CHEMFAB ALKALIS LIMITED (CAL)

CURRENT BUSINESS PROCESS UNDERSTANDING

(AS-IS STUDY)
PRODUCTION PROCESS

Approvals:

Chemfab Alkalis Ltd

Chain-Sys

Author

Vijayasekaran D

Creation Date

18-Nov-2013

Last Updated

03-Dec-2013

Control Number :

Prod/Process/01

Version

1.2

Document Control

Change Record
Date

Author

Version

Change Reference

Reviewers
Name

Position

21-nov-13

V.Saravanan-Process

Distribution
Copy
No.

Name

Location

Table of Contents

1)

CAL PRODUCTION PROCESS FLOW DIAGRAM..................................................................4

1.1.1
1.1.2

2)

Materials and Processes............................................................................................4

Production Process Utilities.....................................................................................7

ANNEXURE POINTS.............................................................................................................. 10

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1) CAL Production Process Flow Diagram

1.1.1 Materials and Processes

Salt, Power, Water

Salt, and Power are the main Raw Materials of this process
Salt and Power are the Purchased materials

Soda Ash

Soda Ash is procured from market.

This same Soda Ash is used as input for Caustic Soda 33%

Brine Solution

It is an intermediate product of the Salt purification process

Brine Solution is sold outside, rarely

Barium / Sodium Sulphate

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This is the By Product of the Electrolysis Process

Barium / Sodium Sulphate is sold outside

Caustic Soda Lye 33%

Caustic Soda Lye 33% is the main output product of the Electrolysis process
Portion of Caustic Soda Lye 33% is sold outside directly
Portion of Caustic Soda Lye 33% is evaporated to Caustic Soda Lye 48%
Portion of Caustic Soda Lye 33% is also used as input for making Caustic Soda Lye 33% itself (Self
Consumption)
Portion of Caustic Soda Lye 33% is used to produce Sodium Hypo Chlorite
Portion of Caustic Soda Lye 33% is transfer to 48% production from 33% storage in closing stock.

Hydrogen Gas

Hydrogen Gas is a co-product from the Electrolysis process and measured in Nm3 unit
This Hydrogen Gas cannot sold outside as it is of low pressure.
Portion of Hydrogen Gas is compressed and filled in cylinders and sold
Portion of Hydrogen Gas is reacted with Chlorine to produce HCL(32%) acid in HCl plant
Portion of Hydrogen Gas may go as loss through Venting
The Production of Hydrogen Gas is by stoichiometry.
The Production of Hydrogen Gas is netting off Return from party in cylinder as Residual pressure in
daily basis.

Chlorine Gas

Chlorine Gas is a co-product from the Electrolysis process and measured in Tons unit
This Chlorine Gas is not sold outside as it is in gaseous form.
Portion of Chlorine Gas is compressed, liquefied and stored in cylinders and sold outside
Portion of Chlorine Gas is reacted with Hydrogen to produce HCL(32%) acid in HCl plant
Portion of vented Chlorine gas from liquefied chlorine cylinder filling and Caustic Soda 33% is used
to produce Sodium Hypo Chlorite
In case of Venting of Chlorine, it is also used to produce Sodium Hypo Chlorite
The Production of Chlorine Gas is netting off venting quantity
The Production of Chlorine Gas is netting off Return from party in cylinder as Residual pressure in
daily basis.

HCL (32%) Liquid

HCL (32%) is Liquid is produced from mixer of H2 and Cl2 ( Burnt with absorption)
HCL (32%) is sold outside
Portion of HCL (32%) is also used as input for Electrolysis process (Self Consumption)

Thermic Fluid / Furnace Oil

Thermic Fluid Oil is used in the Caustic (33%) Evaporation process. This is topped up periodically
when require as makeup.
Furnace Oil is consumable used in a fuel for boiler operation to heat the thermic oil in caustic
concentration (Evaporation process) Plant.

Freon

Freon is a consumable item used for chilled water making in compressors in the production process
of liquid chlorine process and sodium sulphate plant process.

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Sulphuric Acid (98%)

Sulphuric Acid (98% Concentration) procured externally in the form of 98% and it is used for the
Chlorine gas drying purpose.
The consumed quantity of diluted Sulphuric Acid 78% concentration is called as Spent Acid also
sold directly.

