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VOL. 50 | ISSUE NO. 12 | DECEMBER 2015 | MUMBAI | ` 200 NEWS ► Industry News/ 8 Technology News / 22
NEWS FEATURES ► Taking ‘Commitment to India’ to Next Level / 26
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FEATURES ►
Saving in the Air / 38 – Bal Kishan Sharma, Manager- Instrumentation, Indian Oil Corporation Ltd - Gujarat Refinery
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Bahrain Petroleum Company, Kingdom of Bahrain Challenges & Opportunities for Industrial Gas Market
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Anand Pattani, Managing Director, Black & Veatch India
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Bimal Goculdas, CEO, The Dharamsi Morarji Chemical Company Ltd / 78 Dr Peter Martin, Vice President, Business Value Solutions, Schneider Electric / 78 Jeremy Hunter, President, Henkel Group, India / 80 Kevin Shah, Managing Director, Kevin Enterprises Private Limited / 80 SC Mehta, Director, HPCL / 82 Sudhir Shenoy, CEO, Dow India / 82 Vipul Shah, COO – Petrochemicals, Reliance Industries Ltd / 82
To Be Continue... Disclaimer: The Editorial/Content team at Jasubhai Media Pvt Ltd has not contributed to writing or editing “Marketing Initiative.” Readers would do well to treat it as an advertisement.
Printed and published by Mr Maulik Jasubhai Shah on behalf of Jasubhai Media Private Limited, 26, Maker Chamber VI, Nariman Point, Mumbai 400 021 and printed at The Great Art Printers, 25, S A Brelvi Road, Fort, Mumbai 400 001 and published from 3rd Floor, Taj Building, 210, Dr. D N Road, Fort, Mumbai 400 001. Editor: Ms Mittravinda Ranjan, 26, Maker Chamber VI, Nariman Point, Mumbai 400 021.
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LEADERSHIP CEW Contents Ashish Gharpure, Chief Operating Officer, Aker Solutions India / 84 Dr Arup Basu, President, Tata Chemicals / 84 Uday V Kulkarni, Country Head – Offshore Business Development & Offshore Projects Operations Head, Technip India Ltd / 84 M B Parekh, Chairman, Pidilite Industries / 86 Dr Raman Ramachandran, Head South Asia, Chairman & MD, BASF India Ltd / 86
February 14 -17, 2017 Venue: Bombay Convention & Exhibition Centre Goregaon (East), Mumbai, India
Leadership
Yatinder Suri, Country Head, Outokumpu / 86 Nadir Godrej, Managing Director, Godrej Industries / 86
MARKETING INITIATIVE ► Alfa Laval (India) Limited / 88 Sigma HSE / 90 Economy Refrigeration Pvt Ltd / 92
Mr B Narayan, Group President (Procurement & Projects), Reliance Industries Chairman - CAB, EPC World Expo 2017 “Several EPC companies have been offering EPC services directly or indirectly outside India through their parent companies. However, many wrong perceptions continue to prevail across the overseas customers which do not serve well for brand India. We have lined up several renowned speakers who will address relevant issues in the conference on the theme - Strong Indian EPC to Build Brand India Global.”
Italvacuum / 94 Industrial Solvent Recycling Machines – FORMECO (Italy) / 100 BEDA FLOW Systems Pvt. Ltd. / 102 Toshniwal / 106 Nihva Technology Private Limited / 108
PRODUCTS ► / 110 EVENTS ► / 113 PROJECT UPDATE ► / 114 BACK OF BOOK
Dr Raman Ramachandran, CMD, BASF India Ltd & Head - South Asia, Chairman - CAB Specialty Chemical World Expo 2017
Ad Index / 116 Book Shelf / 118
“There are huge challenges that we face globally and in our country. Chemistry can be a big enabler for addressing some of these challenges. In order to come up with the solutions, there is a need to co-create as some of the challenges cannot be addressed by one individual or one company or one institution. “ Dr Deepak Parikh, Vice Chairman & Managing Director, Clariant Chemicals India Pvt Ltd “I am very excited to see Speciality Chemical forum evolving in India. There are not many speciality chemicals forums currently operating in the country and this one is going to bring in a number of key players in the entire value chain including the producers, end users the people who are shaping up the future with respect to Speciality Chemicals together...”
Concurrent Events Disclaimer: The Editorial/Content team at Jasubhai Media Pvt Ltd has not contributed to writing or editing “Marketing Initiative.” Readers would do well to treat it as an advertisement.
Printed and published by Mr Maulik Jasubhai Shah on behalf of Jasubhai Media Private Limited, 26, Maker Chamber VI, Nariman Point, Mumbai 400 021 and printed at The Great Art Printers, 25, S A Brelvi Road, Fort, Mumbai 400 001 and published from 3rd Floor, Taj Building, 210, Dr. D N Road, Fort, Mumbai 400 001. Editor: Ms Mittravinda Ranjan, 26, Maker Chamber VI, Nariman Point, Mumbai 400 021.
6 • November 2015
Chemical Engineering World
CEW Industry News NALCO & GACL to Setup Caustic Soda Plant Kolkata, India: National Aluminium Company Limited (NALCO) and Gujarat Alkalies and Chemicals Ltd (GACL) will set up a caustic soda plant through the joint venture they have set up. The plant would be worth ` 1800 crore. Nalco has a share capital of 40 per cent while the rest 60 per cent is held by GACL. The plant will produce about 2.7 lakh tonnes of caustic soda per annum. The project is in its final stages which involve land transfer and ordering the plant equipment. Being part of Nalco’s backward integration plan, the venture is expected to be a highly profitable one. Nalco has also set up a joint venture with Gujarat Mineral Development Corporation (GMDC) to build a 0.5 million tonnes per annum Alumina Refinery.
IIL to Set-up Plant for Bio-products New Delhi, India: Insecticides India (IIL) is planning to set up a manufacturing plant for producing bio-products and is in the process of launching new products in biotechnology which offer plant nutrition and soil fertility. Last year, the company launched its first bio-product Mycoraja which is Insecticides India’s first in the bio-product segment. The company is in the process of launching 3-4 new products. IIL also plans to set-up a R&D centre which would do specific research in bio-technology for manufacturing bio-products. Rajesh Aggarwal, MD, IIL, said that bio-based products can reduce the usage of chemical fertilisers and also enhance the nutrient uptake which is fixed in the soil. He also added that two products are likely to be launched shortly.
LyondellBasell to Acquire Zylog Plastalloys Compounding Business Mumbai, India: LyondellBasell has entered into a definitive agreement to acquire the polypropylene (PP) compounding assets of Zylog Plastalloys Pvt Ltd (Zylog) of India. Upon completion of the acquisition, LyondellBasell will double its automotive customer base in India and become the third largest producer of PP compounds in the country with an annual capacity of 44,000 metric tons (97 million pounds). Earlier this year, LyondellBasell acquired SJS Plastiblends Pvt Ltd (SJS), a manufacturer of PP compounds located in Aurangabad, Maharashtra, India. The Zylog acquisition includes manufacturing sites in Sinnar, Maharashtra, and in Chennai, Tamil Nadu. “We are very optimistic about India’s economic growth and rapidly expanding automotive market. The acquisition of SJS and Zylog are part of our plan to strategically expand our footprint where it makes sense from an economic and strategic perspective. With these investments, LyondellBasell will be a leading producer of PP compounds in all major automotive growth regions of the world,” said Bhavesh (Bob) Patel, CEO and Chairman - management board, LyondellBasell. 8 • December 2015
Huntsman Textile Effects Baroda Embarked on a Meaningful Water Project Vadodara, India: Huntsman Textile Effects Baroda, part of the Huntsman International (India) Pvt Ltd - a leading specialty chemicals manufacturer and a global manufacturer and marketer of differentiated chemicals, has embarked on a meaningful CSR project in Luna village. The village receives Narmada canal water but due to lack of proper water storage lakhs of water flows in nearby pond and villagers do not have potable drinking water. Recognising the need, Huntsman Baroda as part of its Corporate Social Responsibility has decided to construct 500 KL RCC underground water tank which costs to approximate USD 80,000 and will benefit more than 3500 villagers of Luna Village in padrataluka. Speaking on the occasion, Sanjay Soor, Site Manager, Huntsman Baroda said, “Our dedication and commitment to giving back to the society meaningfully has now been strengthened further, we are extremely happy to undertake this meaningful project alongwith Luna Gram Panchayat. I would also like to thank Sarpanch of the village and key stakeholders who has worked relentlessly to build a valuable society”.
HRS Showcases Energy Efficient Heat Transfer Solutions Pune, India: H R S P r o c e s s S y s t e m s L t d , ( H R S P S L ) h a s participated in the Annual Seminar organised by The Fertiliser Association of India (FAI) held in December 2015 in New Delhi. HRS showcased its range of innovative and cost efficient solutions widely applied in process industries like chemical, agrochemical, fertilisers, pharmaceutical and many more. The theme of the FAI Seminar this year was ‘Unlocking Potential of Fertilizer Sector’. Key factors for the fertiliser sector like reforms, soil health enhancement, improvement in viability of fertiliser production and reorientation of marketing strategies were in focus for discussion. Delegates from HRS’ clients and fertiliser majors such as Nagarjuna, KSFL (KRIBHCO Shyam Fertilizers Limited), IFFCO, KANPUR Fertilizers, Rashtriya Chemicals and Fertilizers Ltd, PBIL, NFL, DCM, Reliance industries, Coromandel Fertilizers were some of the well-known companies that visited this exhibition. V Gokuldas, Managing Director, HRS Process Systems Ltd, said, “India is the second biggest consumer of fertilizers in the world next only to China. Improving viability of fertilizer production is a key challenge. There is a thrust on achieving better efficiency in the existing plants while enhancing production capacity. Companies are striving to reduce specific energy consumption per ton of product. HRS has been at the forefront of pioneering technology and innovation in energy efficient heat transfer solutions for the fertilizer sector for over a decade now,” he added. Our aim is to par tner with our customers for economic and environment conscious solutions to bring final end products at par with global standards in the sector,” he said. Chemical Engineering World
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CEW Industry News SWN Partners with Honeywell to Provide Safe Drinking Water New Delhi, India: Safe Water Network (SWN) and Honeywell India has announced their partnership to provide convenient access to affordable and reliable safe drinking water to water quality affected communities in Telangana. Funded by a Honeywell India grant, Safe Water Network is building 25 iJal safe water stations in Karimnagar and Adilabad districts from 2015 through 2017. These will serve approximately 60,000 people in an area that suffers acute groundwater contamination from flouride. Ten iJal stations are already operational in Karimnagar district. This initiative addresses a critical need in India where 100 million people live in areas of poor water quality. Telegana is ranked second on a list of states with drinking water problems, with Union health ministry data showing 1,174 hamlets across the state affected by fluorosis. Water and sanitation-related illnesses account for 70-80 percent of disease, including fluorosis, in this region. Data from a UNICEF study shows that only 35 percent of households in Adilabad district, and 64 percent of households in Karimnagar district, have access to safe drinking water. Safe Water Network, a not-for-profit dedicated to developing affordable and sustainable access to safe water for those most in need, applies a business approach to a social problem, developing locally-owned water businesses for those beyond the reach of large infrastructure projects. Its iJal safe water stations provide large-scale impact without long-term reliance on corporate funding. Within 24 months of operations, 90 percent of stations are independent of ongoing subsidies for operations, technical support and maintenance. Safe Water Network’s oldest iJal station has operated with less than 2 percent downtime for more than five years, providing more than half a million litres of water to approximately 500 households.
KEPL Awarded at ICQCC 2015 Pune, India: Kirloskar Ebara Pumps Ltd (KEPL), a joint venture company of Kirloskar Brothers Ltd (KBL), won Silver Star Illumination Award at the event organised by ‘International Convention on Quality Control Circle (ICQCC), 2015’ in Korea. The proposition of (ICQCC) was made at the Korean Control Conference 1975 in Seoul. ICQCC is an annual convention organised by Asian countries and it showcases the best international teams (called Quality Circles) by engaging them in a competition that is assessed by a team of experienced Jury members. Current year’s theme was ‘Upgrade Lives through QC Circles’. KEPL team ‘Nav-Nirman’ (New Creation) participated in the International Convention and presented an improvement case study on ‘Elimination of set-up and adjustment loss on Coordinate Measuring Machine (CMM)’under TPM Category. The case study focused on the TPM loss called Setup and adjustment loss on Coordinate Measuring Machine (CMM). A systematic approach for problem solving was demonstrated by presenting effective use of problem solving tools and techniques like identification and defining the problem, root cause analysis, selection of per manent solution from various alter natives, implementation, sustenance, horizontal deployment etc. 10 • December 2015
GSFC to Export Nylon Fibre Products to Africa Vadodara, India: Gujarat State Fertilizers & Chemicals Limited (GSFC) will soon export its first consignment of nylon fibre industrial products to African countries, said a top official form GSFC. Sudeep Kumar Nanda, CMD, GSFC, confirmed the news by saying that this followed the Patent Office granting patent to GSFC for the GUJCON products -- a process for the preparation of nylon 6 discrete fibres for secondary reinforcement in concrete and plaster applications. The products, called GUJCON concrete reinforced fibre (CRF) and GUJCON nylon reinforced fibre (PRF), have applications in the infrastructure industry for secondary fibre reinforcement of concrete and plaster, respectively, he added. These products are made up of 100 per cent virgin nylon 6 fibre, which helps in enhancing the abrasion resistance and durability of concrete structures, reduces shrinkage cracks, rebound loss and water permeability. It also ups the aesthetic value of the structure, he further said.
