DCW IS A DIVERSIFIED manufacturer of basic chemicals, such as:
 
Caustic Soda
Liquid Chlorine and Chlorine based products such as Trichloroethylene and HCL
Upgraded Ilmenite or Synthetic Rutile
Yellow Iron Oxide
PVC Resin
Soda Ash
Ammonium bi-carbonate
Liquid Bromine and Bromide.

DCW is an industry pioneer with a long track record in its markets and has a successful record in developing downstream and related products.

Its competitive position is enhanced by the diversity of its products.
 

DCW has focused on development of value-added and export-oriented products like Upgraded Ilmenite and Pigment grade Yellow Iron Oxide.

DCW has embarked on an ambitious project for the manufacture of Ferrite Grade Iron Oxide with a capital expenditure of around Rs. 1 billion.
 
THE DCW STORY GOES back to 1925 when the foundation stone of India's first Soda Ash factory at Dhrangadhra -- a small principality in Gujarat in West India -- was laid. The plant was taken over in 1939 and run under the name Dhrangadhra Chemical Works. To wish the venture luck, the company adopted the horse shoe as their corporate logo, which stands till today, and is widely recognised as a symbol of excellence.

      It is said that every oak begins as an acorn. The process of growth received a major impetus in 1959 with the commissioning of the chlor-alkali plant at Sahupuram in the southern state of Tamilnadu. At that time, the area was completely barren. Today this complex has made its mark on the chemical map of India as well as the world.

      Growth at the chlor-alkali complex was rapid as between 1965 and 1970 three plants were erected that turned the co-product chlorine into a money spinner; a liquid chlorine plant in 1965, the country's first tri-chloroethylene plant (left) in 1968 and an integrated PVC resin plant in 1970-making the company one of the first in the nascent petrochemicals field.

      In the same year, 1970, the company set up a plant to manufacture upgraded ilmenite, the first of its kind in Asia, and even today, one of the few of its kind in the world. In 1986, to reflect the expanded activity spectrum, and its emergence as a multi-product and multi-locational company, the corporate name was changed simply to DCW Ltd.

DCW has certainly come a long way since its small beginnings and is one of India's soundest and most respected chemical companies.
 

DCW PIONEERED THE manufacture of Soda Ash in India. The original capacity of 60 tonnes per day has been increased in stages to the present day capacity of 300 TPD and new products have been added to bring diversity to the product portfolio.

      A major modernisation programme, aimed at energy conservation was completed in 1993. Based on the "total energy utilisation" concept, the energy consumption per tonne of soda ash was reduced from 6.59 million K Cal to 3.55 million K Cal - almost half. There has been a total revamp of plant and machinery that has improved operating efficiency.

      The product range of the Soda Ash division now reads an impressive 96,000 TPA of Soda Ash, Ammonium Bicarbonate 5000 TPA, Soda Bicarbonate 12,000 TPA, Liquid Bromine 300 TPA; Isopropyl Bromide 120 TPA; Ethyl Bromide 40 TPA; Butyl Bromide 8 TPA. Calcium Chloride is also produced but its production is seasonal. Salt, the major raw material is produced at the company's own salt works - just 22 kms away.

      The products of this division cater to a wide range of end user industries such as detergents, sodium silicate, dye intermediates, brine purification, ore refining, bakeries, cooling agents, pesticides, drug intermediaries, paper, chemicals, glass etc.

      Today, DCW has a range of loyal customers including blue chip names such as Hindustan Lever, Atul Products, Gujarat Alkalies, Grasim Industries etc.

THE CAUSTIC SODA DIVISION  

DCW commissioned a plant for the production of Caustic Soda in 1959. The output of Caustic Soda has been increased in stages from 28,000 TPA to 80,000 TPA, making DCW one of the leading producers of this basic chemical in India. Modernisation has been an ongoing activity to improve productivity & efficiencies in the electrolysis of Caustic Soda, Replacement of old equipment & installation of continuous salt saturators have resulted in substantial energy savings.
      The by-product,chlorine, is fully used to add value in-house. With increasing demand for liquid chlorine, the plant capacity has been increased from 60 TPD to 80 TPD. Process improvement, in terms of medium pressure liquefaction has will resulted in more productivity, less consumption of electrical energy and refrigerant.
      With a capacity of 5,400 TPA, DCW was India's first producer of tri-chloroethylene, an important degreasing agent. Even today, DCW is one of only few who make this solvent in India, and has exported this commodity as well. The Hydrochloric Acid plant capacity has been increased to 46,000 TPA with new graphite furnaces and DCW has been one of the first to export this product.

