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
 Aluminium Industry – Ore digestion & reactive
silica removal
Paper manufacturing -- Digestion of woods &
extraction of Chlorolignin
Thermal Power Plants -- For anionic resin regeneration in
D.M. plants
Textiles -- In finishing operations at mercerizing &
bleaching stages
Pharmaceuticals -- In manufacture of bulk drugs such as
Ciprofloxacin, Analgin
Dye Industry -- Manufacture of intermediates
Viscose -- Manufacture of Rayon Grade Pulp
Soaps & Detergent -- In saponification reaction
Vanaspati -- For Refining
Liquid
Chlorine:
It is used in manufacturing of
Chlorinated Paraffin Wax
White paper -- For bleaching
Water Purification
Pesticides -- Lindane, BHC & Endosulphan etc.
PVC -- Manufacture of EDC
Organic Chemicals -- Chloromethanes, Chlorobenzene
Inorganic Chemicals -- Chlorosulphonic acid, Stable
Bleaching powder etc.
Hydrochloric Acid :It is widely used in
Steel Industry -- For pickling
Ossein/gelatin -- To treat animal skin, bones for making
ossein
Chemicals -- Calcium Chloride, Phosphoric acid etc
Demineralisation Plant -- Cationic regeneration
Sodium Hypochlorite :It is widely used in Bleaching of
paper Bleaching of textiles
Chlorination of drinking water
Effluent treatment
Substitute of phenyl ( 20 times more active than phenyl)
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.
Availability
of cheap manpower.
Easily available power from JSEB.
Availability of raw material as &
when required at lower risk/cost.
Technical and infrastructure support to
entrepreneurs by BCCL.
Availability of quality coal from
nearby collieries as well as minerals such as bauxite, mica, iron ores from minerals rich
state of Jharkhand.
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.
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 :
In oil and gas well drilling.
As
a coagulant in rubber Manufacturing.
As
an accelerator in the ready mix concrete industry.
In
de-icing during winter
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 :
In
dry cell manufacture
In
textiles industry for sizing operation
Acts
as a fiber proofing agent for wood
In
soldering and galvanizing operations.
For
reclamation of rubber
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
:
In dyes
As intermediates
In Benzyl components
For SyntheticTannins
As Rubber Accelerator
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 :
As a fire proof in aeroplanes ,ships, electrical cables etc
Primer for metals & pipe lines.
General maintenance paints
Swimming pool paints
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
:
As a solvent for resins, paints and
varnishes.
In the synthesis of chemicals like
phenol, Aniline, DDT, Nitro chloro benzene etc.
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
:
As a solvent for surface coatings,
rubbers, fats, oils, waxes, sulfur, resins and dye stuffs
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
:
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
:
As a building material. |
