INDUSTRIAL ORIENTATION REPORT-2015

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INDUSTRIAL ORIENTATION REPORT-2015PREPARED BYRAHUL S. APPIKATLACHEMICAL BRANCH13BCH002

ACKNOWLEDGEMENT

I am extremely grateful to my university that gave me the opportunity to get exposed to the activities in various Industries under Industrial Orientation programme. I am grateful to all the companies, which helped us for great learning and giving such opportunities.I especially thank PDPU administration for arranging such an organized Industrial orientation, where we got to look into industries and organized series of technical and non-technical lectures which somehow upgraded our practical thinking and concepts.Special thanks to all the workers and officers of the industries who guided us a lot during the visits.I am also thankful to my faculties Miss Sweta Balchandani, Miss Anvita sharma, Mr. Abhishek kumar, Mr. Anirban Dey,Mr. Himanshu choksi. who gave their best to make us understand the various solid flow operations, physical and chemical processes, those are being carried out in an industry.

Abstract:-The Industrial orientation was conducted to improve our market skills and to give us the knowledge about the industrial system. This internship started on 29th of June. For three days we were oriented at college. In which we had guest lectures and interactive sessions. 29th June we attended general sessions and on 30th June and 2nd July we had technical sessions.On 29th June, it was the first day of the orientation, the campus atmosphere was cheerful. On that day we assembled at the auditorium. The first session was by Miss Yukti Jaiswal from IDP. This session was about career opportunities in USA, Canada and UK after graduation. This session was very helpful for the students who wish to do their masters from these three countries. This session gave us the brief introduction about the criteria and chance of admission in various universities. The next session was by Mr. Parasharan Chari from Endeavor. This session was about career opportunities in India after graduation. The third session was of Sunil Parekh, Advisor Zydus Cadila. He gives us some tips about how to treat our health in this pollutant atmosphere. With this our first day ended.On the 2nd day, Mr. Anil Joshi who is senior engineer in GSPC LPG. He gives us the information about communicate to other people. On the 3rd day, Mr. K. K. Parmar, senior chemical engineer in Reliance industry gives information and some case study about how they solve the problem in the running plant.

IndexSr. No.Name of IndustryPage No.

