A huge majority of industries, such as metals, textile, paper, leather, sugar, plastics, rubber, ceramics, glass, soap, fertilisers, beverages, edible oil, pharmaceutical, and a host of others, are all heavily dependent on chemicals. All over the world the chemical industry is a major contributor to the national economy, playing both a direct and indirect role.
Ittehad Chemicals Limited (ICL) is the pioneer and one of the largest manufacturers of industrial chemicals in Pakistan. It produces Caustic Soda, Liquid Chlorine, Hydrochloric Acid, Sodium Hypochlorite, Bleaching Earth (Shaffaf), Chlorinated Paraffin, Sulphuric Acid 80%, Zinc Sulphate, and Barium Sulphate. ICL has strategically diversified its product portfolio in order to cater for the demand of the market.
History
Ittehad Chemicals Limited (ICL) was established in 1962 under the name of United Chemicals by a private entrepreneur. ICL was commissioned in the year 1964 with an installed capacity of 40 MT/day of Caustic Soda. The initial plant was set up by M/S Oronzio Denora of Italy.
The factory is strategically located on the 19th/20th Kilometer of GT Road and spread over an area of 106 acres. It is approachable from the Lahore-Islamabad Motorway as well as from the main city of Lahore, being less than an hour drive. The place is known as Kala Shah Kaku, an industrial site which has seen the growth of industries over the past decades stretching up and beyond Gujranwala along the G.T Road. Apparently, Kala Shah Kaku and its neighbouring vicinities have both gained tremendous importance and become a hub of commercial, economic and educational activities. As industrialisation flourished over the years, a large number of small townships also mushroomed in and around the vicinity due to availability of livelihood to the local residents at their doorsteps.
Under the Economic Reforms Order, United Chemicals was nationalised in 1971 along with other industries of the country and renamed as Ittehad Chemicals. It was initially managed by the Board of Industrial Management and thereafter the Federal Chemicals & Ceramics Corporation Ltd under the Ministry of Production, Govt. of Pakistan.
During the state enterprise period its production capacity was raised by another 90 tons/day during the year 1984-85. The factory was ultimately denationalised in 1995 by the Privatisation Commission Govt. of Pakistan. It was acquired by the Chemi Group of Industries, a Karachi based dynamic entrepreneurial group. The new management immediately undertook the task of refurbishing the factory, its infrastructure, and updating its production line to improve efficiency and capacity.
Shortly after the take-over, the plant capacity was soon raised to over 200 tons/day. The environmental friendly "Ion Exchange Membrane Plant" was added to the production line in the year 2003 with a capacity of 163 tons/day. This was shortly enhanced to 240 tons/day with the addition of more IEM Electrolyzers. The new technology is not only environment- friendly but also power-conscious. However, due to its subtle and urbane nature, it requires an uninterrupted power supply for trouble-free operations. Accordingly, the company established its own state-of-the-art Power Plant of 30 MW capacity in the year 2005.
With a rich and illustrious history, ICL is the founding company in Pakistan for the Chlor-alkali industry. It has paved the way for other organisations competing in the local market. With a growing interest for ICL products in the international market, the organisation has made the necessary arrangements (and will continue to do so in the future) to cater for the growing demand.
Mission
We work for our customers to provide a trusted and reliable source of chemical products. Hence, through constant innovation and research we pride ourselves on our unrelentless drive to continuously add-value to our stakeholders, employees, and customers. We strive for sustainable growth in harmony with our environment and suppliers to foster a cordial and mutual relationship.
Vision
To be the first choice of preference by customers looking for premium quality chemical products. We aspire to be a trend setter in our industry and always look to the future with courage and a commitment to excellence in all our practices.
Core Values
We have made a commitment to our customers to deliver the highest quality of chemicals in our chosen segments of operation. Our purpose is to honour this promise and continue to meet and exceed both our customer and stakeholder expectations.
Culture (People)
The tremendous success of ICL has attracted high profile employees from near and far. ICL is located at Kala Shah Kaku, District Sheikhupura. This area is reputed for growing high quality high aroma extra long grain rice. The quality of its rice produced is second to none and is acclaimed world-wide. The skilled / semi skilled workers mostly belong to this area and its surrounding vicinity. The establishment of ICL way back in 1962 brought about a revolutionary change in the life style of the people of the area. By nature, the people of the area are hard-working and pride themselves on their commitment. Over the years, Kala Shah Kaku has developed into a hub of commercial, industrial, and educational activities contributing directly towards the prosperity of the local people.
Culture (Quality & Training)
We believe that quality input can only produce quality output. Accordingly, we develop training programs that help polish our human intellectual capital. Our training programs are based on in-house and on-the-job exposure. Accordingly, we constantly monitor the performance and value-addition of our employees through an annual appraisal and compensation system. This assures that our employees are motivated, committed, and constantly updating themselves for the benefit of all parties involved.