SYNTHETIC RUTILE

      High on the list of significant landmarks in DCW's history was the implementation of the project to manufacture upgraded ilmenite, also known as synthetic rutile, for the first time in Asia in 1970. The raw material, ilmenite ore, found in the black sands of Tamil Nadu & Kerala, is chemically upgraded to form synthetic rutile of over 95% Titanium dioxide content and is used as an alternative to natural rutile required for manufacture of Titanium dioxide and Titanium metal. The Plant was commissioned with almost entirely indigenous know-how and is presently one of the few of its kind in the world. The present capacity is 20,000 TPA.

      Besides being one of the highest purity synthetic rutiles in the market, DCW's product also has very low levels of radioactive content, making it a top quality material. DCW has consistently exported synthetic rutile to the USA, Japan and other demanding markets.
      DCW has also developed in-house, a new special "weld grade" synthetic rutile which caters to the requirements of welding & electrode manufacturers by being a substitute for natural rutile. Also through in-house R&D and constant experimentation, a superior product called "UTOX" was developed as a partial substitute for white pigment. The product is manufactured with stringent production & quality controls to ensure consistent particle size & colour. The product finds application in the paint, plastic and rubber industries in India and abroad.

FERRITE GRADE IRON OXIDE

      DCW is now installing a facility for the manufacture of Ferrite grade Iron Oxide from the effluent of ilmenite plant. The quality of the Iron Oxide will enable it to be used in the manufacture of Soft Ferrites which have wide applications in the Electronic Industry. The technology employed is the Solvent extraction process, which ensures a high level of purity of the final product.

SYNTHETIC YELLOW IRON OXIDE

      It is manufactured by the precipitation process using leach liquor - a waste from the Ilmenite plant. The quality of the product matches international standards. It finds application in cement paints, Stainers, Paper, Industrial enamels and construction material.

THE PVC RESIN DIVISION  

      Petrochemicals has been the new buzzword of Indian industry in recent years. In 1970, DCW became one of the first in India to enter this growing field by setting up a PVC resin plant at Sahupuram in Tamil Nadu in Southern India.

      DCW was the first, and is currently the only Indian producer to handle and store imported VCM, a volatile gas. It successfully erected a total storage capacity of 5,600 MT at Tuticorin port (a distance of 30 km from the plant) - including a huge 5000 M3 sphere. This installation is one of the few of its kind in South East Asia and gives the company a competitive edge in meeting its import requirements.
      Constant in-house R&D with modifications in process recipes, resulted in continuous increase in production with very little additional investment. The production crossed 20,000 TPA in 1985-86 after a technical tie up with Atochem, France which also assisted DCW in improving efficiency.

      With installation of stainless steel reactors, a new energy efficient fluid bed dryer and state of the art vapour absorption refrigeration, the production capacity has now reached 60,000 TPA.
      An important spinoff has been the improvement in product quality, production of food grade PVC, and significant consumption efficiencies, comparable with the best in the world.
      PVC Resin is a thrust area for DCW. Having established its excellence in polymer manufacture and marketing, DCW is making efforts to develop new PVC applications. PVC is already the most widely used thermoplastic in India, with a growth rate of over 15%. It finds application in rigid pipes, heavy power cables, footwear, luggage, bottles, flooring & sidings, window profiles, automotive parts, etc.

 
STAYING AHEAD IMPLIES being constantly on the move, keeping track of technology and market needs. And coming up with innovative solutions every time. Something that DCW lays a great deal of emphasis on, with a full fledged Research and Development Centre at Sahupuram. This R&D Centre is recognised by the Department of Scientific and Industrial Research of the Government of India.