1.INDIAN FARMERS FERTILISER CO-OPERATIVE LIMITED5

2.BAYER CROP SCIENCE11

3.GREEN ENVIORNMENT CO-OPERETIVE SOCIETY Ltd.16

4.GODREJ CHEMICALS Pt. Ltd.21

5.MEGHMANI ORGANICS Pt. Ltd.23

6.FINAR CHEMICALS Pt. Ltd.26

Visited Industries Location and Date:-

Industry NameLocationDate

INDIAN FARMERS FERTILISER CO-OPERATIVE LIMITEDKALOL03/07/2015

BAYER CROP SCIENCEHIMATNAGAR13/07/2015

GREEN ENVIORNMENT CO-OPERETIVE SOCIETY Ltd.VATVA(AHMEDABAD)16/07/2015

GODREJ CHEMICALS Pt. Ltd.VALIA(ANKLESHVAR)17/07/2015

MEGHMANI ORGANICS Pt. Ltd.VATAVA(AHMEDABAD)01/08/2015

FINAR CHEMICALS Pt. Ltd.SANAND(AHMEDABAD)10/08/2015

In-Plant Visit Report ofINDIAN FARMERS FERTILISER CO-OPERATIVE LIMITED

INTRODUCTION:- Indian Farmers Fertiliser Co-operative Limited, also known asIFFCO, is the world's largestfertiliserco-operative federationbased inIndiawhich is registered as a Multistate Co-operative Society. IFFCOhas been ranked #37 in top companies inIndiain 2011 byFortune India 500list. During the mid- sixties theCo-operative sectorin India was responsible for distribution of 70 per cent offertilisers consumed in the country. This Sector had adequate infrastructure to distributefertilisersbut had noproduction facilities of its own and hence dependent on public/private Sectors for supplies. To overcome this void and to bridge thedemand-supplygap in the country, a new cooperative society was conceived to specifically cater to the requirements of farmers.It was a unique venture in which the farmers of the country, through their own Co-operative Societiescreated this new institution to safeguard their interests. IFFCO commissioned an ammonia - urea complex atKaloland theNPK/DAPplant atKandlaboth in the state of Gujarat in 1975. Another ammonia - urea complex was set up atPhulpurin the state of Uttar Pradesh in 1981. The ammonia - urea unit atAonlawas commissioned in 1988. In 1993, IFFCO had drawn up a major expansion program of all thefour plantsunder overall aegis of IFFCO VISION 2000. The expansion projects at Aonla, Kalol, Phulpur and Kandla were completed on schedule. All the projects conceived as part ofVISION 2000had been realised without time or cost overruns. All theproduction unitsof IFFCO have established a reputation for excellence and quality. Another growth path was chalked out to realise newer dreams and greater heights throughVision 2010.As part of this vision, IFFCO has acquiredfertiliserunit atParadeep in, Orissa in September 2005. As a result of these expansion projects and acquisition, IFFCO's annual capacity has been increased to 3.69 million tonnes of Urea andNPK/DAPequivalent to 1.71 million tonnes. In pursuit of its growth and development, IFFCO had embarked upon and successfully implemented its Corporate Plans, Mission 2005 and Vision 2010. IFFCO has now visualized a comprehensive plan titledVision-2015which is presently under implementation. The distribution of IFFCO'sfertiliseris undertaken through over 39824Co-operative Societies. The entire activities of Distribution,SalesandPromotionare coordinated by Marketing Central Office (MKCO) at New Delhi assisted by the Marketing officesin the field. In addition, essential agro-inputs for crop production are made available to the farmers through a chain of 158Farmers Service Centre(FSC). IFFCO has promoted several institutions and organisations to work for the welfare of farmers, strengthening cooperative movement, improve Indian agriculture. Indian Farm Forestry Development Cooperative Ltd (IFFDC), Cooperative Rural Development Trust (CORDET),IFFCO Foundation, Kisan Sewa Trustbelongs to this category. An ambitious project 'ICT Initiatives for Farmers and Cooperatives' is launched to promote e-culture in rural India. IFFCO obsessively nurtures its relations with farmers and undertakes a large number ofagricultural extensionactivities for their benefit every year. Today IFFCO is a leading player in India'sfertiliser industryand is making substantial contribution to the efforts of Indian Government to increase food grain production in the country. IFFCO, Kalol, Gujarat, housesfully integrated state of the art facilityand is one of the most well-planned, sophisticated and environment-friendly fertiliser manufacturing complexes. The main products of the IFFCO plant, Kalol are ammonia and urea, and the plant was commissioned for production in 1975 Dry ice, which is solid CO2 , and required for the industrial manufacturing of urea, was later commissioned in March 28, 1978. The present production capacity of dry ice is 1980 tonnes per annum and that of liquid CO2 is 3960 tonnes per annum.

Urea Production Process:-

The in-house urea plant on the premises produces the primary product of commercial importance, which is urea. The urea is produced using ammonia and dry ice as main raw materials, which are supplied from the Ammonia Plant. The urea plant is based on Stamicarbon CO2 Stripping Process and was commissioned in January 1975. Urea plant was revamped to 1650 tpd in the year 1997 by removal of various bottlenecks in the original plant. The non-condensable gases introduced in the CO2 (i.e., passivation air) and part of the unreacted NH3 and CO2 goes to the high pressure scrubber. In scrubber, most of the NH3 and CO2 is condensed and send to reactor. The heat of condensation is dissipated in tempered cooling water. The chemical reaction involved in the formation of Ammonia is:-

N2 + 3H2 2NH3

This ammonia produced is reacted with dry ice, which is the solid form of CO2. This reaction occurs in two steps:-1. First step involves the formation of ammonium carbamate.2. The subsequent decomposition of ammonium carbamate results in the formation of urea and water.