Products
-- Product Portfolio
-- Caustic Soda (Liquid / Solid / Flakes)
-- Sodium Hypochlorite
-- Liquid Chlorine
-- Hydrochloric Acid
-- Shaffaf (Bleaching Earth)
-- CP (Chlorinated Paraffin)
-- Zinc Sulphate
-- Barium Sulphate
-- Research And Development
At ICL, we firmly believe that applied R&D is the only way forward towards achieving optimisation, conservation and economising of our existing process conditions. It also opens door in new vistas for gaining diversity in our production line based on utilisation of process waste as well as surplus streams.
-- R&D activity has always been a hallmark of ICL in all three phases of its existence namely
1) Post commissioning (ie) the initial private era (1964-1971)
2) The state enterprise era (1971-1995)
3) The post privatisation era (1995-todate)
Phase I - Post Commissioning Era (1964-1971):
During the initial period R&D work was confined to in-process development and refinement, utilisation of waste streams and utilisation of surplus chlorine. The R&D Section effectively worked on Brine Purification techniques, (improving quality of cell feed brine for electrolysis) replacing nascent chlorine washing with cooling to remove moisture before contact with Sulphuric Acid for dehumidification.
In those days Bleaching Powder was also manufactured. It was a hot saleable item with textile and yarn industry. A lot of research work was done to improve the quality and stability of Bleaching Powder wherein the later was effectively marketed for a number of years. The product effectively competed with a number of brands especially Adamjee's.
Research work was also carried out for the reclamation of spent chlorinated sulfuric acid obtained from the chlorine drying section. The research was, however, off-set and annulled due to nationalisation of the entire chemical complex in 1971.
Phase II - State Enterprise Era (1971-1995):
During this era, products like Sodium Hypochlorite, Bleaching Earth and Zinc Sulphate were researched upon from lab scale abinitio, to pilot plant stage and ultimately to full scale activity which culminated in setting up prototype plants. From a few hundred kilograms per day during the initial period of development, the plants rose to capacities of 5 tons / day of Bleaching Earth and 20 tons /day of Sodium Hypo until privatisation.
In order to utilise spent Sulphuric Acid from Chlorine Drying section, a pilot plant for the manufacturing of Alum from Bauxite was also established. However, due to constant research the use of spent acid was diverted to produce Zinc Sulphate from Zinc Ash.
Laboratory scale / pilot plant work was also done for the regeneration of Heat Transfer Salt, production of Zinc Chloride (liquid), Ferric Chloride and Calcium Chloride 72% all involving local equipment and expertise.
Another significant R&D achievement was the de-mercurization of Hydrochloric Acid. The later process was developed due to persistent demand of the neighbouring gelatin factory for mercury free acid used in production of edible gelatin.
Phase III - Post Privatisation Era (1995-todate):
The dawn of the post privatisation era brought with it a new dimensional approach together with renewed devotion, resolve and commitment towards rapid industrial growth. The first R&D task undertook by ICL during the private era was the revival of Zinc Sulphate Plant and its up-gradation together with product quality refinement. The product Zinc Sulphate (monohydrate), brand name "Ittehad Zinc", is second to none and is a hot selling commodity with agriculturists due to its quality and high zinc contents.
The balancing and modernisation as well as up-gradation of the Sodium Hypochlorite Plant and Bleaching Earth plant were undertaken simultaneously. Another major step was the enhancement in production capacity of Caustic Soda (by 240 tons) through the installation of mercury-free environment-friendly Ion Exchange Membrane Electrolyzers. A lot of corrosion resistant engineering material including FRP (developed through R&D and local expertise) was the manufactured in the ICL workshops to supplement the installation and commissioning of the IEM Plant.
R&D work also concentrated upon improving the process parameters for ultimate conservation and optimising the inputs thereby reducing the cost of production. A pilot plant for the production of CaCl2 solid was also established. Based on the initial findings of the pilot plant, a full scale CaCl2 prills unit was set up in technical collaboration with M/s NIVOBA BV., Veendam, Holland in the year 2007.
In order to cater for chlorine, which will be used in our future expansion programs, R&D work has already been undertaken for producing Phosphoric Acid through HCL route, a rare process which is in vogue at only a few potential production facilities around the world. Other R&D jobs undertaken are the effective utilisation of carbon dioxide released during acid lime stone reaction for production of calcium chloride liquid for CCIL plant.
R&D work was carried out on a laboratory scale to recover BaSO4 from the sludge through washing of acid soluble impurities. The successful completion of lab work culminated in establishing a proper BaSO4 recovery plant of about 4 tons per day capacity. The product is mostly used in paint industry and favourably compares with several brands which are being imported in the country.