Job PurposeJob Context & Major Challenges There are Seven Units of ABG in India manufacturing Chlor-Alkali products: Grasim Chemical Division Nagda (M.P.), Grasim Chemicals Vilayat (Gujarat) Grasim Chemicals Veraval (Gujarat) Grasim Chemicals Gharwa Road (Jharkhand), Grasim Chemicals Renukoot (UP), Grasim Chemicals Karwar (Karnataka) & Grasim Chemicals Ganjam (Orissa). ABG Chlor-Alkali Business (India) is headed by SBU Head.

The Unit Grasim Industries Limited Chemical

Division Karwar Facility operates Phosphoric Acid manufacturing plant of 24000TPA & 59400TPA Chlor Alkali Chemicals Plant with Mercury Cell Technology in the name of Solaris Chemtech since 1975. For implementing CREP Recommendations for Chlor - Alkali Sector operation of Mercury Technology plant was stopped in Dec 2012.Thereafter, this plant was taken over by Aditya Birla Chemicals ( India ) Limited in September 2013 & replaced old Mercury Cell process of 59400 TPA of Caustic Soda plant by latest state of Art Membrane Cell technology from M/s Uhde Germany .The other By-products are Hydrochloric Acid which is consumed for the manufacturing of Phosphoric Acid ,Liquid Chlorine & Sodium Hypo Chlorite.

Caustic

Soda manufacturing is power based Industry and unit requires 22MW power (Approximately 65% manufacturing cost is power cost) The business environment is multifaceted involving different technologies, various qualities of products for fragmented markets. The Unit is also responsible for procurement of various raw materials and marketing and sales of its products. Initially, after meeting the requirements of Phosphoric Acid Plant, the excess material sold in the market at premium prices because there was a protected market and less supply of material in the market.

With the changing time, the demand and supply position has completely been changed. There are as many as 38 players and total market suffers from excess supply of caustic soda.

The Indian

Chlor-Alkali industry is facing a competition from global market and dumping of Caustic by other nations. By virtue of its strong commitment towards quality management,



company has made efforts to setup Energy Efficient latest Membrane Cell Technology , New Chinese Brine purification Ceramic Filtration ,Variable Frequency Drive for critical Equipment to make the unit more Energy Efficient , Energy Conservation, Quality, Safety, Health & Workplace. The job holder is responsible for planning, monitoring, implementing and control Production& Maintenance activities of Caustic Soda Plant and VAPs so as to optimize plant effectiveness and power consumption to ensure that targeted production achieved with the budgeted cost and adherence to safety and environment including downstream products Liquid Chlorine, Hydro Chloric Acid, Phosphoric Acid and Sodium Hypo in alignment with business mission and EVA targets.

Major Challenges To handle the hazardous products like caustic soda lye, liquid chlorine, HCl, chlorine and hydrogen gas.

To maintain the critical parameters within specified limits to achieve optimum auxiliary power consumption, optimum chemical consumption, increase the life of process equipments.

High Number of Plant tripping due to frequent grid power failures.

To maintain trouble free operation of all equipments to achieve zero break down

New technology of chlorine liquefaction & sodium hypo

Zero Chorine gas leakage to atmosphere To maintain the pollution norms of outgoing streams, air, liquid effluent and solid waste

Water conservation as water is a scare & Highly Expensive commodity at Karwar Compare to other our Group Company Key Result Areas KRA (Accountabilities) (Max 1325 Characters)Supporting Actions (Max 1325 Characters) KRA1 1.

Operations

Ensure targeted quality and quantity Liquid chlorine, Hydrochloric acid, Sodium Hypo production, Air Compressor and CCU Working 1.



Implement production processes and set operation parameters Check plant performance parameters on daily basis and report

Maintain and control raw material and utility consumption

Share management decisions/plans down the line for better execution

Coordinate with other sections to ensure smooth functioning KRA2 2.

Product Quality

Implement process parameters for quality requirements as per customer needs 1. Maintain process and quality parameters Control parameters to optimize consumption of chemicals

Reduce chronic losses like refrigerants and caustic to hypo by process optimization KRA3 3.

Plant Performance

Implement plans to ensure optimum plant performance for achieving targets 1. Support in Implementation of maintenance activities (in coordination with engineering) to ensure minimum losses Follow Standard Operating Procedures for maximum efficiency and less damage

Control spillage and idle running of the equipment Control parameters to maintain consumption of chemicals (caustic lye for sod. Hypo, Lime, etc.). KRA4 4. Operational efficiency & Continuous Improvement Check process conditions to improve the operational efficiency 1. Apply different problem solving tools to reduce the breakdowns Check process parameter deviations

Debottlenecking and following SOPs to avoid any damages

Manage the shift activities and prepare Daily reports

Timely make available all material, resources and infrastructure to the team for efficient operations KRA5 5.

System

Management (Safety, Sustainability & WCM) Adhere to safety & statutory environmental requirements 1. Adhere to safety norms & safe operational procedures Adhere to OSHAS 18001, ISO 14001, SA 8000 & WCM and sustainability norms

Handle emergency situations like Liquid Chlorine leakages etc. under onsite Disaster Management activities

Train the team to comply with these norms KRA6 6.

Customer Service

Maintain system and procedures for customer delight 1. Identify internal and external customer needs & take timely action on the same Initiate corrective actions, when needed

📌 SH CL/HCL/Hypo/Air compressor (GCA Karwar) (Karnataka)
🏢 Aditya Birla Chemicals
📍 Karnataka