Pidilite Industries Acquires Assets of CIC Holdings New Delhi, India: Pidilite Industries Ltd, the adhesives and industrial chemicals maker, has acquired Chemifix trademark and other brands associated with PVAC adhesives business from Sri Lanka-based CIC Holdings Plc. Pidilite Lanka Pvt Ltd (PLPL), a step down subsidiary of the company, has also acquired the commercial and technical knowhow relating to PVAC Adhesive business from CIC Holdings. CIC Holdings is a large conglomerate in Sri Lanka and is involved in number of segments in Sri Lanka such as chemicals, fertilisers, pharmaceuticals, agri chemical and food products etc. Pidilite’s wholly owned subsidiaries, Pidilite International Pte Ltd and Pidilite Middle East Ltd, hold 76 per cent of the paid up capital in PLPL.
Rakesh Kapur Elected Vice-Chairman of IFA New Delhi, India: Rakesh Kapur, Joint Manging Director, IFFCO, has been elected as Vice-President of the Paris-based International Fertilizer Industry Association (IFA) for two years. IFA has 540 Members covering 80 countries. Kapur, an ex-IRS officer who has been with IFFCO for the last 15 years, is also Chairman of the Fertiliser Association of India (FAI). He will also hold the post of Chairman of IFA’s finance committee. Besides Kapur, there are only two other members from South Asia on the board of IFA. IFA’s technical symposium is scheduled to take place in March next year in India. Chemical Engineering World
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CEW Industry News Emami Paper Mills Forays into Packaging Board Business Balasore, India: Emami Paper Mills Ltd, part of the Kolkata-based Emami Group, is setting up a new ` 1,000 crore multi-layered coated paperboard production facility at Balasore in Odisha. In full capacity, this new paperboard manufacturing business will produce 1.5 lakh tonnes of paperboard ` 700 with a turnover target of close to crore. The company plans to start commercial production of packaging board next month, which has been on a dry run since April with production capacity of 1.3 lakh tonnes per annum. Emami Paper Mills is primarily in the business of newsprint production. P S Patwari, CEO, Emami Paper Mills, said that the demand for paperboard in the country is largely driven by e-commerce. He said that there is an immense growth opportunity in the segment, with high end paperboard market growing at 15 per cent annually, where global demand is around 17 lakh tonnes annually, out of which India’s capacity is only 7 lakh tonnes. This plant will produce coated folding box boards, solid bleached boards, cup stock board and recycled grey and black back board, which cater mostly to FMCG, pharma and hosiery sectors. The company is also in talks to export them to Thailand, Bangladesh and Sri Lanka. “We are looking at further expansion to our Balasore facility to double the capcity in 3 years and will pump in an additional ` 1,000 crore,” Patwari said.
National Chemical Policy to Unveil Soon New Delhi, India: The government will soon come out with a National Chemical Policy to provide an enabling environment and infrastructure and duty structure for the industry, said Ananth Kumar, Union Fertiliser Minister. In the sidelines of Assocham event in the national capital, he said that we have taken all the industry inputs, it (chemcial policy) has been circulated to various ministries. We are getting comments and finally, the Cabinet will decide and promulgate the first-ever national chemical policy of the country since Independence. That apart, the government is planning to set up 70 more plastic engineering institutes in the next three years to meet growing demand for engineers in the country. “We are going to add 70 centres in the next three years so that we can at least increase the number of plastics technicians from these institutes by five times,” Kumar said.
Monsanto Plans to Carbon-Neutral by 2021 Mumbai, India: Monsanto has announced plans to make its operations carbon-neutral by 2021 even as it acknowledged climate change as one of the biggest challenges facing humanity. “We plan to make our operations carbon-neutral by 2021 through a unique programme targeted across seed and crop protection operations, as well as through collaboration with farmers,” stated by the company report. “Climate change is one of the biggest issues we face in agriculture, as well as one of the most pressing challenges facing humanity,” said Hugh Grant, Chairman and CEO, Monsanto.
Neam Coated Urea to Stop Divergence for Industrial Use: Govt
“While progress has been made to reduce agriculture’s carbon footprint, we must work collectively to do even more if we are going to sustainably feed 9.6 billion people by 2050,” he added.
New Delhi, India: In aiming to lowering the usage and stopping its divergence for industrial purposes, urea sold in the country will now be completely neem coated, said Ananth Kumar, Union Fertiliser Minister.
Tata Chemicals Bags Three Awards at FAI Awards
The minister informed that research institutes like ICAR has found that neem coated urea also acts as organic pesticide and with slow release of nitrogen there will be 10 per cent less requirement of the fertiliser while the yield could go up by 10 per cent. According to industry estimates, there could be savings of about ` 10,000 crore on account of lower use of urea after neem coating and fall in divergence for industrial use. “December one onwards the entire urea being sold in the country, be it indigenous or imported, will be neem coated and for neem coating of imported urea, required arrangements have been made at all the major 14 ports across the country”, Kumar added. 12 • December 2015
Mumbai, India: Tata Chemicals (TCL) has been honoured with three awards at the ‘Fertiliser Association of India (FAI) Awards 2015’. The company was conferred with the awards across the categories ‘Best in Production Performance’ and ‘Best in Environmental Protection’. Tata Chemicals’ Babrala plant was awarded with ‘Best Production Performance’ FAI award for an operating fertiliser unit for nitrogen (ammonia and urea) for the year 2014-15. The company shared this award with Rashtriya Chemicals & Fertilsers Limited, Thal. Tata Chemicals’ Haldia plant bagged two awards - the FAI Award for the ‘Best Production Performance’ of an operating fertiliser unit for SSP, and was also declared a runner-up for the ‘Environmental Protection’ Award in the SSP fertiliser plants category. Chemical Engineering World
CEW Industry News Govt to set up 12 Petrochemical Complexes New Delhi, India: Government is working on a policy to establish 12 more petrochemical complexes in order to have one complex in each 16 refineries, a move which could entail few lakh crore of investment, said Union Fertiliser Minister Ananth Kumar. At present, there are four PCPIRs or petrochemical complexes in the country. A Petroleum, Chemicals and Petrochemicals Investment Region (PCPIR) is usually a delineated area for manufacturing various types of petrochemical compounds. PCPIRs are currently present in Gujarat, Andhra Pradesh, Odisha and Tamil Nadu. Speaking at the same event, Chemicals Secretary Surjit Chaudhary said that the government is working on a policy to have at least one petrochemical complex in each refinery which could result in an investment of few lakh crore. As per the PCPIR policy, the Centre has to ensure the availability of external physical infrastructure linkages to these regions including rail, road connectivity to national highways, ports, airports and telecom connectivity. The internal infrastructure of the PCPIR is built and managed by a developer. The external linkages will be provided by the central and the state governments. The users of external as well as internal infrastructure will pay for its use.
MCFL’s Capacity to be Doubled by Zuari Group Mangalore, India: Zuari Group is making plans of investing RS 300 crore in MCFL’s Mangalore plant to double its capacity after the company bought a controlling stake in UB Group promoted MCFL. Currently, Mangalore Chemicals and Fertilizers Ltd (MCFL) has one urea plant having an annual capacity of 4 lakh tonnes and another plant for phosphatic fertilisers which have an annual capacity of 3 lakh tonnes. The planned investment will increase MCFL’s annual capacity of phosphatic fertilisers by double to 6 lakh tonnes per annum from its present capacity of 3 lakh tonnes. Zuari Group and UB Group have a combined stake of 75 per cent in MCFL.
JMC Projects Bags Orders worth over ` 1,050 crore Mumbai, India: Civil engineering and EPC firm JMC Projects (India) Ltd (JMC) announced that it has bagged construction projects worth over ` 1,050 crore. The nature of work includes construction of flyover and buildings, it said. Company’s Deputy Managing Director & CEO S K Tripathi said, “We have penetrated well in sourthern region of the country by securing repeat orders from our clients, this would also provide benefits of economies of scale.” JMC Projects(India) Ltd a subsidiar y of Kalpatar u Power Transmission Ltd provides servcies across the construction sector i.e. civil and structural. 14 • December 2015
Indian Oil Corporation Limited Joins DYNAVIS ® Licensee at Excon India Mumbai, India: With rapid economic growth, India has vaulted to the top of the global growth leagues. Infrastructure investments are the main driver among the major economic activities, which require high energy input. For this reason, companies are developing new technologies to achieve lower energy consumption and achieving real savings. At this year’s Excon, Evonik Industries will present its DYNAVIS® technology and demonstrate how it can bring a new level of efficiency to hydraulic fluids (in Hall 1, Stand #54). DYNAVIS® technology from Evonik optimizes the viscosity of hydraulic fluids. Here’s how: like most oils, hydraulic oils lose viscosity at high temperatures. In this state, the hydraulic fluid transfers less hydraulic energy through the hydraulic fluid system, because it has become hot and thin-bodied; “internal leakage” within the system increases and efficiency drops in the desired direction of flow. In contrast, using a fluid formulated with DYNAVIS® technology results in less internal leakage and the hydraulic fluid system retains its efficiency, even at high temperatures. At the other end of the temperature scale, in extreme cold, oils become increasingly viscous and more and more difficult to pump. As a result, the hydraulic system consumes more energy, primarily through its pump drive. Here too, fluids formulated with DYNAVIS ® technology reduce the pump’s energy consumption. Effective this month, Indian Oil Corporation Limited (IOCL) is offering its customers hydraulic fluid formulated with DYNAVIS® technology. “We are confident in introducing SERVO HYVIS EE 46 formulated with DYNAVIS ® technology to our local customers,” says K L Murthy, Executive Director (Lubes) for IOCL. “This oil will help the hydraulic equipment owners and operators (e.g. excavators, loaders, etc.) achieve higher levels of fuel efficiency and productivity.” DYNAVIS® technology for optimizing the viscosity of hydraulic fluids is currently available from seven DYNAVIS® technology licensees globally. “The global network allows us to quickly response to our customers,” explains Carlos Vernet. “You’ll find the DYNAVIS ® insignia clearly marked on their product containers.”
CCI Approves JBF Group-KKR Credit Deal New Delhi, India: The Competition Commission (CCI) has approved polyster products manufacturer JBF Industries’ USD 150 million deal with global investment firm KKR Credit. In July, JBF Industries signed an agreement with global investment firm KKR, under which KKR would invest USD 150 million into JBF Group, an entity that includes JBF’s international subsidiaries. A portion of the proceeds would be used by KKR to acquire a 20 per cent stake in JBF, while the remaining would be invested into zero-coupon convertible preference shares with 14.5 per cent voting rights in JBF Global Pte, Singapore. Chemical Engineering World
Sinocalci (India) Technology Private Limited 中圣园(印度) 印度)技术私人 技术私人有限 私人有限公司 有限公司 Contact Address: DL-238, Salt Lake City, Kolkata, W.B, India 700 092. Tel: +91-33-4007 8665 Engineering & Project Site Office: Pkg-08 of NISP, NMDC, Nagarnar, Jagdalpur, District Bastar, Chhattisgarh, India 494 001 Telephone No: +91-87188 88213, +91-78981 90528 E-mail: akgupta@sinocalci.com, wangshengqun@sinocalci.com Sinocalci Corporation (ISO: 9001-2008 certified) Address: No. 185 Yanhu Road, Jiangning Economic & Technological Development Zone, Nanjing, Jiangsu, China 211102 Telephone No: +86-25-5807 1620, +86-25-8317 2895. Fax No: +86-25-5807 1640 E-mail: sales@sinocalci.com website: www.sinocalci.com
CEW Industry News India to Become a Urea Surplus State Soon: Govt New Delhi, India: India will soon become an urea surplus state from a deficit state and start exporting it, said Union Fertilizer Minister Ananth Kumar. Kumar told Lok Sabha during question hour that the country will produce 20 lakh tonnes additional urea this year after a number of pro-active steps, including revival of defunct fertilizer plants, taken by the government. “We will soon become a urea surplus country from a urea deficit country as we are going to produce 20 lakh tonnes additional urea this year. We will start exporting urea soon,” he said. The Minister said there was no crisis of fertilizer anywhere in the country and all states and union territories were satisfied with its availability. “There is no shortage of fertilizers during the current sowing season,” he said. Further, to ensure adequate availability of fertilizers, Fertilizers Ministry has taken a number of steps that include assessment of month-wise demand, regular monitoring of movement of all major subsidised fertilizers throughout the country by a web-based monitoring system besides others, he said.