Spent Sulphuric Acid (78%)

The spent chemical of the chlorine drying process is diluted Sulphuric Acid (78% Concentration)
This dilute Sulphuric Acid (78% Concentration) called as Spent Acid is sold outside

Sodium Hypo Chlorite

Portion of Chlorine and Caustic Soda 33% is used to produce Sodium Hypo Chlorite
In case of Venting of Chlorine gas during (sniff) liquid chlorine filling in cylinders, it is also used to
produce Sodium Hypo Chlorite
This Sodium Hypo Chlorite is sold outside

Caustic Soda Lye 48%

Caustic Soda Lye 33% is concentrated (By using Hydrogen and Furnace oil as fuel for heating the
Thermic oil to concentrate the 33% to 48% CSL)
This Caustic Soda Lye 48% is sold outside

Hydrogen Gas Bottling (Cylinders)

The Hydrogen Gas is compressed and filled in Cylinders

The volume of Hydrogen cylinder is 6.725 Nm3 as standard
This compressed Hydrogen filled Cylinders are sold outside directly in loose cylinders and manifold
trucks.
The balance/end quantity available in the cylinders received back from the customers is called as
Residual Pressure (return from Party)
This quantity is adjusted with that production for the day

Chlorine Gas Bottling (Cylinders)

The Chlorine Gas is liquefied and filled in Cylinders

The Produced liquid Chlorine is stored in 50 Ton capacity storage Tanks
From the storage Tanks the Chlorine is filled by using Air padding in cylinders and the volume of
chlorine cylinder each is 900 Kg (0.9 Tons) as standard.
This Chlorine cylinders are sold outside
The Total Stock of Chlorine is sum of Storage Tank stock and Cylinders stock
The balance/end quantity available in the cylinders received back from the customers is called as
Residual Pressure/Stock (as return from party)
At present, this Residual Stock quantity is calculated during filling of the cylinders

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1.1.2 Production Process Utilities

The following are the Utilities which are part of the production process,

1)
2)
3)
4)
5)
6)
7)
8)
9)

RO-Plant
EDI (Electro De-Ionization)
DM Plant
Air Compression
Nitrogen Plant
Cooling Tower (Dry & WET)
Boiler (IAEC)
Saacke Diesel Boiler
Chiller

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RO Water

Raw Water / Bore water used for produce the RO Water (Reverse Osmosis).
Power used for RO treatment.

DM Water
RO water used to produce the DM water (De-Mineralised Water.)
DM water produced through EDI (Electro de-Ionization ) using RO water as input and consumables
like HCL, Caustic Soda and Power in DM (De-mineralisation) process.
Compressed Air
Atmosphere Air used through compressor to produce the Compressed Air.
Compressed Air used for instrumentation control valves
Nitrogen Gas
Atmosphere Air used for produce the Nitrogen Gas.
Nitrogen gas is used at the time of plant shutdown and Start up for purging the cell house system
Cooling Tower
DM Water used for Dry and Wet purpose.
Power and water used for Dry cooling tower to cool the system .
Water and power used for (Wet) Main cooling tower.

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Steam Production

Boiler used for steam production. Steam used for process heating
In IAEC old boiler, Furnace oil and DM water used for steam production.
In SAACKE New Boiler, Diesel, DM water, Hydrogen used for steam production.
From New Hcl by product of generated steam is utilized in caustic concentration plant in NIFFE & SS
evaporator.

Steam Consumption

Steam will use for Caustic Soda Evaporation process. Steam will use in Stainless Steel Evaporator
and Nickel Evaporator and when unusable as venting.

Chiller Compression

Chilled water , Freon Gas and Power used for Chiller Compression

Diesel Boiler

Diesel Boiler used for Steam Generation.

Generated steam is used for Process heating.

Generator

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Diesel generator used for power generation in case of power failure for lighting load only.

2) Annexure Points
S.N
o

A.N
o

18

33

34

35

36

Business Process

Rice Type

Inventory Costing weighted Average; Issue

- FIFO

Standard
Process

Continuous Process
Manufacturing; Daily
Capacity - 100 ton / day

Standard
Process

Yearly budget - demand

Not Feasible

Monthly break up demand

Manufacturing Process:
Sales forecast +
confirmed order - Gross
Demand --> Net
demand (Gross demand
- availability) --> Daily
plan --> Issue Slip -->

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Not Feasible
Standard
Process

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Detail Understanding
Weighted average costing method used for
Inventory costing. Raw material and other
material consumption based on the First in First
out method.
Continuous manufacturing process and per day
100 ton produced. Every day morning production
supervisor provides details for production data
entry purpose
The budgeted amount w.r.t specific products are
to be calculated as per yearly basis. Not feasible
with OPM
The budgeted amount w.r.t specific products are
to be calculated as per monthly basis. Not feasible
with OPM
Manufacturing happens based on the net demand
i.e. the gross demand subtracted with availability.
Total gross demand is obtained as a sum of sales
forecasted and the confirmed order obtained
through the sales executives. Daily plan and issue
slip are to be given for the consumption and
subsequent production.