      Some of the significant efforts undertaken by DCW people:
The bench scale process developed by Wah Chang for benefication of ilmenite ore was scaled up and engineered entirely by DCW in the first plant of its kind in Asia. (1970)

Development of a product called "Utox" from waste liquor of digestors in the ilmenite plant and used as a partial relplacement to Titanium Dioxide. (1978)

Replacement of graphite anodes with metal anodes in the Caustic Soda cells for the first time in India - resulting in substantial energy savings. (1979-82)

Covering for the first time, 205 acres of sandy waste land with polyethylene to avoid seepage of concentrated brine, increasing salt production by 60%. (1979-83)

Improvisation of recipes, entirely in - house, resulting in a capacity utilisation of 180 % in the PVC plant. (1984 - 86)

Process of de-mercurisation of mercury - bearing water effluent developed for the first time by DCW. (1985)

Development of a new product called "Weldgrade beneficiated ilmenite" developed by DCW for the welding rods industry. (1985)

In collaboration with CSIO, Chandigarh, a process for current monitoring based on microprocessors was developed in the Caustic Soda Cells to result in energy saving of 125 KWH per ton of Caustic Soda. (1986)

Apart from these, in 1992-93, DCW also perfected the production of high purity synthetic rutile wherein the purity of TiO2 is over 95%. The product has low silica and alumina content and radio active matter that is much below the normal levels.

      The R&D section at DCW has also developed Synthetic Iron Oxide pigment using leach liquor - a waste from the ilmenite plant. The developmental work commernced in 1992 and the pilot plant was commissioned in 1993. This is a prime example of DCW being a forerunner in converting waste into wealth and in its contribution towards pollution control.

ENERGY SAVINGS  

The PVC plant has achieved significant energy efficiency by the installation of a fluidised bed drier which consumes 50% less steam than the conventional drying system and the installation of vapour absorption refrigeration for cooling during polymerisation during 1992. The PVC plant also utilises the steam produced from the waste heat of the Captive Power unit, slashing its fuel bills.
      The company undertook an extensive energy audit to not only effect savings in power, fuel oil and steam consumption but to initiate an improvement in process, equipment optimisation and upto date quality control monitoring in 1992 - 93. This energy audit has resulted in a saving of almost Rs. 20 Million per annum. This has been achieved mainly in the Caustic Soda Unit through the following:
Minimising bus bar losses at identified places to reduce the drop in bus bar
Improving current distribution in identified cells to have uniform distribution of current
Utilising gravity flow in the cooling tower in the HCL absorber to avoid the running of the hot water pump

GHH Turbine driven CO2 Screw
Compressor - Soda Ash Division

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DCW BELIEVES THAT it has obligations not only to itself and its shareholders, but to the citizens of India at large. Towards fulfilling these obligations, DCW has undertaken a considerable amount of social work at both Dhrangadhra and Sahupuram in the area of education and social upliftment.
      At Dhrangadhra, DCW contributes substantially to the S.P. Jain Arts and Commerce College, and the Panjarapole Trust which maintains old cattle. In addition, DCW maintains a club for the welfare of its employees and runs a primary school at the labour colony. The company also makes contributions to the Kidney Disease Research Centre for hospital patients and to the Tiffin Seva Mandal for feeding the poor.

      At Sahupuram, DCW runs an English medium school (right), maintains a full fledged hospital facility, runs a recreation club and has a unique scheme called "Own your own housing" - by extending loans to employees for construction of their own houses. The company also subsidises a co-operative run canteen for all workers. Various social welfare activities are undertaken from time to time in the area.
      DCW, Sahupuram, has the distinction of having a charter of the Indian Society for Training and Development to impart regular training programmes and arranging guest lectures.

      DCW has also promoted the S.P. Jain Institute of Management and Research, a leading management institute in Bombay, offering post-graduate degrees in management. The institute is recognised as one of the best in India. DCW has also contributed towards the S.P.Jain Sadhana School for the mentally handicapped in Bombay. Both institutions have been named after the late founder - Chairman of the company, Mr. Shriyans Prasad Jain.
      DCW firmly believes that the business of business is not only business, and hence it contributes towards improving the quality of life of its people by active participation in social welfare activities.

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DCW CORPORATE OFFICE  

Nirmal 3rd Floor
Nariman Point
Mumbai-400 021
INDIA.  Tel: +91 (22) 22871914, 22871916
Fax: +91 22 22028838
Email: ho@dcwltd.com

For queries/investor matters/all compliance matters E-mail to : chital@dcwltd.com