Internship Report
Saurashtra Chemicals (Division of Nirma Ltd.) – Porbandar
Duration: 16th June 2025 to 28th June 2025
SAUKEM Logo
1. Company Overview
Saurashtra Chemicals, a division of Nirma Ltd., is a prominent chemical manufacturing plant located in
Porbandar, Gujarat. The plant specializes in the production of soda ash (sodium carbonate), an essential
industrial chemical used in glass manufacturing, detergents, and other applications.
Plant Wide View
2. Objectives of the Internship
• To understand the industrial manufacturing process of soda ash.
• To study various utility systems like RO, DCS, and environmental monitoring systems.
• To gain insights into mining operations and raw material handling.
• To explore environmental practices like EIA and HIRA conducted at the plant.
3. Key Learnings and Observations
A. Soda Ash Manufacturing Process
The process observed primarily follows the Solvay Process, which includes: - Brine Preparation:
Seawater or salt water is purified. - Ammoniation of Brine: Ammonia gas is added to the brine. -
Carbonation: Carbon dioxide is bubbled through ammoniated brine to precipitate sodium bicarbonate.
- Calcination: Sodium bicarbonate is heated to produce soda ash.
Industrial kilns, reactors, and settling tanks were seen in use throughout the process.
Plant Equipment Kiln Section
B. Distribution Control System (DCS)
• DCS is used for centralized monitoring and automation.
• It manages temperature, pressure, flow rate, and chemical dosing.
• Real-time data and alarms help in immediate fault detection.
• Ensures safe and efficient plant operation.
DCS View
1
C. RO System for Water Purification
• Converts seawater into drinking-quality water.
• Reverse Osmosis process includes:
• Pre-filtration
• High-pressure pumping
• Membrane separation (removal of salts, heavy metals, pathogens)
• Post-treatment (pH correction and remineralization)
RO System
D. Environmental Practices
i. Environmental Impact Assessment (EIA)
• Assesses impact on air, water, soil, flora and fauna before plant operations.
• Helps in minimizing ecological damage.
• Includes baseline data, prediction models, and mitigation plans.
ii. Hazard Identification and Risk Assessment (HIRA)
• Identifies potential hazards (chemical leaks, equipment failure).
• Risk matrix used to classify severity and probability.
• Preventive measures and emergency response planning implemented.
E. Mining of Limestone
• Raw material (limestone) used in soda ash production.
• Open-cast mining observed with blasting and excavation.
• Limestone transported via trucks to the plant.
• Controlled excavation helps reduce environmental impact.
Limestone Mining
Mining Site 2
Mining Operation
F. Ambient Air Quality Monitoring System
• Monitors pollutants like:
• PM2.5 and PM10 (particulate matter)
• NOx (Nitrogen Oxides)
• SO2 (Sulfur Dioxide)
• CO (Carbon Monoxide)
• Uses real-time sensors and data loggers.
• Data used to comply with CPCB norms and reduce emissions.
Ambient Monitoring
2
4. Visual Observations
• Images were captured of:
• The factory layout and chemical plant structures.
• Limestone mining sites.
• RO water purification facility.
• DCS control room interface.
• Air quality monitoring station.
5. Conclusion
This internship provided valuable industrial exposure, especially in chemical manufacturing,
environmental monitoring, and safety assessment. It enhanced technical knowledge and awareness of
sustainability practices in a large-scale industrial setup.
6. Acknowledgment
I express my sincere gratitude to the staff and management of Saurashtra Chemicals for their guidance
and support throughout the internship.
Intern Name: [Your Full Name]
Enrollment No: [Your Enrollment Number]
Institute Name: [Your Institute Name]
Date: 28th June 2025
