R&D

R&D/Patents

  • CCAL has a Research and Development wing recognised by the Department of Scientific & Industrial Research (DSIR), Ministry of Science and Technology, Government of India. The year of initial recognition was in December 1992, with the current recognition (F.No. TU/IV-RD/1607/2014, d/01.04.14) valid upto 31.03.2017.
  • All the new products, processes and equipment are the products of the R&D.  

 

Technology & Innovation

S.NO TECHNOLOGY YEAR SALIENT FEATURES / ACHIEVEMENTS
1 Introduced membrane chloralkali technology for the first time in India 1985
  • Energy efficient, savings of approximately 600 kWh/MT of caustic compared to the mercury cell process.
  • Totally eliminated the use of mercury and associated pollution.

       FIRST IN INDIA

2 Patented the process for the recovery of barium sulphate from solid waste 1989
  • Reduction in solid waste to the tune of 30% 

     FIRST IN INDIA

3 Introduced ultrafiltration membrane system for brine clarification Introduced in 2003 and full capacity achieved in 2011-12
  • Elimination of precoat filter and alpha cellulose.
  • Savings in wood as a result of elimination of alpha cellulose = 20 MT/annum
  • Quantum of trees felling averted as a result of elimination of alpha cellulose = 28 MT/annum
  • Carbon offset across the life span of the trees (28 MT) = 50 MT
  • Energy conserved : 1.3 lakh kWh/annum

       FIRST IN THE WORLD

4 Ultrafiltration technology for recycling cylinder pit washings 2004
  • Recycled  2 cu.m/day of wastewater.
  • Reduction in effluent generation to the tune of 2 cu.m/day
5 Enormous cost savings and reduction of impurities in brine 2005
  • Use of toxic barium chloride chemical was reduced.
  • Green technology wherein sulphate was separated by membrane process without using any chemicals.
  • Cost savings of more than 75%.

      FIRST IN INDIA

6 Electrodeionisation (edi) technology for the production of DM  water 2006
  • No use of chemicals for regeneration.
  • Reduction in effluent generation to the tune of 1.5 cu.m/day.
7 Installation of new hydrochloric plant with heat recovery unit 2007
  • Waste heat converted to steam. Generates a maximum of 32 MT of steam/day which is equivalent to a reduction of 4600 MT of CO2/year or 4600 carbon credits, besides saving water.
8 Awaiting clearance from PPCC for implementation 2007
  • The sodium sulphate is physically concentrated and separated without using any chemicals.
  • The product sodium sulphate decahydrate or anhydrous sodium sulphate can be sold to customers directly.
  • Reduction in the solid waste to the tune of 30 %
  • An environment-friendly technology.
  • This process has been patented, application #:748/CHE/2007
  • Applied to the Puducherry Pollution Control Committee (PPCC) for permission to implement this process. Awaiting clearance from the PPCC.
9 Awaiting clearance from PPCC for implementation 2012
  • Reduction of greenhouse gases to the extent of 600 MT/year or 600 carbon credits.
  • The soda ash + sodium sulphite lye produced will be used for the treatment of brine, thus eliminating the purchase of soda ash.
  • The total reduction of CO2 emissions after taking into consideration the elimination of soda ash purchased for market works out to 3600 MT/year equivalent to 3600 carbon credits.
  • This process has been patented, application # 1694/CHE/2013.
  • Applied to the Puducherry Pollution Control Committee (PPCC) for permission to implement this process. Awaiting clearance from the PPCC

     FIRST IN THE WORLD

10

CCAL has designed, installed and commissioned the fully enclosed negative pressure system for containment of accidental release of chlorine gas.

2011

Chlorine is sensed at 0.5 ppm and the whole system is activated. The leaked gas is sucked and neutralised in the scrubber. The system is totally automatic and has been designed as per the applicable standards. 

This composite system is first of its kind in the world covering the liquefier, filling station and the chlorine storages.

11 CCAL has prepared the first carbon footprinting for the year 2012-13 with the base year as 2011-12. 2013

The carbon footprint is being calculated every year. The carbon footprint report was prepared with the guidance from TERI. This is first of its kind in the chloralkali industry in India

12 Development of greenary and upgradation of the environment.

CCAL campus has 37,000 trees of various species which contribute to the carbon sequestration and ground water recharge. The carbon sequestration potential due to greenery will be roughly 390 MT CO2e/annum

 

Elimination and Reduction of Chemicals in the Manufacturing Process

Major Raw Materials used in Conventional Membrane Chloralkali Plant

 

Major Raw Materials used in Chemfab Alkalis Limited

 
  • Alpha cellulose and Barium salts have been eliminated, due to introduction of “Ultrafiltration Membrane technology”.
  • Process has been developed for the production of soda ash from flue gas and elimination of barium chloride.
  • Trials for the substitution of sodium sulphite and sulphuric acid is in progress

 

Application of these Innovative Technologies has resulted in

  • Lowest specific water consumption and discharge compared to other industries in the Chloralkai sector.
  • Elimination/reduction of two raw materials namely Alpha cellulose and Barium salts.
  • Robust mitigation system for toxic gas release.
  • Lower solid waste generation due to elimination of alpha cellulose and barium salts.
  • Elimination of soda ash and reduction of green house gases upon implementation of the process developed for production of soda ash from flue gas.
  • Reduction in the solid waste upon implementation of the process developed for the recovery of sodium sulphate from brine.