NH3 + CO2 NH4COONH2 NH2CONH2

The urea thus obtained is only 35% concentrated by nature. Further concentration of 55% is achieved through multi-effect evaporators. Fluidised air cooler is used to cool the formed urea from from 90 C to 55 C (max.). Air is used as fluid for fluidising the column. Product from Stripper is let down to the Rectifying Column for recovery of small amount of unconverted ammonium carbamate. To unload the evaporators, Pre-evaporator is installed downstream of the Flash tank to concentrate the 55% concentrated urea solution to 82.6 %. The product urea solution is further concentrated in two Evaporators installed in series to produce molten urea which is pumped to the top of a Prill Tower from where it is passed into a rotation Prill Bucket. Prills, formed in the Prill Tower, are collected at the base by Prill Tower Scrapper which transfers urea to a conveyor to Prill Cooling System. In Fluidised Bed Prill Cooling System urea is fluidised on perforated plate, heat of hot prills is taken away by air and cooled to 55 C (max.). Since April 2011, Neem Coated Urea Production has been started at Kalol Unit, Neem oil is being sprayed at exit of Fluidised Bed Prill Cooler and from here it is conveyed to Bagging Plant or to Urea Silo. The coating of neem oil on urea serves various purposes. It helps in :-1. Prevention of formation of lumps in the dried urea.2. It acts as a natural pesticide by controlling pest formation.3. It controls the nitrogen fixation in the plants. Urea, as such provides all the nitrogen present in the compound, to the plants, but the addition of neem controls this process. It allows plant to absorb N2 in the amount required by the plant/crop which is beneficial for its growth.ProductionAmmonia(in metric tons)Urea(in metric tons)

Todays(03/07/2015)11391777

Monthly22803553

Yearly91166143175

Activities undertaken during the visit

Around 10:30 A.M. we reached IFFCO Kalol site, students assembled near the site security office, where we were provided safety helmet. Then we were taken to urea production control room where they explained the flow diagram of the urea process. Then we were taken to main process plant, where we saw the process plant and site explainer explained each process and how the equipment is run. About one and half hour of visit, we went to security office and gave back a helmet. Then we took a lunch.

In-Plant Visit Report ofBAYER CROP SCIENCE

INTRODUCTION:- Mission: - Our Bayer Group mission Bayer: Science for a Better Life is the foundation of what we at Bayer Crop Science strive to achieve within the agricultural sector.

Facts and Figures: - In 2014 Bayer Crop Science raised sales by 11.2% (Fx & portfolio adj.) to 9,494 million. Crop Protection/Seeds achieved double-digit growth, due to the attractive market environment.

Business Operations: - Our active ingredient pipeline currentlyincludes five late and two early stage developmental candidates, with a total of30 projects in the research phase.

Management: - The Executive Committee ofBayer Crop Science is entrusted withdirecting the companys activities.

The global presence and cultural diversity are key conditions for the success of Bayer Crop Science as a world market leader in the industry. As a result of comprehensive market analysis, they know the needs of the customers in both small, specific segments and the major global markets. Bayer Crop Science also maintains a global network of research & development and production sites.

Products and innovation : - 1. Key Crops: - Bayer Crop Sciences is committed to the food security with a focus on innovative crop solutions as well as seeds and traits to secure harvests and to increase productivity. The various crop seeds whose productivity were increased as a result of research are cotton, various fruits and vegetables, corn, oilseeds, rice, soy, wheat, sugar beets and sugar cane.

2. Brands: - The various products manufactured by Bayer Crop Science guarantee high quality and high yields, providing reliable support for farmers. Because farmers are always facing new challenges, were right by their side with high yielding seeds and innovative crop protection products. The various products meant for crop protection are insecticides, fungicides, herbicides, seed growth, and high quality seeds.

3. Research: - The research activity at Bayer Crop Science pushes the boundaries of what science can do. And their passion comes from a very urgent concern: to make sure everyone gets enough to eat, due to the ever increasing population on earth.

PLANT PROCESS DETAIL:- The Bayer Crop Science, Himmatnagar plant houses fully integrated facility for the production of insecticides and fungicides, which are its main products.

The major products manufactured at the Bayer Crop Science, Himmatnagar plant are:

1. Weighable Granules (WG): - These consist of granules which have been formed into regular shape after passing through various unit processes and unit operations.

2. Suspension Concentrate (SC): - The SC is formed by concentration of the suspension, usually solids suspended in liquid, with the help of MEE.

3. Weighable Powder (WP): - WP is obtained by crushing of the granules. The granules are so crushed that their particle size does not become too small, such that their collectable weight can be measured.

4. Emulsifying Concentrate (EC): - First of all, an emulsion is formed consisting of dispersed phase and dispersing medium. The emulsion is then concentrated to the required product specification.

