of versatile Aditya Birla Group, which holds an equity of 25 % It was incorporated in the year 1976 and subsequently the factory was commenced in extremely backward district Palamau in the state of Jharkhand .

The Plant was formally inaugurated by then Prime Minister, Late Smt. Indira Gandhi on 5th September 1984. The main products of the company are

a)Caustic soda lye - Rayon Grade
b)Liquid chlorine,
c)Hydro-chloric acid,
d)Sodium Hypo Chlorite and
e)Electricity.

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The Company’s Products are having great demand by Aluminum, Paper, Textiles, Soaps, water treatment Plants and others Chemical industries. Major customers are Hindalco, Tisco, Indal , Usha Martin and NTPC. We have also been exporting our products to Bangladesh and Nepal.

It was at this juncture that we set out on a second journey of triumph from 1st Jan.’01 with commissioning of new 30 MW Captive Power Plant subsequently followed by capacity Up-gradation of Caustic plant to 150 TPD through debottlenecking and augmentation of Chlorine Liquefaction capacity from 60 TPD to 90 TPD to turnaround the company and to make it viable.

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MISSION

To sustain profitable growth, meeting reasonable expectations of all stake holders and fulfilling commitment to community and environment.

VISION

To strengthen our position as market leader in the eastern region and increase profitability through focus on quality consciousness, cost competitiveness, product diversification and innovation

MILESTONES

a)BCCL has been accredited with the coveted certifications of ISO-9001- 2000 and ISO-14001-1996 within a record time of six months reckoned from the date of initiation.
b)BCCL is the lowest mercury consuming caustic plant in India

c)BCCL has Cell efficiency of 96.5% that is bench marked the world over.

BCCL was coveted “ Excellent Pollution Control Implementation Gold Awards “ By International Greenland Society of Hydrabad for the most stringent pollution control steps taken by it.
d)BCCL got Best Pollution Control Award from State pollution control Board for two consecutive years.The saga of BCCL initiated through conceptualization and implementation of CPP project has been further boosted up with the launching of cost-cutting drive by focusing on other value drivers, such as mercury consumption, cell efficiency, system upgradation, HR management and commitment to environment and society at large. Fueled with a winning instinct BCCL is poised to steer on growth path.

ITS PRODUCTS FIND APPLICATION IN VARIOUS INDUSTRIES VIZ.,

Caustic Soda Lye:

It is used in

bullet.gif (960 bytes)Aluminium Industry – Ore digestion & reactive silica removal

bullet.gif (960 bytes)Paper manufacturing -- Digestion of woods & extraction of Chlorolignin

bullet.gif (960 bytes)Thermal Power Plants -- For anionic resin regeneration in D.M. plants

bullet.gif (960 bytes)Textiles -- In finishing operations at mercerizing & bleaching stages

bullet.gif (960 bytes)Pharmaceuticals -- In manufacture of bulk drugs such as Ciprofloxacin, Analgin

bullet.gif (960 bytes)Dye Industry -- Manufacture of intermediates

bullet.gif (960 bytes)Viscose -- Manufacture of Rayon Grade Pulp

bullet.gif (960 bytes)Soaps & Detergent -- In saponification reaction

bullet.gif (960 bytes)Vanaspati -- For Refining

Liquid Chlorine:

It is used in manufacturing of

bullet.gif (960 bytes)Chlorinated Paraffin Wax

bullet.gif (960 bytes)White paper -- For bleaching

bullet.gif (960 bytes)Water Purification

bullet.gif (960 bytes)Pesticides -- Lindane, BHC & Endosulphan etc.

bullet.gif (960 bytes)PVC -- Manufacture of EDC

bullet.gif (960 bytes)Organic Chemicals -- Chloromethanes, Chlorobenzene

bullet.gif (960 bytes)Inorganic Chemicals -- Chlorosulphonic acid, Stable Bleaching powder etc.