Indian Agro-chemicals Sector to Reach USD 7.5 billion by 2019: Report New Delhi, India: The agro-chemicals sector in the country is estimated to touch USD 7.5 billion by 2018-19 with 60 per cent of the contribution coming from exports, says a Tata Strategic Management Group report. “The Indian crop protection industry is estimated to be USD 4.25 billion in FY14 and is expected to grow at a CAGR of 12 per cent to reach USD 7.5 billion by FY19,” it said. The report was released by Hukumdev Narayan Yadav, Chairman, Parliamentary Standing Committee on Agriculture, at a Ficci event here. Releasing the report, Yadav suggested balanced approach in using agrochemicals and due care for environment. He also urged the scientific community to rise to the challenge of developing agro-chemicals that increase the yield but have no adverse impact on the environment. “Training the farmers was also essential. Farmers, the users of agrochemicals, at present, are not adequately informed about its use and impact. Many a times, farmers without knowledge apply inappropriate amount of agro-chemicals resulting in crop failure,” Yadav said. It is critical for both the government and crop protection chemicals manufacturers to work closely with farmers to educate them on judicious use of pesticides and new researches and developments, the report added. 16 • December 2015
UPL Announces Merger of Seed Firm Advanta Mumbai, India: Agrochemical major UPL Ltd has announced the merger of the group’s seed firm Advanta with itself as part of its strategy to provide all agri-solutions through one single entity and enhance shareholder value. Post merger, UPL’s geographical reach would expand and result in cost savings of Rs 90 crore annually. The Mumbai-based UPL, formerly known as United Phosphorous Ltd, holds 48.44 per cent in Advanta Ltd and the same would be cancelled after the merger. “The board of directors of UPL Ltd and Advanta Ltd today unanimously approved Advanta’s merger with UPL, subject to necessary approvals,” UPL said in a regulatory filing. As per the proposed amalgamation scheme, the shareholders of Advanta Ltd will get one share of UPL for each held in the seed company. That apart, Advanta’s resident shareholders, holding one share, will get three optionally redeemable conver tible preference shares in UPL. Similarly, non-resident shareholders of Advanta will get three compulsory convertible preference shares of UPL in exchange of one share in the seed company. That apart, Advanta’s resident shareholders, holding one share, will get three optionally redeemable convertible preference shares in UPL. Similarly, non-resident shareholders of Advanta will get three compulsory convertible preference shares of UPL in exchange of one share in the seed company.
Indian Chemical Industry to Reach USD 214 billion in Next 4 Years: Report New Delhi, India: The chemical industry in the country has the potential to grow at 9 per cent annum to touch USD 214 billion in next four years, according to a Tata Strategic Management report. The report highlights that at USD 139 billion, the current domestic chemical market constitutes only 3.3 per cent of the global chemical market. The sector is highly diversified, with more than 80,000 chemicals and currently accounts for 15 per cent of India’s industrial output, which makes it very crucial for the economic development of the country. “The Indian chemical industry is an integral component of the economy and has the potential to grow at 9 per cent per annum to reach USD 214 billion by 2019,” Tata Strategic Management Group Practice Head (Chemical and Energy) Manish Panchal said in a statement. “The Indian chemical industry is an integral component of the economy and has the potential to grow at 9 per cent per annum to reach USD 214 billion by 2019,” Tata Strategic Management Group Practice Head (Chemical and Energy) Manish Panchal said in a statement. Panchal further said that key imperatives for the growth of chemical i n d u s t r y a r e t o s e c u r e fe e d s t o ck , r i g h t p r o d u c t m i x a n d identify partnership opportunities to gain capital and technology support. Chemical Engineering World
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CEW Industry News Fluor Completes Isononanol Plant Project for BASF and Sinopec
Texas LNG Selects Honeywell Technology for New LNG Production Facility
Irving, USA: Fluor Corporation has completed a world-scale Isononanol (INA) plant for BASF and China Petroleum & Chemical Corporation (Sinopec) in the Maoming Hi-tech Industrial Development Zone, Maoming, China. The plant, which is a firstof-its-kind in China, was recently inaugurated by the owners and will serve the growing demand for next-generation plasticizers. Fluor applied its integrated project execution experience in China, including its knowledge of working with joint ventures involving multi-national foreign investors and Chinese national oil companies, to complete the project safely and on schedule.
Houston, USA: Honeywell announced that its natural gas technology and process automation have been selected by Texas LNG to remove contaminants from natural gas in preparation for liquefaction and export to customers around the globe. The two-phase project, located on the north shore of the Port of Brownsville’s deep-water ship channel, will produce 4 million tons of liquefied natural gas (LNG) beginning in 2020. Langtry Meyer, Chief Operating Officer, Texas LNG said, “As an independent liquefaction operator in a very competitive environment, bringing on board a company like Honeywell with such broad and integrated capabilities – proven in LNG – adds significant credibility and value to our venture. We are confident this relationship will deliver over the long term for Texas LNG.”
“Completion of the INA plant demonstrates true excellence in execution backed by world-class safety and a focus on quality. This project is also a testament to our partnership with BASF and Sinopec which allowed us to complete the facility on time and on budget,” said Ken Choudhary, Fluor’s president of Energy and Chemicals for the Asia-Pacific region. “This project is a great example of our One Fluor approach. We used the breadth of Fluor’s tools and knowledge to provide solutions to the project. Most importantly, we delivered the project safely and in a quality manner that met the business needs of our client,” said Richard Meserole, Fluor’s vice president of Construction. The project is a continuation of the long-standing partnership between Fluor, BASF and Sinopec, and builds upon the successful completion of various projects at the Verbund site in Nanjing, China.
De Dietrich ® embraces Green Chemistry and establishes a partnership with SAS PIVERT Texas, USA: In April 2015, De Dietrich® and SAS PIVERT signed a partnership agreement to equip the BIOGIS Center and to combine the resources of both companies to develop innovative plant-based chemistry solutions. This partnership allows both companies to share their expertise and industrialize new processes using bio-based raw materials, particularly oilseed biomass. “Sustainable development is a value shared by both of our companies. We are very pleased to initiate this partnership.” declared De Dietrich® President and CEO Daniel Steck at the time. “Research advances in catalytic chemistry require adaptable equipment capable of working in diverse conditions in order to develop sustainable and competitive solutions. We work towards this goal with De Dietrich, to develop innovative plant-based chemistry solutions.” declared SAS PIVERT CEO Gilles Ravot. The BIOGIS Center is equipped with a complete and innovative reaction and distillation system which is entirely remote controlled (utilities and automation), allowing distillations and reaction mixtures (homogenization, suspension, dispersion, crystallization...) to be performed on a variety of oilseed biomasses. 18 • December 2015
Texas LNG will use Honeywell’s UOP Amine Guard FS process to reduce acid gas to very low levels and its proprietary adsorbents to remove water, mercury and sulfur from the natural gas, which is necessary for LNG transport. Honeywell will help Texas LNG reduce risks and minimize potential schedule delays by using its integrated solutions including LEAP, Honeywell’s lean project execution services, Experion PKS with Distributed Systems Architecture (DSA), Experion Security Integrator, Fault Tolerant Ethernet (FTE), Universal process and safety I/O, virtualization, advanced control, Safety Manager, Fire and gas systems, OneWireless Network, Digital Video Manager (DVM), UniSim operator training simulator, DynAMo advanced alarm management software, and PHD data historian.
CB&I to License Catofin Technology for Hengli’s Dehydrogenation Plant Beijing, China: China-based Hengli Petrochemical (Dalian) Refinery has awarded a contract to CB&I to use its Catofin catalytic dehydrogenation technology for a grassroots propane and butane dehydrogenation unit to be constructed in Dalian of Liaoning Province. Under the deal, CB&I will license and provide engineering design for the proposed dehydrogenation unit. As well as CB&I’s Catofin technology, the unit will use Clariant’s Catofin catalyst to process 300,000t per annum of propane and 600,000 tonne per year of isobutane feedstock for jointly produce propylene and isobutylene. CB&I technology operating group president Daniel McCarthy said: “CB&I’s CATOFIN technology provides our customers with proven reliability and the flexibility to co-process multiple feed compositions at world-scale capacities. “In addition to this award, CLG, CB&I’s joint venture with Chevron, was awarded the ISODEWAXING catalytic isomerisation and ISOFINISHING hydrofinishing processes for this project. This multi-technology award underscores CB&I’s broad portfolio of technology solutions.” CB&I’s Catofin propane dehydrogenation process is a fixed-bed process that helps to produce propylene from propane commercially. The company said that with the help of recently improved catalyst technology, the Catofin process has been able to accomplish highest conversion rate for propane dehydrogenation. Chemical Engineering World
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CEW Technology News
New Model Develops to Track Underground Nuclear Explosions Los Alamos, USA: Scientists at Los Alamos National Laboratory have developed a new, more thorough method for detecting underground nuclear explosions (UNEs) by coupling two fundamental elements -- seismic models with gas-flow models -- to create a more complete picture of how an explosion’s evidence (radionuclide gases) seep to the surface. Their findings will appear in the journal Nature’s Scientific Reports in a paper titled, ‘Radionuclide Gas Transport through Nuclear Explosion-Generated Fracture Networks’. The Los Alamos research team compr ises Team Leader Anderson, Philip Stauffer, Chris Bradley, Earl Knight, Esteban Rougier and first-author Amy Jordan (now at Neptune and Company in Los Alamos). Los Alamos Computational Earth Science Group Leader Carl Gable supported the team’s use of the Los Alamos Grid Toolbox (LaGriT) unstructured finite element mesh generation for simulation development. The United States’ Defense Threat Reduction Agency (DTRA) funded this research.
New Technique both Enhances Oil Recovery, Sequesters CO 2 Pennsylvania, USA: A proposed recovery technique for oil extraction developed by a Penn State-led research team not only outperforms existing drilling and recovery techniques, but also has the potential to sequester more carbon dioxide in the process. The team estimated that companies using this new technique would greatly improve oil recovery rates. They developed a model that indicates that the process could extract between 78 and 90 percent of the oil in a reservoir over several decades. Existing drilling techniques in use today extract a maximum of 50 to 60 per cent of the estimated total volume of oil before production, and on average, that number is closer to 35 per cent. The model uses horizontal drilling, in which wells are drilled up to about 4,000 meters (13,000 feet) underground, parallel to the Earth’s surface, through known oil reservoirs. This differs from vertical drilling techniques, in which wells run perpendicular to the Earth’s surface. Two wells, organized in a staggered line drive, form the basis of the model -- one well in the top of the reservoir to inject supercritical carbon dioxide into the system, and another well at the bottom of the reservoir to extract oil. Carbon dioxide normally behaves like a gas at room temperature and pressure, but when it is pressurized and heated past a certain point -- the critical point -- it becomes a supercritical fluid, which exhibits liquid density and gas viscosity. When injected at a continuous rate, supercritical carbon dioxide is an excellent solvent that is able to contact oil and form two hydrocarbon phases -- one that is light, containing a significant amount of carbon dioxide, and one that is denser, containing more oil. 22 • December 2015
Fuel Cell for ‘Green’ Methanol London, UK: The type of catalyst studied by Fabris and co-workers is important in fuel cells, that is, devices that convert chemical energy into electricity (by means of a reaction between a fuel, hydrogen or another fuel, and oxygen). “An important line of research in the area of renewable energy is currently investigating the production of methanol using technologies that mimic photosynthesis,” explains Fabris. “Should we succeed in producing methanol on an industrial scale using these technologies, then we would also need an efficient and clean way of converting it into electrical energy.” For this reason methanol fuel cells will be used, where the combination of methanol and oxygen produces water and carbon dioxide as a waste product (note that the carbon footprint in this case is neutral in that the methanol will be produced by photosynthesis, removing CO2 from the atmosphere). “The type of catalyst we are studying is the one that will be needed in these fuel cells.” The study was in fact funded by the European project ChipCAT, which aims at finding novel materials for the next generation of fuel cells.