5. Active Ingredient (AI): - Anactive ingredient(AI) is theingredientin apharmaceutical drugor apesticidethat isbiologically active. The similar termsactive pharmaceutical ingredient(API) andbulk activeare also used in medicine, and the termactive substancemay be used forpesticide formulations.

6. Oil Dispersion (OD): - For preparation of oil dispersion, sunflower oil is used. The dispersed phase is present in oil, which is the dispersing medium.

Majority of the Himmatnagar facility is involved in the packaging and marketing capacity of various products, some of which are prepared at the on-site facility. Most of the products, with varying specifications, are imported from the various Bayer Crop Science production facilities throughout the country.

The packaged and finished products are then shipped and exported to various countries some of which are Brazil, Thailand, Vietnam, Pakistan, and various countries in Europe.

The Himmatnagar plant has worked 5613 days (15.37 years) without any injury or accident occurring on the plant premises.

Bayer Crop Science believes in utmost safety, as is clearly seen by their excellent track record in the safety department. Their leadership in safety is clearly established by following various safety protocols and taking appropriate measures for the prevention of any industrial accident. The various activities undertaken to ensure complete safety of the plant and personnel are: -

1. Continuous training to people for safe behaviour.2. Tool box talks.3. TOPPS training.4. Safety works permit system.5. Celebrating Bayer Safety Day and National Safety Day.

Activities undertaken during the visit Around 10 A.M. we reached BAYER CROP SCIENCE site, students were taken to conference hall where lectures on INTRODUCTION OF BAYER GROUP, PLANT PROCESSES AND PACKAGING were conducted. After one hour theory sessions, we were taken to the working site where we show the SC and OC processing plant, packing plant, control room, warehouse and product storage plant. In the warehouse and storage plant, all the containers arrange with barcoded system. After one and half hour site visit we went back to conference hall and their experts gave answers of our problems. Then we assembled at main gate. Then we take a lunch.

In-Plant Visit Report ofGREEN ENVIORNMENT CO-OPERETIVE SOCIETY LTD.

OBJECTIVE:- GESCSL was formed in 1992 with the main objective to abate pollution and conserve energy and environmental resources to achieve sustainable growth and development in VATVA. To achieve this objective approximately a sum of Rs. 100 crore has been spent to set up the following Environmental Infrastructure Facilities and Management Systems Establishment and operation of common facilities for the collection, treatment (CETP) and disposal of industrial effluent in the estate of Vatva having membership of 674 member industrial units. Establishment and operation of common secured landfill facility (SLF) for the safe disposal of solid waste being generated by industrial units in Vatva and elsewhere.

COLLECTING EFFLUNT BY INTERNAL COLLECTION SYSTEM (ICS) AND CONVEYANCE NETWORK:- The 680 member units of the estate are spread in an area of 13.5 sq. km. in Vatva industrial estate. The effluent from each member unit is conveyed through ICS to CETP in a systematic manner. Adequate arrangement is made for monitoring quality and quantity of effluent from each unit. The 680 member units which are scattered in different parts of the complex are covered by 92 Sump Rooms from where the wastewater flows by gravity to 6 Pumping Stations. The effluent is pumped from these Pumping Stations into CETP for treatment. All the member units discharge their effluent from their overhead discharge tank into respective sumps. The butterfly valves and magnetic flow meters are provided in each sump room for measuring flow rate of effluent from each member unit. It is obligatory on the part of every member to install overhead effluent collection tank having enough holding capacity to facilitate gravity flow to the respective sump. The gravity mains of the ICS have a total pipeline length of approximately 18000 meters; with sizes varying from 250 mm to 600 mm diameter. These pipelines are made of RCC and stoneware. The rising mains are made of HDPE having a total length of approximately 6200 meters with sizes varying from 180 mm to 400 mm diameter.