bullet.gif (960 bytes)Hydrochloric Acid :It is widely used in

bullet.gif (960 bytes)Steel Industry -- For pickling

bullet.gif (960 bytes)Ossein/gelatin -- To treat animal skin, bones for making ossein

bullet.gif (960 bytes)Chemicals -- Calcium Chloride, Phosphoric acid etc

bullet.gif (960 bytes)Demineralisation Plant -- Cationic regeneration

bullet.gif (960 bytes)Sodium Hypochlorite :It is widely used in Bleaching of paper Bleaching of textiles

bullet.gif (960 bytes)Chlorination of drinking water

bullet.gif (960 bytes)Effluent treatment

bullet.gif (960 bytes)Substitute of phenyl ( 20 times more active than phenyl)

bullet.gif (960 bytes)General disinfectant

INDUSTRIALISATION – A FOOT FORWARD

In order to give a push to the Industrial growth of the area BCCL have identified many potential products based on Chlorine and Hydrochloric Acid for potential entrepreneurs. BCCL is extending all support in technical and infrastructural fields to the Entrepreneurs to set up their manufacturing activities at Garhwa Road.

At present, three Small Sector Units are already manufacturing Chemicals Garhwa Road based on the Liquid Chlorine and Hydrochloric Acid which has contributed to the development and has directly/indirectly improved the per-capita income of the local people

Looking to the high prospect of business in Jharkhand with friendly industrial policy of the government and proactive support of BCCL two entrepreneurs have already set up their manufacturing units at Belchampa Industrial Area (5 km away from the factory) and one adjacent to BCCL main gate. Two units are in final stage of commissioning of their plant (adjacent to factory boundary).

WHY ENTREPRENEURS ARE INTERESTED IN SETTING UP OF THEIR FACTORY IN PALAMAU REGION OF JHRKHAND

Availability of cheap land.

There are 50 acres land are available in Belchampa Industrial Area (just 5 km away from the factory).

Availability of abundant water due to proximity of Koel river and other water sources.

 bullet.gif (960 bytes)Availability of cheap manpower.

 bullet.gif (960 bytes)Easily available power from JSEB.

 bullet.gif (960 bytes)Availability of raw material as & when required at lower risk/cost.

 bullet.gif (960 bytes)Technical and infrastructure support to entrepreneurs by BCCL.

 bullet.gif (960 bytes)Availability of quality coal from nearby collieries as well as minerals such as bauxite, mica, iron ores from minerals rich state of Jharkhand.

 bullet.gif (960 bytes)Garhwa Road Railway Station is on main railway line from Muri / Barakakhana to Delhi/Kanpur, Daltonganj to Lucknow, Howrah to Jabalpur, Patna to Barakakhana/Singrauli.

 bullet.gif (960 bytes)Rehla is also well connected by road. It is located 250 km from Varanasi, 225 km from Ranchi, 285 km from Patna, 200 km from Gaya and 130 km from Dehri-on-Sone.

PROJECTS BASED ON HCL/CHLORINE:SMALL SCALE SECTOR.

Name of the project – CALCIUM CHLORIDE

Plant Capacity – 10 TPD

Calcium Chloride is a white crystalline salt. It is very soluble in water, extremely hygroscopic and liberates large amount of heat during water absorption and on dissociation It forms series of hydrates containing one, two,four and six moles of water per mole of Calcium chloride.

Raw Materials :

Lime stone- CaCO3

Hydrochloric acid

Manufacturing Process :

Calcium Chloride is obtained by direct neutralisation of lime stone with hydrochloric acid

CaCO3 + 2HCl = CaCl2 + H2O + CO2

Consumption Norms
Raw materials Consumption per ton Consumption per day(MT)
Lime stone(Min.88% CaCO3) 950 Kg 9.500
Hydrochloric acid (32%) 3565 Kg 36.00
Water 2000 Kg 20.00
Fuel – Furnace oil/ Coal 100 Ltrs 1.00
Power 80 Kwh 800 Kwh
Packing material (HDPE Bags) 20 nos 200 nos

Cost of Project : Apprx. Rs 85 Lacs.