Consumption
6

37

38

39

40

10

42

12

43

14

15

44

46
47

17

48

19

20

Salt ,electricity and power used for Salt

purification process to produce the brine solution

Process: Electrolysis
happen

Standard
Process

Electrolysis process for produce the caustic soda

from brine solution

Output: Hydrogen +
Chlorine + caustic Soda
lye (33%)
Further Process: Further
processed to caustic
soda lye (48%). HCL
+Sodium Hypo chlorate
+barium Sulphate

RO-SRS -DM water

Standard
Process

sulphuric acid
monitoring

Report

Soda ash monitoring

Report

After Salt purification and electrolysis process,

Main product Caustic soda and by product
chlorine and Hydrogen will be produced.
Caustic soda 33% produced is further processed
to 48% CSL and from H2 andCl2 HCL and sodium
hypo chlorite are produced
Also other by-products like Barium Sulphate is
produced
Steam is produced in two different boilers namely
IAEC and SAACKE where in which furnace oil and
diesel/H2 are used respectively for heating. Steam
is also produced from New HCL process. Steam is
used in evaporation process namely NIFFE &
SSFFE and in process heating.
Report requirement for H2, Furnace oil and Steam
mutually
Raw water is treated with RO process and the
output is taken and used in EDI with power and in
DM process with HCL, Caustic Soda and power
respectively to produce Demineralized water.
Report requirement for H2SO4 98% and 78%
concentration consumption and conversion with
comparison
Report requirement for Soda Ash item quantity
availability and the template can be obtained from
core team

Concentration plant
monitoring

Report

Report requirement for monitoring the steam,

CSL and chemicals used in concentration process,
core team would provide the stencil for the report

chemical utilization
balance

Report

Daily report, MMO report

( Weekly, monthly,
yearly)

Report

Power- consumptionmonitoring

Report

UF membrane

Report

Ion exchange column

data

Report

Report requirement for all the chemicals utilized in

production process and balance available
Report requirement for raw material and
chemicals and consumables on daily, weekly,
monthly and yearly basis, the template can be
obtained from the core team
Report requirement for power consumed product
wise.
Power from each MCC fixed for each process can
be calibrated and respective power consumed for
each product are calculated
Report Requirement for UF membrane utilization
w.r.t consumption. Template can be obtained from
core team. UF Membrane used is to be replaced
after a period of time which is considered as an
asset.
Report Requirement for Ion exchange column
utilization w.r.t consumption. Template can be
obtained from core team. Ion exchange column
used in electrolysis process which is considered as
an asset.

Product Costing

Standard
Process

Costing of various raw material and products are

to be obtained

Gas Chromate meter

Custom
Component

Requirement to be discussed as its been informed

as not a requirement from user team

Standard
Process

Standard
Process

steam utilization
H2 Vs FO Vs steam
tracking

Report
Report

45

16

18

Standard
Process

41

11

13

Input: Salt + Electricity

49

50

51

21

88

22

119

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23

120

Energy monitoring
system

24

200

Daily weighed loads

report like Salt, Sludge &
Others

Report

Sludge generation at
plant

Standard
Process

Cl2 Cylinder filling / H2

cylinder handling

Custom
Component

Casual Labour in the

entire Plant/Plant wise

Standard
Process

Venting of H2

Report

Self consumption of FG

Standard
Process

Report requirement for daily loads of salt used for

brine preparation and sludge from clarifier.
Template can be obtained from core team
Amount of sludge generated as per the
clarification process in brine production should be
calculated
In H2 and Cl2 bottling plant cylinders are to be
used for filling.
The cylinders used are classified as CAL or clients
or specific product cylinders, these are to be
tracked completely at any given point of time
Labour used for both plant and internal purpose.
The amount of labour used w.r.t the plant and
particular process is to be calculated, which can
be done in cost component class as analysis code
or can be done with GL expense allocation code
Report Requirement for amount of H2 venting,
utilization and consumption based on the amount
generated in the process. Hydrogen Gas is a coproduct from the Electrolysis process, is
compressed and stored in cylinders ,mixed with
Chlorine to produce HCL(32%) acid, may go as
loss through Venting &is netting off Return from
party in cylinder as Residual pressure in daily
basis.
CSL 33% is produced as a main product in the
electrolysis process and is store and also
consumed in to further process. This detail has to
be captured.

Soda Ash Production

Report

Report requirement for soda ash produced in the

plant. Soda ash is produced through adsorption
process of flue gas with the CSL 33% process.

AMC calls made report

Report

25

203

26

205

27

28

29

30

206

207

209

210

31

211

32

234

33

Custom
Component

237

Costing method at CAL

Uploading of Raw
Material Consumption,
FG generation with
other data related to
production-in an Excel
file to the Oracle EBS.

Confidential

Energy monitoring system readings are to be

interface and taken in to system

Standard
Process

Report requirement for all calls being made for

annual maintenance activity / services.
Costing method at CAL is periodic moving average
cost and this is required in EBS .Costing of various
raw material and products are to be obtained.
Ref : Point 24

Custom
Component

The raw material consumed and the utilities used

for the production process are to be uploaded
from an external source file like excel to oracle
EBS

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