Treatment Process:- Each member unit is required to arrange for pre-treatment of the effluent to meet the CETP inlet norms. The CETP consists of the following units.1. Equalization2. Tank Flash Mixer3. Flocculator4. Dissolved Air Floatation Unit5. Aeration Tank6. Secondary Clarifiers The pre-treated effluent from the member units is pumped to the Equalization Tank. The Equalization tank is designed to provide residence time of 24 hours under the maximum flow condition. The contents of the Equalization Tank are thoroughly mixed / equalized with the help of coarse bubble diffused aeration supplemented by a Turbo Aerator. From the Equalization Tank the wastewater flows through flow-control arrangement into Flash Mixer where coagulants and flocculants are added. After complete mixing of the chemicals with the effluent it flows into Flocculator where coagulation and flocculation of suspended solids, colloids and some of the dissolved pollutants take place. The overflow from the Flocculator goes to Dissolved Air Floatation (DAF) Unit. The unit works on the principle of super saturation of the liquid with dissolved air. The super saturation is achieved by mixing pressurized recycled wastewater with compressed air. The saturated recycle flow is released at about atmospheric pressure in the DAF Tank which results in the formation of fine bubbles. These fine bubbles get attached with flocculated particles and are floated to the top of the tank. These particles as well as those settled at the bottom of the tank are removed and collected by the top and bottom scrappers in the form of primary sludge and is collected in the Primary Sludge Holding Tank from where it is sent to Centrifuge Decanter for dewatering. The dewatered sludge is then disposed of into Secured Landfill Site at Vinzol. In the outlet of DAF the concentration of suspended solids is maintained at less than 100 mg/l. Some reduction in COD content is also observed due to removal of organics in colloidal state. This effluent flows to Aeration Tank by gravity. The total capacity of Aeration Basin is 27800 cu. m. Medium bubble aeration supplemented by 18 nos. Triton type Aerators supply air to maintain the desired DO level and also to maintain the MLSS in suspension. The organic matter is aerobically degraded by the micro-organisms contained in the activated sludge. Nutrients in the form of nitrogen and phosphorous containing compounds are added as per the requirement. The various parameters including MLVSS, MLSS, F/M ratio, DO level and concentration of nutrients are closely monitored and maintained to achieve the maximum degradation of organics. The effluent containing MLSS flows into the two Secondary Clarifiers after passing through the Flow Distribution Chamber. Provision is made for adding coagulant in the Clarifiers depending on the requirement. The suspended solids get settled by gravity and are collected at the bottom of the Clarifiers from where they are taken to the Sludge Sump. This is activated sludge containing biomass along with inert. A portion of this activated sludge is recycled into the Aeration Tank for the maintaining biomass in the form of MLVSS at the desired level. The rest of the sludge is taken into Sludge Holding Tank from where it is pumped to Centrifuge Decanter for dewatering. The dewatered sludge is transported to SLF for final disposal. The supernatant from the Clarifiers is collected in Holding Tank / Pumping Station from where it is pumped to the Mega Pipeline for ultimate conveyance into river Sabarmati at Pirana after mixing with the treated sewage discharged from Pirana STP of Ahmedabad Municipal Corporation.

Activities undertaken during the visit

Around 10 A.M. we reached GESCSL site, lectures on PLANT SAFETY & INTRODUCTION TO GREEN ENVIORNMENT CO-OPERETIVE SOCIETY LTD were conducted. After one hour theory sessions, we were taken to the working site where we were showed effluent treatment plant. In the plant, we saw Equalization, Tank Flash Mixer, Flocculator Dissolved Air Floatation Unit, Aeration Tank and Secondary Clarifiers and site explainer explain their function briefly. After one and half hour site visit we assembled at main gate.

In-Plant Visit Report ofGODREJ CHEMICALS Pt. Ltd.INTRODUCTION:- Godrej continues its century old tradition of innovation with the manufacture of oleo chemicals for the first time in India Since 1963. Godrej Industries is the market leader in a range of Oleo chemicals in India. It is also the market leader in the product category of Alpha olefin Sulphonate. It is also a major player in the field of Glycerin & Surfactants such as Sodium Lauryl Sulphate (SLS) and Sodium Lauryl Ether Sulphate (SLES). Godrej Industries Limited has a modern, integrated manufacturing facility at Valia in the Indian state of Gujarat. This faculty uses vegetable oils as the raw material to manufacture Fatty Acids, Glycerin, Fatty Alcohols & Surfactants such as Sodium Lauryl Sulphate, Sodium Lauryl Ether Sulphate & Alpha Olefin Sulphonate. The installed capacity for Fatty Alcohols is 65000 MT per annum which includes a dedicated Export Oriented Unit of 30000 MT. The facility is ISO 9001 & ISO 14001 certified and has been Kosher certified for manufacturing Fatty Acids, Fatty Alcohols and Glycerin. Godrej Industry produce fatty alcohols 65,000 MT, surfactants - 15000 MT, stearic acid - 18000 MT and glycerin - 5,000 MT per annum. The facility which operates on Distributed Control System is well equipped to deliver the products of superior Quality, in time and at competitive price. The products made at this facility are exported to more than 60 countries across the globe.