Return on Investment (ROI) – 20% Uses :

bullet.gif (960 bytes)In oil and gas well drilling.

bullet.gif (960 bytes)As a coagulant in rubber Manufacturing.

bullet.gif (960 bytes)As an accelerator in the ready mix concrete industry.

bullet.gif (960 bytes)In de-icing during winter

bullet.gif (960 bytes)As drying agent, food additive and also in pharmaceuticals.

Name of the project – FERRIC CHLORIDE

Plant Capacity – 10 TPD

Ferric chloride is soluble in water, alcohol ,glycerol , methanol, ether etc. It decomposes to yield Hydrochloric acid if exposed to moist air or light. Ferric Chloride has a very good demand because of its wide applicability in various fields.

Raw Materials : Iron (scrap ) and Chlorine

Manufacturing Process : Ferric Chloride is obtained by chlorination of scrap iron in a vertical cylindrical reactor

2Fe + 3 CL2 = 2FeCl3

Consumption Norms:

Raw materials Consumption per ton Consumption per day(MT)
Iron (scrap) 375 Kg 3.75
Chlorine 700 Kg 7.00

Cost of Project :Approx. Rs 100.00 Lacs.

Return on Investment (ROI) -20%

Uses :

bullet.gif (960 bytes)In dry cell manufacture

bullet.gif (960 bytes)In textiles industry for sizing operation

bullet.gif (960 bytes)Acts as a fiber proofing agent for wood

bullet.gif (960 bytes)In soldering and galvanizing operations.

bullet.gif (960 bytes)For reclamation of rubber

bullet.gif (960 bytes)In manufacture of activated carbon

Name of the project - BENZYL CHLORIDE (Alpha ChloroToluene)

Plant Capacity - 5.0 TPD

It is a colourless liquid with a pungent odour. A lachrymator, soluble in alcohol and ether and insoluble in water.

Raw Materials: Toluene and Chlorine

Manufacturing Process : Benzyl chloride is manufactured by passing chlorine over boiling toluene.

Light

C6H5CH3 + Cl2 C6H5CH2Cl+HCl

110 0 C

Consumption Norms:

Raw materials Consumption per ton Consumption per day(MT)
Toluene 1000 Kg 5.00
Chlorine 800 Kg 4.00

Uses :  

bullet.gif (960 bytes)In dyes

bullet.gif (960 bytes)As intermediates

bullet.gif (960 bytes)In Benzyl components

bullet.gif (960 bytes)For SyntheticTannins

bullet.gif (960 bytes)As Rubber Accelerator

bullet.gif (960 bytes)In Pharmaceuticals

 

Name of the project -  CHLORINATED RUBBER

Plant Capacity - 10 TPD

Chlorinated rubber is a versatile film forming polymeric substance that contains about 65% combined Chlorine.  It is a free flowing solid material, often powdery with no toxicity or odour, is tasteless having good compatibility & flame resistance.

Exposure to sunlight causes decolouration and embrittlement but this effect is minimised by the use of pigments and stabilisers. It is soluble in carbon disulphide and carbon tetrachloride.It is available in different grades and Grade-20 is general purpose grade.

Raw Materials : Natural rubber, Chlorine gas, Solvent(CCL4) and Plasticiser

Manufacturing Process : Chlorinated rubber is prepared by Chlorinating the rubber solution in Carbon tetrachloride (Solvent).

Consumption Norms:   

Raw materials Consumption per ton Consumption per day(MT)
Natural rubber 420 Kg 4.2
Chlorine gas 1300 Kg 13
Solvent(CCl4) 950 Kg 9.5
Plasticiser 30 Kg 0.3

Cost of Project : Approx. Rs 800.00 Lacs

Return on Investment (ROI) - 25 %

Uses :

bullet.gif (960 bytes)As a fire proof in  aeroplanes ,ships, electrical cables etc

bullet.gif (960 bytes)Primer for metals & pipe lines.

bullet.gif (960 bytes)General maintenance paints

bullet.gif (960 bytes)Swimming pool paints

bullet.gif (960 bytes)Chemical resistance paints.