Trapping Climate Pollutant Methane in Porous Carbon Durban, South Africa: As talks of global warming are once again making headlines, scientists have renewed their efforts to understand how to best limit its effects. For example, sequestrating short-lived climate pollutants, such as methane and black carbon, yields much faster reductions in global warming compared to reductions in CO2. To do so, it is essential to have a better grasp of the nature of physicochemical properties of gases interacting with porous carbon. Now, a team of chemical engineering researchers based in South Africa has established ways of accurately simulating methane adsorption and desorption in carbon with nanopores. These findings have been published by Matthew Lasich and Deresh Ramjugernath from the University of KwaZulu-Natal, Durban, South Africa, in EPJ B. Alternative applications for such findings are relevant for future energy research, such as energy storage and the development of natural gas extraction methods. Activated carbon, which is a type of carbon material containing numerous nanopores, is often used to adsorb gases in the energy sector. The authors chose to use computational methods to study the influence of intermolecular interactions between different types of molecules -- in this case, they simplified the approach by limiting it to methane and activated carbon -- on adsorption. Their goal was to identify molecular interactions that could prevent such a process. First, they employed a standard simulation approach, which was dubbed grand canonical Monte Carlo simulations. Parallel to that, they used a simple lattice gas model coupled with equations describing the intermolecular interactions, otherwise referred to as classical density functional theory. They found that both approaches yielded qualitative agreement with previously published experimental data. However, the second approach yielded results more in line with experimental data for gases adsorbed into carbon materials when equations are amended through simple corrections pertaining to energy levels, rather than by corrections related to the difference in the size of the various molecules involved. Chemical Engineering World
CEW Technology News New Catalyst Paves way for Bio-based Plastics, Industrial Chemicals Washington, USA: Washington State University researchers have developed a catalyst that easily converts bio-based ethanol to a widely used industrial chemical, paving the way for more environmentally friendly, bio-based plastics and products.The researchers have published a paper online describing the catalyst in theJournal of the American Chemical Society and have been granted a US patent. The chemical industry is interested in moving away from fossil fuels to bio-based products to reduce environmental impacts and to meet new regulations for sustainability, said Yong Wang, Voiland Distinguished Professor in the Gene and Linda Voiland School of Chemical Engineering and Bioengineering. The catalyst works on bio-based ethanol to create isobutene used in plastics and other products. The industry has traditionally made a widely used chemical called isobutene -- used in everything from plastic soda bottles to rubber tires -- by superheating crude oil. But in collaboration with the Archer Daniels Midland (ADM) Company, Wang and his colleagues developed a catalyst to convert bio-based ethanol, which is made from corn or other biomass, to isobutene in one easy production step. The researchers examined the costs and lifetime of their catalyst to determine its practicality for the marketplace and determined that it could be used for other closely related feedstocks. They also discovered just how their catalyst works, knowledge that could be used to design more efficient catalysts for a wide range of applications.
Efficient way to Conver t Ethanol to Better Alternative Fuel Rochester, USA: Ethanol, which is produced from corn, is commonlyused as an additive in engine fuel as a way to reduce harmful emissions and scale back US reliance on foreign oil. But since ethanol is an oxygenated fuel, its use results in a lower energy output, as well as increased damage to engines via corrosion. But now a research team, led by William Jones at the University of Rochester, has developed a series of reactions that results in the selective conversion of ethanol to butanol, without producing unwanted by-products. In fact, Jones was able to increase the amount of ethanol converted to butanol by almost 25 per cent over currently used methods. Jones describes his process in a paper just published in the Journal of the American Chemical Society. Converting ethanol to butanol involves creating a larger chemical molecule with more carbon and hydrogen atoms. Although both molecules have a single oxygen atom, the higher carbon-to-oxygen ratio in butanol gives it a higher energy content, while the larger size make it less volatile. One method of converting the ethanol to butanol is the three-step Guerbet reaction, which involves temporarily giving up hydrogen atoms in an intermediate step, then adding them back in to create the final product. One problem with the Guerbet reaction is that an intermediate product--acetaldehyde--can react with both itself and the butanol product to create unwanted molecules. 24 • December 2015
Carbon Capture Analyst: ‘Coal should Stay in Ground’ Michigan, USA: Serious flaws have been found in a decade’s worth of studies about the best way to reduce greenhouse gas emissions and stabilize the climate. The findings, from the University of Michigan, are released as world leaders at COP21 attempt to negotiate the globe’s first internationally binding climate agreement. The U-M researchers have found that most economic analysis of carbon capture and storage, or CCS, technology for coal-fired power plants severely underestimates the technique’s costs and overestimates its energy efficiency. CCS involves sucking carbon out of coal-fired power plants’ flue gases, compressing it and then injecting it deep underground. The new analysis puts the cost of reducing carbon emissions with CCS-equipped coal plants higher than any previous study -- and most importantly, higher than wind and comparable to solar power. It’s the first study to confront the so-called ‘energy loop’ inherent in the CCS process. Beyond a one-time ‘energy penalty’ these plants pay because they have to burn more coal to power devices that capture carbon, the researchers say the disadvantage compounds until fuel costs leap to four times today’s accepted estimates. Coal-fired power plants produce nearly a third of the world’s electricity. Today, they also emit more than half of the world’s energy-sector carbon dioxide -- the primary driver of climate change. Scientists recommend reducing CO2 emissions dramatically to keep the planet from warming more than 2 degrees Celsius (3.6 Fahrenheit) over its pre-Industrial average.
Cooperative Catalysts Offer Unique Route to Alkenes Princeton, USA: Chemists at Pr inceton have developed a new chemical method to introduce valuable alkenes into simple hydrocarbon molecules, a transformation known as dehydrogenation, which is found in important processes such as the biosynthesis of essential fatty acids in the body and the commercial production of detergents. Leading approaches in the natural and synthetic classes of reactions possess attractive features that are unavailable to the other. Existing synthetic methods produce hydrogen gas as a useful by-product but require very high temperatures, while natural methods run at mild temperatures but produce a full equivalent of an unusable by-product. “What if we could have a method that offers the benefits of both approaches? Can we be greedy?” asked Julian West, a graduate student in the Sorensen lab and first author of the study published in Nature Communications. Guided by this goal, the researchers devised a novel two-component catalyst system that performs the dehydrogenation reaction at room temperature, making hydrogen gas and a molecule containing an alkene, or carbon-carbon double bond. Chemical Engineering World
CEW News Features
Taking ‘Commitment to India’ to Next Level Ingersoll Rand has been one of the oldest American investments in India dating back to 1921 and one of the first companies which made India the global sourcing hub for its different product lines, says Amar Kaul, Ingersoll Rand’s Territory Vice President in India, Middle East and South Africa for Compression Technologies and Services. According to Kaul, the company has been pioneers in bringing centrifugal technology into the country as well as the Award winning ‘Nirvana’ energy saving VSD Rotary Compressors, and Best in Class ‘Trishul’ Dryers.
I
ngersoll Rand invested in manufacturing of centrifugal compressors in India in 1989, when the technology was barely known and hardly accepted in India. Kaul believes that this leading approach has been handsomely rewarded by the market. “Over and above bringing global innovations to India, we also continue to design and develop local innovative solutions for our customers in India. Apart from Centrifugal Air Compressors, we have localised Contact Cooled Rotary Air Compressors, Refrigerated Air Dryers, and many other products and services, the latest being the graduation from old concept of Annual Maintenance Contracts (AMCs) to Package Care and Package Care+.,” he states. Ingersoll Rand, which has 60 manufacturing units across the globe, invested heavily in ‘remote monitor ing’ to monitor the perfor mance of its machines through remote access system. With two stateof-the-ar ts ISO-9001 and ISO-14001 a p p r ove d m a n u fa c t u r i n g fa c i l i t i e s a t Ahmedabad and Sahibabad, the company has a Pan-India presence with direct sales and service offices and a well-networked distribution setup. The organisation, as Kaul says, inspire progress through releasing the potential in people and technologies to advance the quality of life by making environments comfortable, sustainable and efficient, and
help enable our customers to achieve real progress and create a positive impact in their world. With a major emphasis on ‘Innovation’ to drive ‘Productivity’, the company has had many firsts to its credit. Kaul further adds that its products help conserve energy, improve user safety, enhance economic growth, increase the yield of the global harvest, and provide a host of other benefits to society. Kaul exalts, “Ingersoll Rand is a pioneer in bringing centrifugal technology into India and star ted manufactur ing CENTACS (Centrifugal Compressors) way back in 1989 when centrifugal technology wa s h a r d l y k n ow n a n d a c c e p t e d .” I n recent times, with the focus shifting to energy efficient compressor technology, I n g e r s o l l R a n d l a u n c h e d t h e awa r d winning ‘Nirvana’ energy saving rotary compressors. Kaul further explains that there is a greater demand for energy efficient (low life cycle cost or operating cost) and minimum maintenance (high reliability) machines. Today, the purity of air has become the most important element if you have critical oil-free applications which are catered to by our Class 0 range of oil-free compressors for rotary screw and centrifugal technologies. Over the past few years, the company has been consistently investing in initiatives t h a t h ave i m p r ove d o u r p r o d u c t i v i t y and this continues to be the jour ney
Today, the purity of air has become the most important element if you have critical oil-free applications which are catered to by our Class 0 range of oil-free compressors for rotary screw and centrifugal technologies. 26 • December 2015
o f o p e ra t i o n a l ex c e l l e n c e. “ I n g e r s o l l Rand is at the forefront of customercentric ‘Innovation’ and we are constantly innovating products and solutions that are relevant to the Indian market and our customers. To sum up, our innovative approach, customer-first and solutionising mind-set has driven us into the position of market leaders,” Kaul validates. Expansion Plans and Strategy Kaul reveals that the company is committed to India and had announced last year that it is investing ` 100 crores to upgrade i t s m a nu fa c t u r i n g fa c i l i t y i n N a r o d a , near Ahmedabad. The transfor mation is in progress and the phase-I of this project is completed. While discussing the technology trends, Kaul explains, “We see a definite shift from oil-injected compressor technology to class O oil-free compressor technology. In centrifugal compressor space, we see a movement from small and medium capacity machines to large capacity machines. Today, energy efficiency is not a unique selling proposition, it is considered given. Customers prefer solutions that have the lowest cost of ownership. Often compressed air systems in factories and facilities are not energy efficient.” Kaul further elucidates the significance of energy efficient products and says it is Chemical Engineering World
CEW News Features Ingersoll Rand has a strong n e t wo r k o f i t s p a r t n e rs i n m o r e than 50 locations covering all Tier I-II cities in India. Globally, it has 60 manufacturing sites employing 40,000 employees spread across different parts of the world. It also have tie ups with institutes like IITs & IISC for Technology Development & Innovation as well as with Top Engineering colleges for the skill development of their graduates.
very important to design a compressed air system which is highly reliable, efficient, provides right flow and pressure at right price. “Our buying process study tells us that efficiency is key to power plants as against the myth that it’s not important since they produce power at low cost and in big quantity. Power saved is power sold for power plants. We design compressed air system keeping in mind continuous usage for one year without maintenance. Ingersoll Rand understands this well and offers highly reliable proven equipment w i t h a d v a n c e d s y s t e m c o n t r o l l e r s ,” Kaul claims.
feature of recovering the heat energy from the compressor to generate hot water for various applications like boiler pre-feed, space heating, sanitary purposes and any other process applications,” he adds.
Kaul continues explaining the technology trend further and illuminate that the focus of the industry is moving towards the quality of air considering critical applications in cer tain industr ial sectors. “As this requirement becomes critical in deciding the selection of the air compressor, our best-in-class Oil-free technology provides customers with the peace of mind that t h ey l o o k fo r. A l s o, t h e i n d u s t r y h a s moved towards higher energy efficiency (low life cycle cost or operating cost) and lower maintenance (high reliability), for offsetting the capital cost which is incurred on the machines. The new wave in the market is the Heat Recovery Unit which is gaining impor tance due to its
Research and Development The company has made significant investments in Research and Development (R&D). It runs a DSR approved laboratory in Naroda which is benchmarked against Ingersoll Rand’s global R&D facilities on regular basis for accuracy and consistency. Kaul further reveals, “We test the entire range of our products in this lab for its performance & reliability. In addition, we also operate Engineer ing Technology Centres in Bangalore and Chennai. Number of patents filed by us in US talks a b o u t o u r c o m m i t m e n t t o i n n ova t i o n through R&D. With local innovations, we have produced products like Evolution compressors (Rotary), Trishul dryers &
28 • December 2015
Kaul also comments on the energy audits, and believe in encouraging their customers to par ticipate and learn the methodology during such audits apar t from just monitoring and implementation. With compressed air being one of the poorly managed industrial utilities, there is enormous opportunity to change the way it works now, Kaul justifies.