Activities undertaken during the visit

Around 12:30 P.M. we reached GODREJ Industry Valia site, students assembled near the site security office, where we were provided safety helmet About 5 minutes of visit, we went to back security office and gave back the helmet.

In-Plant Visit Report ofMEGHMANI ORGANICS Pt. Ltd.INTRODUCTION:- It was in 1986, when Gujarat Industries was established as a partnership firm in Gujarat to manufacture pigments. High productivity and profitability transformed Gujarat Industries to a joint stock company, under the name of Meghmani Organics Limited, by 1995. Since then Meghmani Organics Limited has diversified its business interests to include a range of pesticides and other pigment products as well. Today, Meghmani Organics Limited is a leading manufacturer of pigment and pesticide products in the country and is the recipient of several prestigious awards in recognition of its outstanding business performance. Sound fundamentals, outstanding export performance, strong presence in the domestic market and a focused management team has seen Meghmani Organics Limited grow at a compounded annual growth rate (CAGR) of 17% and profits 10% over the past 3 years The Rs 6000 million Rupees Meghmani Organics Limited is:1. One of the largest producers of pigment blue in the world2. One of the leading producers of pigment green3. One of the largest producers of pesticides in India More than 80% of our pigment products and over 50% of our pesticides products are exported the world over. We have four multifunctional production facilities in Gujarat (India) of which three are ISO 9001-2000. Our production facilities are strategically located with high accessibility and close proximity to source of raw material. In Meghmani group have an extensive network of 20 overseas distributors worldwide, Over 1000 stickiest, agents, distributors and dealers covering India market and Warehouses in Belgium and Uruguay.

Chemical Process:- Meghmani Pigment Green Plant, Vatva, Gujarat, is very well designed and some part is still under construction. The plant has two different parts one is pilot plant and another one is main plant. Copper Phthalocyanine Blue is raw material to produce Pigment Blue. It is imported from Meghmani Panoli Plant, Gujarat. Chlorine is another raw material which is added with Copper phthalocyanine Blue and Aluminum Chloride is used as catalyst. These three raw materials are added into batch reactor. These process is anhydrous and heating is provided by oil and 800 kilogram of Copper Phthalocyanine blue is added and this process works under vacuum pressure, and temperature maintained between 165 175 degree centigrade 800 kg of Copper Phthalocyanine blue and this process works about 65 75 hours. For utility chilling water plant is also there in which ammonia is used to cool water. Hot water enters in heat exchanger in which other liquid is ammonia and after cooling water is return to plant and hot ammonia is also cooled. For heating of oil remaining cottonseeds after extraction of oil are utilized with sand heating. Water is also heated to generate steam with same process. After chlorination mixture is dumped into 30 KL container which is enclosed and crystallization of mixture takes place and HCL and Cl2 gases are taken out from container and transferred into scrubber In first column water used for scrubbing of HCL gas and in second column also water used to dissolve more HCL and in third column caustic water used to dissolve Cl2. Now water added to crystal pigment green about 50%. This washing is done to neutralize solution and after it is subjected to filter press in which polypropylene cloth is used for filtration, where the 4000 kg of product is produce in one pass. After the filter press 80% concentrated pigment green is produced. This product is fed into the spin flash dryer, where the dry pigment green is produced, which is conveyed for packing.

Activities undertaken during the visit:- Around 10:30 A.M. we reached Meghmani Organics Ltd. site, students assembled near the site head office, where site explainer gave important safety instructions. Then we went to main process plant, where we saw the process plant and site explainer explained each process and how the equipment is ran. After the plant visit we saw the chemical effluent treatment plant, where they treat the chemical dissolved water treated. Then we go to pilot plant where site explainer briefly explains the treatment to reduce waste water and energy consumption. Then we were taken back to site head office, where we saw how they conduct the event which is based on plant safety and when the any poison gas leakage then what step is taken by the works and how to handle this situation.