Name of the project -  CHLOROBENZENES

MONOCHLOROBENZENE

Plant Capacity -    5 TPD

It is a clear transparent mobile liquid ,volatile, flammable,toxic by inhalation and ingestion. Miscible with most organic solvents. It is insoluble in water.

 

Raw Materials : Benzene and Chlorine.

Manufacturing Process : By passing dry chlorine into benzene in the presence of a catalyst.

 C6H6 + CL2                             C6H5Cl + HCl

Consumption Norms

Raw materials Consumption per ton Consumption per day(MT)
Benzene 800 Kg 4.0
Chlorine gas 700 Kg 3.5

Cost of Project : Approx. Rs 150.00 Lacs

Uses :

bullet.gif (960 bytes)As a solvent for resins, paints and varnishes.

bullet.gif (960 bytes)In the synthesis of chemicals like phenol, Aniline, DDT, Nitro chloro benzene etc.

bullet.gif (960 bytes)To manufacture drugs, perfumes, agro chemical products and dye intermediates.

 

Name of the project -  CHLOROBENZENES

DICHLOROBENZENE

Ortho dichlorobenzene

Plant Capacity -   5 TPD

Soluble in most organic solvents but insoluble in water. It is a colourless , water clear liquid with a pleasant odour.

Raw Materials : Benzene, Chlorine

Manufacturing Process : Dichlorobenzene is manufactured By chlorination of Benzene. Firstly it produces monochlorobenzene  which  again reacts with chlorine  to give dichlorobenzene.

C6H6  +  CL2                              C6H5Cl + HCl

C6H5Cl + CL2                             C6H4Cl2 + HCl

Consumption Norms:

Raw materials Consumption per ton Consumption per day(MT)
Benzene 600 Kg 3.0
Chlorine gas 1000 Kg 5.0

Uses :  

bullet.gif (960 bytes)As a solvent for surface coatings, rubbers, fats, oils, waxes, sulfur, resins and dye stuffs

bullet.gif (960 bytes)For dyes intermediates, disinfectants, pest control products, pharmaceuticals etc.

Name of the project -  CHLOROBENZENES, DICHLOROBENZENE and Para dichlorobenzene

Plant Capacity -   5 TPD

Soluble in commonly used organic solvents but insoluble in water. It is white to pinkish with a penetrating odour, volatile and readily sublimes, toxic by ingestion, irritant to eyes.

Raw Materials :

Benzene and Chlorine

Manufacturing Process : Dichlorobenzene is manufactured by chlorination of Benzene. Firstly it produces monochlorobenzene  which  again reacts with chlorine  to give dichlorobenzene.

C6H6 + CL2                             C6H5Cl + HCl

C6H5Cl + CL2                             C6H4Cl2 + HCl

Consumption Norms:

Raw materials Consumption per ton Consumption per day(MT)
Benzene 600 Kg 3.0
Chlorine gas 1000 Kg 5.0

Uses :

bullet.gif (960 bytes)For deodorants, dye intermediates, insecticides, moth proofing composition, pharmaceutical products etc.

Name of the project -  FLY ASH BRICKS

Plant Capacity -   4500 bricks per day

Fly ash brick making plant which is designed to manufacture fly ash bricks with FAL-G technology is a simple and cost effective project available in the country. The heart of the plant 'Brick Man" is an indigenously designed , a relatively low cost and high productivity machine. Fly ash has got very high compressive strength and low water absorption compared to conventional clay bricks.

Raw Materials : Fly ash, Gypsum, Lime sludge and Sand

Manufacturing Process : All the above raw materials are mixed in the pan mixture and finally compressed with the hydraulic pressure machine which can be moulded as per requirement.

Consumption Norms:

Raw materials(RM) Percentage of RM Consumption per 1000 bricks
Fly ash 60 2 MT
Gypsum 5 0.12 MT
Lime sludge 7 0.54 MT
Sand 10 0.39 M3
Water 6 0.2 M3

Cost of Project : Rs   6.00  Lacs

 

Uses :

bullet.gif (960 bytes)As a building material.

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