3CIIi Centac machines which are best in class of their own with multiple patents. Often compressed air systems in factories and facilities are not energy efficient.” According to Kaul, system owners have great opportunities to improve operating margins and reduce costs through energy savings. He again talks about the benefits of energy audits and says, Ingersoll Rand’s Audit Solutions offers services that help its customers identify potential leakages and take corrective actions to conserve energy. Some of the real cases after acting on actions from energy audit have had pay back of less than six months after which is pure savings. Commenting on the growth in the next five years, product improvement is a continuing goal at Ingersoll Rand and this is not done in isolation. “We are continuously engaged with our customers through ‘Voice of customers’, survey and interviews to find out their exact requirements and unmet needs.” A positive Kaul explains that the Indian e c o n o my h a s s t a r t e d s h ow i n g s i g n s of gradual improvement with business ex p e c t a t i o n s, ex p o r t s a n d i n d u s t r i a l production recuperating. This more favo u r a bl e o u t l o o k r e f l e c t s s t r o n g e r sentiment resulting from the new g o v e r n m e n t ’s p r o m i s e t o p r i o r i t i z e e c o n o m i c r e fo r m s a n d e n h a n c e t h e country’s business environment.
Chemical Engineering World
Chemical Products Finder | November 2013 | 57
CEW Features Guest Column
Industry 4.0 - Internet of Things, Service and People In the coming decades, the power of Internet supported by increased connectivity, advanced computing, analytics and low cost sensors will transform the industrial plants and production processes - just as it has changed the behaviour of consumers in recent decades. The key is to smartly integrate the technologies and needs with Internet of Things, Services and People to boost productivity, enhance reliability, save energy and costs.
I
ndustry has evolved from steam engine to using electricity in industrial production and automation using electronics and software based control. Today we are in 4th Industrial revolution. Whether you call it Industry 4.0, Industrial Internet, or Internet of Things, the digitisation of the world, particularly the industrial world, is on everybody’s agenda these days. Initiatives around this trend are appearing on company strategies, and even on countries’ agendas strategic research programs are initiated. The interpretation of the overall trend varies. Whereas the Industrial Internet Consortium defines ‘industrial’ as ‘everything non-consumer’ (and is therefore including areas such as medical, retail, transport, manufacturing), the German Industrie 4.0 term is more focusing on manufacturing and process industries. What is common to all initiatives is their focus on the integration of (industrial) data and its analysis on a large scale.
Figure1: The Industry revolution
30 • December 2015
Analysing what is important to plant ownersoperators, only communicating devices and advanced analytics will not address the needs that we generally observe in the market. In essence, Internet of Things concepts and digitised objects help better understand what is happening in a plant, but based on the knowledge gained, decisions need to be taken, and corrective actions need to be performed. This is where the other components of automation technology providers come into play: people and services. It is essential that people remain in charge of taking decisions, and when operational or maintenance issues are observed, fixing them requires different stakeholders in the value chain to provide services to address them. We therefore believe, that the platform to properly address plant owner-operator’s needs lies in an Internet of Things, Services, and People (IoTSP). In this article, we will explain how these play together,
and how technology can help address these challenges. Internet What began as the intranet of things (connecting devices to each other within a plant or site) has evolved into the Internet of Things (connecting devices to each other over the Internet) and ultimately, into the Internet of Things, Services and People, in which all three elements are integrated via the Internet. This allows data analysis between different installations, either to do benchmarks or fleet analysis of devices that are installed in different areas of the world. Data access is also available for different service teams that are cooperating on solving an issue on a particular plant site. Things Things, or devices, are equipped with sensors, computing power and software. While these devices have been communicating with each other in the past, IoTSP extends the communication from the intranet to the Internet via technologies such as mobile communication and cloud computing. When extending into the internet and cloud technology, it is essential not to lose some of the relevant properties of today’s automation system: safety and reliability. Not everything makes sense to be moved to a cloud. When time critical deterministic behavior of a controller or safety system is required, functionality is best kept at the level it is currently installed: close to the equipment. Chemical Engineering World
CEW Features When it is about analysing the performance of a whole plant, or even a whole fleet of devices, moving KPI data to a cloud and analysing it makes more sense. To properly align available sensors in the field, computing power in the device, in the control system and in the cloud, we are carefully designing solutions to benefit from the best of both worlds: safety and reaction time close to the device in the OT environment and computing and storage power in the IT environment of the cloud. Service Data analytics provide the valuable clues for preemptive diagnostics and maintenance, and the plant owner-operator benefits of these services can be substantial. The Internet of Things enables a new service model for turning identified improvements into actions. To execute corrective, preventive, or optimising actions, skilled service technicians need to implement the identified improvements on the plant in order to provide the full value of the knowledge gained from the data analysis. People People will always be a crucial part of the picture. They will remain the decision makers, and will program and control all production processes and activities performed by things. People will be able to cooperate more efficiently by interfacing through common analysis systems. Their decisions will be based on better knowledge about what is happening in the plant, and why it is happening. Decisions are taken faster, and better informed. Industry Initiatives Industrial Internet Consortium and Industrie 4.0 are just two of the initiatives that are currently on the way to push the new concepts ahead. The benefit from those initiatives will be a more common understanding of the issues to be dealt with. In the long run, some of these concepts will require standards to be applied to achieve interoperability on different scales as today. As a global player, we are a major participant in those initiatives, making sure that plant owners and operators benefit from new technologies and concepts seamlessly, 34 â&#x20AC;˘ December 2015
Figure2: IoTSP - Internet of Things, Services and People
protecting the investment in plant equipment and automation systems.
more intelligence to be added to the fastest control loops even within a drive.
Realising IoTSP Data based services - what to do with the data? As one common theme among the initiatives mentioned earlier, data is on everybodyâ&#x20AC;&#x2122;s agenda. This hot topic, the digitalisation of the industrial world, involves collecting data from large numbers of sensors, and then analysing the data for the benefit of the plant operations, maintenance and management responsible persons.
New insights to the predictive maintenance That is a lot of data that is processed locally in the device. With increased processing and communication bandwidth, we can think about getting even more information out of this data. Properly analysed, signals from within a drive can not only reveal the health of the attached motor, they can also be used to tell something about the driven equipment. When we then combine the information with other signals already collected in the control system, the advanced compressor diagnostics is possible without adding extra sensors to the equipment.
Is this the picture of the future? Partly it is. But large parts of what is frequently described as the bright future of intelligent devices communicating with each other, is reality at your plant already today. If you look at all the control loops, where sensor data is analysed in real time by the controller and then fed back to the drive, all those devices are intelligent, and some of them are already communicating on IP-based protocols. So is it just about denominating already existing matters in a more engaging way? Again, partly it is, but the enabling technologies permit functionalities that are not available today. The computing power available in todayâ&#x20AC;&#x2122;s industrial control systems has steadily increased. It allows more and
This is one aspect of advanced data handling: combining information from different sources to come up with new insights. Another aspect is the analysis of a large number of signals. Analysing the measurements in a plant is already done today to some extent. To analyse signals across plants can provide additional benefits. By that, we do not mean to exchange confidential production data. Comparing measurements from a type of device throughout all the installations will allow for statistical analysis of failure patterns to come up with statistically relevant predictive models. Analysing data from even a few dozen devices within the same plant will Chemical Engineering World
CEW Features
Figure3: Remote Monitoring and Diagnostics Platform - example of IoTSP
not reveal all possible failure modes, whereas the analysis of all failures of that type of device will expose early fault indicators that can then be tracked in the signals of all devices installed. All those new means of data analytics are not worth a lot if no action is taken to resolve the issue. Remotely accessing data and analytics by service experts will close the loop to continued improvement. Online availability of the support of a device or process expert to advise in any unexpected situation is essential for quick reaction to those circumstances. Proper action can then be commonly planned and immediately called for. The new technologies enable earlier detection and diagnostics and there for service with faster reaction, and better planning increasing plant and operational efficiency. Conclusion Our lives are touched daily by the Internet. It widens our horizons and improves our capabilities by connecting us to a wider community and their collective knowledge. The IoTSP revolution in industry is connecting intelligent machines and the collective data generated from a growing number of electronic sensors. We are ‘seeing, hearing, and feeling’ our industrial processes like never before and this empowers the decisions we make to optimise performance. IoTSP allows us to operate machines more safely, with greater efficiency, and with lower environmental impact, not just individually, but as complete systems, working in harmony to enhance power and productivity for a better world.
Author’s Details Christopher Ganz Group Service R&D Manager, ABB E:christopher.ganz@ch.abb.com Akilur Rahman Head of Corporate Research Center (Bangalore), ABB E:akilur.rahman@in.abb.com 36 • December 2015
Chemical Engineering World
CEW Features Technical Article
Saving in the Air This paper shows and explains the different ways to efficient compressed air production and distribution to the end user and provides the insight of various production and distribution issues like correct generation pressure, efficient control of multiple compressors, leakages etc with example of their application in Indian Oil Corp Ltd (IOCL) - Gujarat Refinery.
C
ompressed air is widely used throughout industry and is often considered the ‘fourth utility’ in industries, other being power, water and steam. Almost every industrial plant, from a small machine shop to an immense pulp and paper mill, from small chemical plant to large oil refinery and petrochemical unit has some type of compressed air system. In many cases, the compressed air system is so vital that the facility cannot operate without it. In many industrial facilities, air compressors use more electricity than any other type of equipment. Inefficiencies in compressed air systems can therefore be significant. Energy savings from system improvements can range from 20 to 50 per cent or more in terms of electricity consumption. For many facilities this is equivalent to thousands, or even hundreds of thousands of rupees of potential annual savings, depending on the use.
may be known, but just not applied due to lack of knowledge about the financial savings possible. Compressed Air Compressed air is one of the most important utilities used in industrial applications worldwide if not the most important. It has been in use for many years. The first known application is almost as old as Christian time scale. Over the years industry became used to the presence of compressed air. It is just there, a utility, very much comparable to electricity in a private household. But just like electricity, compressed air does have its costs. It is not as cheap as we think, in fact, it is one of the most expensive utility in a manufacturing plant. About eight horsepower of electricity is used to generate one horsepower of compressed air in electrical motor driven compressor. But despite the tremendous energy saving potential in compressed air production and distribution system, saving in compressed air system were hitherto not taken as seriously as it should have been taken. However, with the ever increasing cost of energy and awareness about the saving
A properly managed compressed air system can save energy, reduce maintenance, decrease downtime, increase production throughput, and improve product quality. Many of the different levers for cost reduction
1. Leaks 2. Artificial Demand 3. Inappropriate Uses
Compressor Air Delivered by Compressors
1
2
3
4. Production
5. Heat Loss 85%
4 5
Electricity Consumed by Compressor
Delivered Compressed Air is only 15% Figure 1: A properly managed compressed air system can save energy, reduce maintenance, decrease downtime, increase production throughput, and improve product quality.