In-Plant Visit Report ofFINAR CHEMICALS Pt. Ltd.INTRODUCTION:- Established in 1998, Finar has been working towards strengthening manufacturing base and product portfolio. The company focuses on continuously reviewing opportunities in the pharmaceutical industry as well as other growing segments to offer new and innovative products. Within a span of decade, the company has expanded its manufacturing capacity to over 12000 MTPA with a high end infrastructure & setup for chemical synthesis, purification & manufacturing to address the growing needs of existing and new clients. Finar technical team is working towards synthesis & purification of various chemicals used in manufacturing in the electronic and pharmaceutical industries. Finar ensures that manufacturing meets all environment, Health and safety standards. The company helps and supports all its client industries to improve operational efficiency in chemical analysis and manufacturing processes. The company operations are integrated with systemized supply chain, decision making based on data provided for analysis on product movement cross geography, maintain inventory of raw material and finished products and with on-time delivery facilitated through SAP system. With the stricter regulatory compliances being implied in the Pharmaceutical, Cosmetic, Food industries the product requires more than just specifications. Finar has successfully met this stupendous challenge of delivering range of products due to high quality manpower with proven skill sets and enviable processes with commitment to safety, health and environment. Finar are an ISO 9001:2008, 14001:2004, OHSAS 18001:2007 certified company. Successfully filed type IV DMFs with USFDA. All valuable clients can be rest assured of high quality products that are manufactured with cutting edge technology and contemporary analytical methods to monitor the entire process from manufacturing to finished product.PLANT PROCESS DETAIL:- Finar possesses a contemporary manufacturing facility expanded to meet the growing needs of high purity chemicals. The facility spread over 1 lakh sq. feet area and plant is designed as per CGMP norms. The company has a built in facility for 16 reactors from 1.6KL to 3.0 KL, these reactors are GLR and SS with a column height up to 30 feet. Plant has capacity to purify 15,000 liters of solvent per day. The facility also has dedicated infrastructure for inorganic and organic salts manufacturing and purification. First low concentration fluids likes Methanol, Acetone, Propanol, etc. are fed to the distillation column, which is placed at 1st flour. Hear solvent is evaporated using steam and vapor is formed. This vapor is condensed at 20 feet elevation by using condenser. Finar have one water purification plant using reverse osmosis, pressurized bed purification chamber, distilled plant. This water is used in generating steam. Dedicated pipelines for materials and utilities such as compressed air, nitrogen gas, steam etc. have been duly installed. The utilities include a boiler, cooling tower, air compressor and water purification Reverse osmosis plant etc. Condensed high purity liquid is collected at the bottom of distillation column due to density difference. Then they collected liquid in the storage tank and then this high purity fluid is fed into trucks. Adequate storage area has been created to ensure that all material is safely stored across the entire facility. Solvents are stored in underground tanks as well as drums in designated areas. Hear total of eight underground tanks have been installed with the capacity of 15 KL each. Finar understands the need for accuracy in quality for all products and thus, pays high attention to the quality control approach to achieve precision in analysis. Changes in regulatory requirements always impact the manufacturing processes and methods of analysis of purities and impurities. Finar Chemicals has developed different purification processes and analytical methods to analyze impurities in ppb levels using various equipment likes GC, HPLC, Layer chromatography, X-Ray, etc. At Finar, they have one effluent treatment plant, which is purified the water, which is used in kitchen, planting in trees, washing the ground.

Activities undertaken during the visit:-

Around 02:15 P.M. we reached Finar Chemicals Ltd. site, students assembled in presentation room, where site explainer gave brief introduction about companys goals, mission, and production. Then we went for the site visit, where site explainer gives safety instruction. They give us brief idea about how they control the hazards solutions and how they controls fire accidents. Then we went to main distillation plant, where we saw the process plant and site explainer explained each process and how the equipment is run. After the plant visit we saw the chemical effluent treatment plant, where they treat the chemical dissolved water treated. After one and half hour site visit we go to auditorium and their experts give answers of our questions.

KEY LEARNING:-

It was privilege to get a chance to understand the most important and inevitable qualities or skills that have made these industries and the company a huge success: Facing all the turbulences with a positive outlook. Always be ready to handle any unexpected situations. Adapt new technology to compete with other industries in market. Do appropriate time management for production and sales cycles. Maintain good business relations with market and always keep in touch. Utilize maximum technology with minimum cost.