A History of Many Firsts
CCAL has a number of ‘firsts’ to its credit, and has received numerous patents and worldwide recognition for the viability of its innovative technologies. Some of these are listed below:
CCAL introduced Membrane Technology for the first time in the Indian chloralkali industry, significantly improving energy efficiency and completely eliminating the use of mercury in the process. The monopolar electrolysers which were installed in 1985 were upgraded subsequently to the latest bipolar state-of-the-art BiTAC® electrolysers.
Another first in the Indian industry was the patent for the process that recovers barium sulphate from solid waste. This resulted in the reduction of solid waste to the tune of 30 percent.
CCAL became the first chloralkali plant in the world to introduce an Ultrafiltration membrane system for brine clarification. Full capacity was achieved in 2011-12. This process eliminated precoat filter and alpha cellulose as well as felling of trees to the extent of 28 MT and an effective carbon offset of 50 MT per annum.
Ultrafiltration technology for recycling of wastewater was implemented, resulting in reduced quantum of effluent generated.
For the first time in India, CCAL brought in a green technology for the separation of sodium sulphate from brine to reduce the use of toxic barium chloride.
A new hydrochloric plant was installed, with a heat recovery unit that converted waste heat into steam. This earned 4,600 carbon credits for the organisation, as well as saving precious water.
CCAL designed, installed and commissioned a fully enclosed, negative pressure system for containment of accidental release of chlorine gas. This composite system is the first of its kind in the world.
For the first time in the world, CCAL developed a patented process for the manufacture of soda ash from flue gas. This resulted in the reduction of greenhouse gases and eliminated the purchase of soda ash for the brine treatment.
Introduced enclosed solar evaporation system for the evaporation of the wastewater generated from the ETP-RO.
With an objective of Sustainability and Generating Wealth out of Waste, CCAL has developed a process for converting the brine sludge to bricks or blocks. Patent application has been filed for this process.
CCAL is in the process of installing a Membrane based Seawater Desalination plant with a capacity of 2 MLD to provide a sustainable source of water for the plant operations. This will be the first Seawater Desalination Plant in the Union Territory of Puducherry.