38 • December 2015
potential in this expensive utility, the scenario has changed in last couple of years. This is much more important considering the fact that only about 20-30 per cent of the energy given to generate compressed air is converted into usable energy at the point of end use. (See Figure 1 below)
Components of Typical Compressed Air System A modern industrial compressed air system is composed of several major subsystems and many sub-components. Major subsystem include air inlet filters, compressor, prime mover, control panel, intermediate and after air cooler, lubricant coolers, dryers, air receivers, air distribution network and end-user equipment like air tools, pressure regulators, pneumatic operated valves etc. The compressor is the mechanical device that takes in ambient air and increases its pressure. The prime mover powers the compressor. Controls serve to regulate the amount of compressed air being produced. The treatment equipment removes contaminants from the compressed air, and accessories keep the system operating properly. Distribution systems are analogous to wiring in the electrical world—they transport compressed air to where it is needed. Compressed air storage can also serve to improve system performance and efficiency. Interestingly each and every component of this system has the potential and can contribute significantly in the energy saving plan of the system. (See Figure 3 on next page) Cost of Compressed Air Having the word ‘Air’ in compressed air, which is available for free, we often mistaken in realising the cost of compressed air? There are three major components of the Chemical Engineering World
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CEW Features compressed air cost namely capital cost invested for installation of facility, operating cost which is basically electrical energy as most of the compressors are electric motor driven and maintenance cost. Depending upon the size of the installation and operating hours of the system, proportion of these components varies slightly but still as shown in the fig about 70-95 per cent is the operation cost. (See Figure 2) Annual Operating cost of operating air compressors at IOCL Gujarat Refinery can be calculated by the fact that there are total 08 numbers of electric motor driven (832 KW each) compressor installed in the facility, out of which 04 compressors run continuously to meet the refinery plant air and Instrument air requirement. As per simple calculations, annual electricity consumption for operating 04 numbers of compressors considering motor efficiency as 85 per cent and 8760 hours of operation is: Annual Energy Consumption = 4 x 832 x (1/0.85) x 8760 KWhrs = 34297976.5 KWhrs Annual energy cost = 34297976.5 KWhrs x 4.55 ` /KWhr = `15.61 Cr Major Deficiencies in Compressed Air System • Finding the correct demand and system pressure requirement • Lack of integrated system for control of multiple units • Leakages at the end point and in the distribution system • Failure to store compressed air energy for use during peak demand periods • Severe fluctuation in pressure due to indiscriminate use of open blowing • Simple lack of maintenance, including neglect of dirty filter cartridges • Lack of efficient heat recovery mechanism Finding the Correct Demand and System Pressure Requirement A very important factor affecting the energy consumption of a compressed air system is the working pressure required. The pressure generated should always be such that to meet the minimum pressure requirement of the air operated equipment and also to meet 40 • December 2015
Figure 2: Cost Components of Compressed Air
the exigencies should there be any sudden requirement of the compressed air. This is easier to evaluate and implement the same in high volume networks than in small volume networks as the previous one has the higher surge observing capacity. A rule of thumb for systems in the 100 psig range is, for every 2 psi decrease in discharge pressure, energy consumption will decrease by approximately by 1.0 per cent at full output flow. Additional incentive being reduced in consumption through unregulated use, leakages, open blowing etc which gives additional 0.6 -1.0 per cent reduction in energy consumption. So, in total for every 2.0 psi reduction in discharge pressure energy consumption
will reduce by 1.6 - 2.0 per cent A 2.0 psi reduction in discharge pressure at Gujarat Refinery will result in annual saving of ` 28.0 Lakh (considering 1.8% reduction in energy consumption). This is very much possible at Gujarat Refinery as we are generating air at 7.9 Kg/ cm2 (113 psi) and available pressure in most of the end user process units is in the range of 6.2 - 6.5 Kg/cm2 (88.2 psi - 92.5 psi). All critical control valves and power cylinders installed in process units are designed for 4.5 - 5.0 Kg/cm2 instrument air pressure so surely there is scope of reduction of generation pressure by 2 - 4 psi without affecting the plant operation.
Figure 3: Components of Typical Compressed Air System.
Chemical Engineering World
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CEW Features Cost Of Leakages Diameter of Air Leak
Leakage Qty in CFM
Annual Electricity cost per CFM (0.157 KW * 8760 hrs.* ` 4.55/KWhr)
Annual Leakage Cost In `
1/16”
6.40
6258
40,051.00
1/4”
104
6258
6,50,832.00
1/2”
415
6258
25,97,070.00
1”
1661
6258
1,03,94,538.00
Minor Leakage – Big Menace A typical plant that has not been well maintained will likely have a leak rate equal to 20 percent of total compressed air production capacity. Most common sources of leakage are Couplings, hoses, tubes, and fittings, Pressure regulators, Open condensate traps and shut-off valves and Pipe joints, disconnect, and thread sealants. In addition to being a source of wasted energy, leaks can also contribute to other operating losses. Leaks causes a drop in system pressure, which can lead to malfunctioning of all critical Instrument air operated control valves, power cylinders and other equipment. (See the table and the graph above)
See Table 1 on next page; All Figures Are in NM3/hr Total Air Leakage Rate = 3636.5 Nm3/hr or 2140.08 CFM
Air Leak Detection Since air leaks are almost impossible to see, it is difficult to detect even the bigger leakages let alone the small leakage which are equally important.
Annual Leakage Cost = ` 6257/CFM x 2140.08CFM = `1.34 Cr
The best way to detect leaks is to use an ultrasonic acoustic detector, which can recognize the high-frequency hissing sounds associated with air leaks. These portable units consist of directional microphones, amplifiers, and audio filters, and usually have either visual indicators or ear-phones to detect leaks. To detect the air leakages and ascertain the amount of air leaking through an exhaustive air leak survey through ultrasonic detector was carried out in the year 2013 in Gujarat Refinery all over the compressed air network covering all process units, power plants, offsite and utilities section. The number of leakage and amount of air leakage detected though this survey was an eye opener for all. 42 • December 2015
As a thumb rule, for any large motor driven compressor, 01 HP (0.7457 KW) can produce 4.5 - 5.0 CFM of compressed air at 100 psig pressure. Cost of Generation of 01 CFM@100 psig = 0.7457/4.75 KW* ` 4.55/Kwhr Annual Cost of Generation of 01 CFM = 0.7457/4.75 KW* ` 4.55/Kwhr* *8760 hrs = ` 6258.00
So, at IOCL Gujarat Refinery annual saving of ` 1.34 Cr can be achieved by just plugging the leakages identified through ultrasonic leak detection. Integrated System for Control of Multiple Compressor Units Compressed air system controls match the compressed air supply with system demand and are one of the most important determinants of overall system energy efficiency. Proper control is essential to efficient system operation and high performance. The objective of any control strategy is also to shut off unneeded compressors or delay bringing on additional compressors until needed. All units that are operating should be run at full-load, except one unit for trimming. Compressor systems are typically comprised of multiple compressors delivering air to a common
plant air header. The combined capacity of these machines is generally sized to meet the maximum plant air demand with a breakdown contingency. System controls are almost always needed to orchestrate a reduction in the output of the individual compressor(s) during times of lower demand. Compressed air systems are usually designed to operate within a fixed pressure range and to deliver a volume of air that varies with system demand. System pressure is monitored and the control system decreases compressor output when the pressure reaches a predetermined level. Compressor output is then increased again when the pressure drops to a lower predetermined level. The difference between these two pressure levels is called the control range. Depending on air system demand, the control range can be anywhere from 2 to 20 psi. In the past, individual compressor controls and nonsupervised multiple machine systems were slow and imprecise. This resulted in wide control ranges and large pressure swings. As a result of these large swings, individual compressor pressure control set points were established to maintain pressures higher than needed. This ensured that swings would not go below the minimum requirements for the system. Today, faster and more accurate microprocessor-based system controls and variable speed compressors with tighter control ranges allow for a drop in the system pressure set points. Precise control systems are able to maintain lower average pressure without going below minimum system requirements. At Gujarat Refinery there are total 08 compressors available for meeting the plant air and Instrument air requirement. These compressors are divided into section namely Chemical Engineering World
CEW Features Unit
Leakage Big
Total
Medium
Small
DM Plant CGP-II
180.23
45.06
23.46
248.75
Compressor House
67.59
11.26
8.8
87.65
TPS Turbine
0
0
2.93
2.93
TPS Boiler House
67.59
33.79
18.57
119.95
CGP-II HRSG
0
5.63
11.73
17.36
DMp Plant CGP-I
45.06
45.06
45.96
136.08
CGP-I HRSG
22.53
16.9
11.73
51.16
CGP-I Compressor House
45.06
0
0.98
46.04
AU-I
157.7
22.53
28.36
208.59
AU-II
135.17
33.79
28.36
197.32
DHDS
0
0
9.78
9.78
HGU-II
0
16.9
12.71
29.61
AU-V
67.59
22.53
16.54
106.66
CRU
0
11.26
17.6
28.86
FPU-II
45.06
22.53
16.62
84.21
HGU-III
0
11.26
0.98
12.24
HGU-I
0
5.63
12.71
18.34
HCU
67.59
33.79
46.93
148.31
LAB
22.53
22.53
7.82
52.88
AU-III
22.53
16.9
10.76
50.19
UDEX
0
0
9.78
9.78
DHDT
45.06
16.9
9.78
71.74
SRU-I (OLD)
45.06
0
5.87
50.93
SRU-II (OLD)
0
11.26
1.96
13.22
ISOM PENEX
0
11.26
7.82
19.08
ISOM (NHT &NSU)
22.83
5.63
5.87
34.33
SRU-III
90.12
28.16
1.96
120.24
SRU-B
0
11.26
1.96
13.22
MTBE
0
0
0
0
FGH
0
0
0.98
0.98
VDU & BBU
225.29
56.32
10.76
292.37
CDU
135.17
11.26
6.84
153.27
FPU-I
0
5.63
8.8
14.43
VBU
90.12
39.43
24.45
154
DCU
22.53
22.53
11.73
56.79
FCC-LPG MEROX
0
0
0
0
ATF MEROX
0
0
0
0
COKER LPG MEROX
0
0
0
0
VGO HDT
22.53
5.63
4.89
33.05
MSQ
67.59
33.79
22.49
123.87
GANTRY – 5TH
202.76
61.96
46.93
311.65
GANTRY- 6TH
112.64
107.01
9.78
229.43
GANTRY-1/2
45.06
33.79
41.16
120.01
FCCU
135.17
11.26
10.76
157.19
TOTAL
2208.16
850.43
577.9
3636.49
Table 1: Leakages detected in various units of Gujarat Refinery
46 • December 2015
TPS & CGP-II with 04 compressors in each section. The outputs from these two sections are connected to common header. But the compressors were maintained at two different header pressures. The basic problems with the old architecture were: • Non-existence of system wide control & monitoring of compressed air system • Two different set-points for two different headers • In case of increase in demand it may so happen that two different systems can give start command to two different compressors which will lead to simultaneous start of two compressor and availability of excess air which may result in unloading of running compressors and also opening of blowoff-valves which is highly undesirable in an efficient system. • Continuous running of compressors at part-load. (See the old architecture of this system on next page)
In order to achieve the maximum efficient control of all compressors it was decided to integrate both these two system with a common setpoint. All these compressors were brought the common control network utilising the features of Ingersoll-Rand Air System Control Package (ASC). (See the new architecture of this system on next page) Features of the integrated System are: • Integration of the complete compressed air system • Energy management through base load and trim sequencing and/or load sharing; ASC controls the number of operating compressors, matching best efficiency with dynamic system demand • Time-based scheduling tool that enables virtually unlimited sequence change and compressor set operational combinations • Graphical interface – summary, setup and equipment-specific screen sets as well as object oriented graphics and dynamic icons made to represent the integrated system • Remote monitoring and communications – monitor from anywhere at any time and get real time data Heat Recovery from the Compressed Air During the compression process a high percentage of the consumed energy is transferred into heat. As much as 80 to 93 per cent of the electrical energy used by an industrial air compressor is converted into heat. In many cases, a properly designed heat recovery unit can recover anywhere from 50 to 90 per cent of this available thermal energy and put it to useful work like • Preheating boiler water • Makeup air heating • Supplemental space heating • Heating process fluids • Industrial process heating • Heat-driven chillers As a thumb rule, approximately 50,000 British thermal units (Btu) per hour of energy is available for each 100 cfm of capacity (at full-load). This value is based on 80 per cent recoverable heat from the compressor and a conversion factor of 2,545 Btu/bhphr. (See Figure 4 on next page) Chemical Engineering World
CEW Features The Old Architecture of the System
Set Point: 7.66 Kg/cm2
The New Architecture of the System
Set Point: 7.85 Kg/cm2
= [(796,170,470,40 Btu/yr)/(2644 Btu/Kg of MP steam) x (` 1.8/Kg of MP steam)]/ 0.85 = ` 637, 673, 24.31 = ` 6.37 Cr Conclusion As illustrated in this paper, compressed air system in overall has tremendous energy saving potential utilising the measures like optimisation of discharge pressure control, efficient use of individual machines in multi-unit system, plugging the air leakages and efficient heat recovery mechanism. On an average each compressed air system has approximately 33 per cent of energy saving potential. In addition to that, improving the performance of compressed-air system reduces plant wide energy costs. It can reduce downtime, increase production throughput, lower scrap rate, improve product quality, improve the plant reliability and create longer equipment life.
Figure 4
Energy Saving in Heat Recovery Energy Saving (Btu/year) = 0.80 x compressor bhp x 2,545 Btu/bhp-hour x hours of operation Gujarat Refinery has four compressors running at full load, each of 1116 bhp (832kw) with yearly running hours of 8760. So even if 80 per cent of the heat generated is recovered then the Energy Saving (Btu/year) = 0.80 x (4*1116) x 2545 x 8760 [= 796,170,470,40 Btu/year] The above heat generated can be used in Boiler feed water pre-heating, fuel oil pre-heating, air pre-heating, VAM air conditioning units etc. If we consider the case of fuel oil heating with hot compressed air instead of MP steam then Cost Savings (`/yr) = [(Energy savings in Btu/yr)/(Btu/unit of fuel) x (`/unit fuel)]/ Primary heater efficiency 48 â&#x20AC;˘ December 2015
Authorâ&#x20AC;&#x2122;s Details Bal Kishan Sharma Manager- Instrumentation Indian Oil Corporation Ltd - Gujarat Refinery E: sharma_bk@indianoil.in Chemical Engineering World
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CEW Features Technical Article
Laboratory Scale Assessment of Adsorbents for Gas Separation Applications Adsorption is widely used to separate and purify gases. Process design and optimisation plays a crucial role in the practical implementation of this technology, but laboratory scale studies are required in order to initially assess the suitability of new materials for practical use. Preliminary analytical measurements can be made with pure gases; for example, N2 adsorption measurements performed at 77 K for surface area determination are now a routine part of the porous material characterisation process. As a next step towards determining the capability of a material for a given separation, however, adsorption measurements with mixtures are necessary. The difficulty is that equilibrium multicomponent gas and vapour adsorption measurements are challenging and time-consuming (Broom and Thomas, 2013). A more efficient alternative is the use of chromatographic techniques, including the measurement of breakthrough curves, which we will focus on in this article.
I
n a breakthrough analyser, the adsorbent is packed into a column, through which gas and vapour mixtures â&#x20AC;&#x201C; either pure species in a carrier gas or a multicomponent mixture â&#x20AC;&#x201C; can be passed. A method for detecting the change in gas composition at the outlet of the column is also required. The choice of detector is dependent upon the species but quadrupole mass spectrometry is one of the more versatile options because it allows continuous sampling and is sensitive to a wide range of monatomic and light gases, as well as hydrocarbons and different isotopes. This is in contrast to most other methods, which are normally either non-selective or restricted to specific species (McNair and Miller, 2009), or require a sample to be extracted for analysis and are thus non-continuous. Dead space minimisation is also important in order to maximise response times. A measurement is performed by first preparing the adsorbent bed via heating and degassing, or by inert gas purging. Carrier gas is then flowed through the bed and a step change in the inlet composition introduced. The composition at the outlet is monitored until breakthrough occurs. The breakthrough curve is then a plot of the composition at the outlet against time, relative to the initial inlet composition. Depending on the adsorption behaviour of
50 â&#x20AC;˘ December 2015
the bed, an increase in the concentration will be seen at a given time, tb, known as the breakthrough time. This will depend primarily on the adsorption capacity of the column, but the shape of the curve will be determined by various other factors, including interparticle diffusion and intraparticle sorption kinetics, axial flow dispersion, and heat transfer effects. What can they Tell Us? For mixtures, differences in tb for each component provide a clear indication of the capability of the adsorbent to separate the components under the tested conditions of temperature, pressure, flow rate and inlet gas composition. The measurement of breakthrough curves can thus be used as a rapid method to compare the potential performance of new materials for separation applications.
other separation and purification processes - including distillation, chemical absorption and cryogenic methods. However, the choice depends on a number of factors, including the scale of the process and the availability of adsorbents with the right combination of properties, such as a high working capacity, sufficient selectivity, and good thermal, hydrothermal and mechanical stability. Another important consideration is the required purity of the product. In some cases, adsorption has significant advantages in this respect although membrane separation
Although breakthrough first occurs at tb, another parameter is the stoichiometric breakthrough time, ts, which is defined as the time taken for the outlet composition to reach 50 per cent of that of the inlet (Broom and Thomas, 2013). For a given column size, these parameters can be directly compared between materials but data can also be modelled to provide a more detailed analysis. Why is Adsorption of Interest? Adsorption has long been established as an effective and energy efficient alternative to
Figure 1: An automated breakthrough analyser
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CEW Features on 13X zeolite using an 80/20 per cent mixture of N 2/O 2 at 10 bar and 25 0C, with the O 2 clearly breaking through the bed before N 2.
Figure 2: Breakthrough curves determined for an 80%/20% N2/O2 mixture at 10 bar and 25°C for 13X zeolite. The concentration is the mass spectrometer signal, in arbitrary units, for the peaks in the mass spectra at m/e = 28 (N2) and 32 (O2), as determined from the peak heights.
can also offer a competitive alternative (Baker, 2012). Different processes are available, including temperature swing adsorption (TSA) and pressure swing adsorption (PSA). These differ in the method used to regenerate the adsorbent (Yang, 1997). TSA involves heating, whereas PSA involves reducing either the total pressure or the partial pressure of the adsorbed component. In each case, the adsorption properties of the materials must be understood. Which Separations Use Adsorption? Examples of separations that already use PSA commercially include H 2 separation from syngas, N 2 and O2 production from air, and He purification following raw or crude helium production from natural gas (Häring, 2008). In each case, the process exploits either the different equilibrium or kinetic behaviour of the gases adsorbed in microporous adsorbents such as zeolites and carbon molecular sieves. For hydrogen production, H 2 interacts weakly with materials, whereas other typical components of syngas, which include CO, N 2, CO2 and hydrocarbons, show a stronger interaction, and thus tend to adsorb more strongly. PSA is the main technology used for this application with over 85 per cent of 52 • December 2015
the global hydrogen production units using this method for purification purposes (Sircar and Golden, 2010). Activated carbons, zeolites and silica gels are all used but new adsorbents are also under investigation. Breakthrough curves determined with H 2/ CO, H 2/N2 and H 2/CO2 and multicomponent mixtures of these will clearly provide an indication of the ability of a new adsorbent to retain the more strongly adsorbing species. Air separation, meanwhile, relies on different adsorption mechanisms depending on the required product. N 2 production, for example, typically uses carbon molecular sieves in which the diffusion rates of N 2 and O 2 through the pores differ considerably. On the other hand, O2 production uses zeolites that show significantly different equilibrium uptakes for O 2 and N2. The choice of material for this application, of course, depends on its adsorption properties, with Ca-A and low silica X (LSX) zeolites both being used commercially (Kulprathipanja, 2010, Ruthven, 2011). For either N 2 or O 2 production applications, breakthrough curve measurements provide a rapid laboratory testing method for different materials, compared to other more laborious multicomponent techniques. As an example, Figure 2 shows data measured
As for H 2, helium production and purification using adsorption exploits the weak interaction of He with materials compared to the typical components of the feed mixture, which include CH 4 and N 2. Raw or crude helium is typically produced from natural gas, in which He is present at relatively low levels as a result of radioactive decay (Häring, 2008). This typically consists of between 50 and 90 per cent He, and is produced using other processes, but PSA with zeolites or activated carbons can be used to purify the product to levels of up to 99.9999 per cent (Häring, 2008). Breakthrough curves measured using mixtures of these species will again provide important information regarding the suitability of different adsorbents for this application. As He does not interact strongly with any solid or surface, it is the working capacity of a particular material for CH 4 and N 2, combined with its cost and other practical considerations that will ultimately determine its suitability. An emerging application, which is currently attracting a significant amount of attention, is CO 2 capture. Many new porous materials are being investigated for this purpose, including novel porous carbons, metal-organic frameworks (MOFs) and microporous organic polymers (Lu and Dai, 2014). There are two main types. Pre-combustion capture involves the separation of CO 2 from syngas that has undergone the water-gas shift reaction (Häring, 2008, Platon and Wang, 2010). This mainly involves the separation of a H 2/CO 2 mixture at an elevated pressure of a few MPa. Post-combustion capture, meanwhile, involves the separation of CO 2 from an N 2-rich flue gas at ambient pressure. Another important consideration is that flue gas often contains contaminants. It is thus important to assess the resistance of a material to species such as H 2O and sulphur-containing compounds, such as H 2S, as well as their ability to perform separations in the presence Chemical Engineering World
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CEW Features of these impurities. All of these aspects can be investigated using breakthrough curve measurements. Conclusion In this article, we have introduced breakthrough curve measurement, which provides a rapid alternative to laborious multicomponent adsorption measurements for the characterisation of adsorbents for gas separation and purification applications. We have seen that breakthrough curves can provide useful information on the mixture adsorption or separation properties of porous materials, which is important during the laboratory scale assessment of new adsorbents. A number of gas separation applications that are in practical use have been discussed, and CO2 capture used as an example of a future application that has recently been attracting a great deal of interest. References 1. Baker, R. W. (2012) Membrane technology and applications, 3rd Edition. Wiley, Chichester
2. Broom, D. P., Thomas, K. M. (2013) Gas adsorption by nanoporous materials: future applications and experimental challenges. MRS Bull. 38, 412-421 3. Häring, H.-W. (ed.) (2008) Industrial gases processing. Wiley, Weinheim 4. Kulprathipanja, S. (ed.) (2010) Zeolites in industrial separation and catalysis. Wiley, Weinheim 5. Lu, A.-H., Dai, S. (eds.) (2014) Porous materials for carbon dioxide capture. Springer, Heidelberg 6. McNair, H. M., Miller, J. M. (2009) Detectors. In: Basic gas chromatography, 2nd edition. Wiley, New Jersey, p. 104128 7. Platon, A., Wang, Y. (2010) Water-gas shift technologies. In: Liu, K., Song, C., Subramani, V. (eds.) Hydrogen and syngas production and purification technologies. Wiley, New Jersey, p. 311328 8. Ruthven, D. M. (2011) Molecular sieve separations. Chem. Ing. Tech. 83(1-2), 44-52
9. Sircar, S., Golden, T. C. (2010) Pressure swing adsorption technology for hydrogen production. In: Liu, K., Song, C., Subramani, V. (eds.) Hydrogen and syngas production and purification technologies. Wiley, New Jersey, p. 414450 10. Yang, R. T. (1997) Gas separation by adsorption processes. Imperial College Press, London
Author’s Details Dr Darren Broom Product Manager Hiden Isochema Ltd E: dbroom@hidenisochema.com
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CEW Features Guest Column
Tenets of Operational Excellence: Do It Safely or Don’t Do It At All Unpleasent incidents in chemical and petrochemical industry that lead to “massive financial loss and property damage and cause multiple fatalities” can be avoided if an organisation looks into the matter seriously. Ram K Goyal, Adviser - Risk Management and Leader - Central Reliability Engineering, Bahrain Petroleum Company, Kingdom of Bahrain, shares his perceptions on how can industry learn from past incidents and ensure industrial safety.
D
o we really learn from past incidents? Well, the general public’s perception is that we in the chemical, petrochemical, oil and gas industries mostly do not learn well from loss incidents of the past and that is why we keep having repeat incidents. In our region alone in the past decade we have had several major incidents that have resulted in massive financial loss and property damage and/or multiple fatalities in the oil and gas industries in Algeria, Kuwait, and Saudi Arabia. We want to assure our readers that there definitely are some organisations and individuals who take this learning from incidents very seriously. We can draw useful lessons from not only major incidents that have caught the public and media eye, but also from smaller incidents that occur in one’s industry. When an incident is reported in the media, everyone is naturally curious as to what has happened. But if we want to learn from the incident, we have to go beyond simple curiosity. There are some known hurdles in our ability to learn from other people’s incidents. In order to learn lessons, we need to review the incident in depth. In analysing these incidents for the purpose of learning lessons for the future, there is no point in trying to blame a specific person or persons. ‘Culpability’ is applicable in cases of sabotage or other deliberate actions with malice aforethought. In accidents and incidents, it is better to concentrate on systemic or procedural failures or design deficiencies 58 • December 2015
so that viable, effective, and long-term remedial measures can be proposed and implemented. The learning process is not easy. You need to have the will and ability to pay attention to detail. Bapco has recently adopted a unique tool called ‘Tenets of Operational Excellence’ which lists two over-riding principles: Do it safely or not at all, and There is always time to do it right. All recorded incidents related to process plant, equipment, instrumentation, and environmental consequences are analysed at Bapco to identify which of the above ten tenets was most likely violated so as to cause the loss incident. This viewing
of the historical records through the lens of tenets of operational excellence yields some very interesting results. On the basis of the results, the company is then able to direct resources that remedy the specific shortcomings identified through this analysis. The system provides a ready and usable means of assessing cost-effectiveness of remedial measures. Looking at Company’s Historical Data for Trends Learning lessons from specific in-company incidents is no different from learning lessons from external incidents. However, in the case of our internal incidents, we can also look at historical trends since we have access to data
300 250 200 150 100 50 0
Figure 1: Bapco Incidents Overview
Chemical Engineering World
CEW Features pertaining to all incidents that occur in the company. An example set of data is shown in Figure 1. If no other information was taken into consideration, then it can be surmised that there has been an increase in the total number of incidents recorded in the company. In fact, a trend analysis will show that the total number has more than doubled over the past nine years. Recording of personnel injury incidents, motor vehicle collision incidents, and fires had been carried out from very early days. Like most other companies in the region, Bapco had also adopted the recording guidelines issued by various ANSI standards (American National Standards Institute) in recording incidents. In 1994, Bapco formally adopted the Process Safety Management (PSM) system following the 1992 legislation and guidelines issued by the US OSHA (Occupational Safety and Health Administration) as Code of Federal Register 1910.119. Under PSM, we began to centrally record many other types of incidents as well; for example: process-related incidents, equipment failure incidents, damage incidents, and so on. Initially, the notification and recording process was manual, and not all stakeholders had been fully trained in the notification system. In 2001, we adopted a commercially available database system to capture all information related to incidents; the software package was primarily used as an integrated reliability management tool, and recording of all loss incidents in that system made good sense from a
Figure 2: Enivronmental Incidents and Trend Line
60 • December 2015
Figure 3: Process related Incidents and Trend Line
data analysis standpoint. Equipment or property-damage-related incidents could be linked to the plant and asset register already maintained in the system as a part of the reliability trend analysis module. As with all other systems, initially there was some reluctance on the part of incident notifiers to record all incidents. However, a major campaign was launched in 2004 highlighting the benefits of learning from past incidents, and gradually reporting improved. Also, in 2007, incident notifications from other parts of the company (namely Marketing and Oil and Gas Production) were added to the system. These are the reasons for the increase in the total number of incidents on record. Recording of incidents in a computer database afforded easy access and the ability to conduct data analysis and identify trends. An example is shown in Figure 2 where a trend in the data related to ‘Environmental’
incidents has been identified. Under the ISO14001 certification process, a major campaign was launched in 2006 in enhancing environmental awareness in the company. This effort has continued. The fruits of that awareness campaign are reflected in the downward trend in the number of environmental incidents occurring in the company. The number of leak/ spill incidents has reduced drastically; the number of other environmental excursions has also gone down significantly. Similar types of trend analyses can be performed on data recorded in other categories such as electrical incidents, fires, personnel injury, occupational illness cases, and others. There has been a very significant increase in the number of records categorised as ‘process-related’ incidents. This rising trend is depicted in Figure 3. It was a cause for serious concern, and a detailed review was performed of all incidents recorded in this category. There were several clearly identifiable reasons for this increase. The two most prominent were: (1) Due to some unclear guidelines in the PSM standard the number of ESD-related trips (instrumented emergency shutdown systems) were not being reported during the earlier years; this situation was remedied in 2006, and (2) In 2007, several new process plants came on line (eg, the Low Sulfur Diesel Production Complex in the refinery) and as these were going through their initial Chemical Engineering World
CEW Features phases of production, the expected number of process-related incidents was high. This is expected to come down to normal rates after the first turnaround cycle. Nonetheless, the company recognised the need to actively arrest and reverse the increment in the number of incidents, especially those related to equipment or property and process-related incidents. It was decided to spearhead this effort as a part of the company’s adoption of a formal Operational Excellence Management System (OEMS). One of the key elements of OEMS is a set of Tenets of Operational Excellence (as listed in the Abstract) which is seen as the primary driver to achieve an incident-free environment in the company. Looking at company’s incidents through OE Tenets All incidents recorded since 2005 were reviewed by a group of reliability specialists from Bapco’s Risk and Reliability Management group and each incident was assigned a single OE Tenet violation deemed to be the most significant causal factor. The raw results are summarised in Table 1. With the above analysis, it became quite clear that violations of Tenets 2, 4, 8, 6, and 1 were dominating the incident causes during this period (2005-2009). This is illustrated in Figure 4. Once it was established which tenets were being more frequently violated, it was possible to recommend corrective action that could specifically address the identified shortcoming. Lessons from some historical incidents We can learn valuable lessons from incidents that have happened in the process industry (including oil & gas, petrochemicals, chemicals – onshore and offshore installations). These incidents created a great deal of public interest at the time of their occurrence; some are etched forever in the memories of people affected by them, and all of them have gone into the history books of safety, loss prevention, or allied subjects. In examining these, one should not delve unnecessarily 64 • December 2015
Figure 4: OE Tenets Voilated 2005-2009
in any controversial issues of culpability or partisan agenda. The purpose must be to merely extract pertinent lessons so as to prevent or minimise chances of occurrence in your own organisation. The Feyzin LPG BLEVE (Boiling Liquid Expanding Vapor Explosion) incident resulting in 18 fatalities occurred back in 1966 in a French refinery where the operator was unable to close a drain valve due to the valve freezing open. This OE Tenet
incident triggered our pursuit for a greater understanding of the risks associated with bulk storage of LPG. The phenomenon called ‘BLEVE’ had not really been well understood prior to Feyzin. There was a fundamental error in thinking that a relief valve on an LPG sphere, designed and sized for the ‘external fire’ contingency, was sufficient to provide protection regardless of the overall fire exposure duration. It was not 2005
2006
2007
2008
or
41
13
37
11
23
125
2. Always operate in a safe and controlled condition
44
49
55
50
40
238
3. Always ensure safety devices are in place and functioning
7
7
6
14
21
55
4. Always follow safe work practices and procedures
33
39
31
58
59
220
5. Always meet or exceed customers’ requirements
8
2
10
5
9
34
6. Always maintain integrity of dedicated systems
4
70
34
35
29
172
7. Always comply with all applicable rules and regulations
6
2
19
7
12
46
8. Always address abnormal conditions
56
8
45
31
57
197
9. Always follow written procedures for high-risk or unusual situations
3
2
9
9
13
36
10. Always involve the right people in decisions that affect procedures and equipment
6
22
24
9
9
70
1. Always operate environmental limits
within
design
2009 Total
Table 1: Tenets of Operational Excellence Violated in Bapco Incidents
Chemical Engineering World
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CEW Features clearly recognised at the time that LPG would generate a ground-hugging pancake-shaped vapor cloud that could drift over larger distances and find a source of ignition. The significant hazards associated with the sphere dewatering procedure were not recognised. It is a pity that even with the lessons drawn from Feyzin, vessel BLEVEs caused the heavy losses suffered in November 1984 at the LPG terminal belonging to PEMEX (the national oil company of Mexico) – over 500 people were killed in that accident! The Flixborough incident forced the researchers into recognising the reality of the ‘unconfined’ vapor cloud explosion. Prior to this incident, an UVCE was considered somewhat of a theoretical possibility – Flixborough changed that overnight. The UK Government had promulgated ‘The Health and Safety at Work Act’ in that year (1974), and this incident brought home in a shocking way the need for employers to be proactive when dealing with the health and safety of their work forces. Another major lesson from this incident was that changes and modifications to plant and equipment, whether temporary or permanent, must be ‘managed’ in a thorough and systematic manner. The Seveso incident was the primary motivator in the EEC’s adoption of the Seveso Directive that enshrines into law the public’s right to know about the hazards posed by the plants and industrial installations in their midst. Bhopal, and its aftermath, will remain a black mark in the history of our industry. Management that was so single-mindedly driven by short-term profit maximisation and cost-cutting with no regard to safety – how else could one justify the switching off of the refrigeration unit of the tank to save a few rupees – has no business running our industry. Piper Alpha taught us that adherence to the work permit system must be ensured at all times and every time. The UK Government 66 • December 2015
passed extensive legislation related to safety at offshore installations following the Piper Alpha disaster. The incident was very thoroughly investigated by a royal commission headed by Lord Cullen. His report provides excellent details and a careful analysis of the root causes of this incident. The Houston Phillips explosion (1989) acted as the wake-up call for the American Petroleum Institute (API) which, soon after the incident, issued its recommended practice RP-750 (1990) detailing the process safety management system that had been originally conceived and popularised by the Center for Chemical Process Safety of the American Institute of Chemical Engineers (c. 1985, immediately post-Bhopal). Not only the API, but the US government bodies had to respond, which they did in the form of Federal Register OSHA 1910.119 (Process Safety Management) in February 1992. The BP Texas City incident highlights the need to eliminate all on-plot relieving vents in favor of properly designed flare systems. We must make sure that when we permit ‘oil-in’ during the start-up of a unit after a turnaround and inspection phase, there are no personnel present on site who are not directly involved in the unit startup. Furthermore, we must make sure our senior management clearly understands the difference between ‘personnel safety’ and ‘process safety.’ Risks to process plants, especially pipelines, from vandals and saboteurs have become a serious cause for concern over the past decade. Transportation of crude and products via pipelines in many parts of the world was seen as the most cost-effective option – for example: lines from the Russian Federation to Europe, Nigeria, Angola, South Africa, and neighboring countries, and Southern Iraq; and routing from Oman to India, and Iran to India; and a host of other proposals. In general, the history of incidents teaches us that in the field of loss prevention in
the process industry, there are a few key features related to layout and design which tend to enhance the intrinsic safety of a plant. For example: • Proper spacing (between equipment/ units) • Proper size (pipe/vessel size/wall thickness, etc.) • Proper steel (correct metallurgy) These features, when incorporated into the layout and design of a refinery or process plant, provide a significant degree of safety by mitigating the consequences of process deviations and other incidents. Furthermore, they are, by and large, immune from the adverse effects of human error or other uncalled-for human intervention. In well laid-out refineries, risk exposures will be limited because of the generous inter-unit distances. The EML (Estimated Maximum Loss) calculations carried out by the insurers in such cases reflect this lower risk, which, in turn, translates into lower premiums. The intrinsic safety principle aimed at avoiding incidents needs to be fully supported by efficiently working management systems and robust leadership accountability philosophy in a company. Even though the number of incidents in modern times might be decreasing slightly, the cost per incident keeps on escalating. Likewise, a greater awareness and sharing of information with the public is a must. It makes it far more important for company leadership to promote the concept of ‘Zero Accidents and Zero Incidents’ as viable corporate targets. Proactive leadership does not wait for an incident to occur or the public to complain before striving for excellence in all its operations and business practices. Bapco intends to march towards operational excellence by creating a work culture and ethos based on our ‘value’ system that consists of the following elements: Businesslike approach, Respect for everyone, Teamwork, Integrity, Innovation, and Personal accountability. Chemical Engineering World
CEW Features Guest Column
Challenges & Opportunities for Industrial Gas Market The article talks about industrial gases and challenges and opportunities associated with the industry. It also provides an insight into the Indian market scenario, the key growth drivers and opportunities of industrial gases through applications development. According to Prof R C Bhattacharya, Vice Chairman, Globsyn Business School, Director, Globsyn Technologies Ltd & Technical Consultant, AIIGMA and Prof Avik Mukherjee, Assistant Professor of Finance, Globsyn Business School, the application of industrial gases will grow in all areas of manufacturing industry.
T
he industry started in 1935 with the take-over of three small high pressure gaseous oxygen plants in Calcutta, Howrah and Asansol by the then British Oxygen Company, BOC. This subsidiary of BOC in India came to be known as Indian Oxygen and Acetylene Co Ltd and later, taking advantage of liberalisation, it got rechristened as BOC-India in 1995. By mid-60s, two other companies, viz, Hindustan Gas of Birlas and Asiatic Oxygen of Jalans came into existence. By mid 70s, many small and medium scale manufacturers sprang up using small size gaseous plants all over India to serve the need of local manufacturing industries which could not be served by the existing companies as the distribution cost from long distance was too high. Many of these plants are of East European design using medium pressure technology in place of BOC’s high-power consuming high pressure plants.
Prof R C Bhattacharya (Email: rcb@globsyn.edu.in)
Prof Avik Mukherjee (Email: avik@globsyn.edu.in) 70 • December 2015
Since liberalisation in 1991, the industry has restructured itself into three tiers – Tier 1, Tier 2 and Tier 3. Tier 1 comprises of major world players like Linde, AG, Praxair-India, INOX-Air Products & Air Liquide. Almost all of them opted for on-site captive plant route to gain economy of scale and low production cost. They invested in large tonnage plants using low-pressure technology. Gases division of Linde AG, entered India very late by taking over erstwhile BOC-India although its engineering wing had been in existence for many decades. Praxair,
USA entered the country by taking over a few small size companies but later grew in size by putting up on-site tonnage plants for captive users. Air-Products formed a JV with INOX-India known as INOX-Air Products. Air Liquide, started with its Engineering Division as a JV with BHPV but later, entered gas production domain by buying up a small company in north India, having a tonnage contract. Recently, Air-Water, Japan has entered the country by forming a JV with a medium-sized indigenous company. These are tier one companies. Tier 2 includes companies like Goyal Gases, Bombay Oxygen, etc. There are more than 140 other companies in the SME sector, which fall under Tier 3. The total turnover of all these companies is estimated to be around ` 62,000 million per annum or about USD 1.1 billion. The Indian Market Scenario Industrial gases worldwide grew at around 14 per cent in the decade up to 2014 of which Asia-Pacific was the fastest growing market, mainly due to shift of manufacturing base of the world to this area. India is the 10 th largest economy in the world in nominal terms but it is the third largest economy in terms of PPP. The global industry size was USD 63 billion in 2008. With an expected CAGR of 5 per cent, the world industry size can be assumed to be USD 80 billion. India has more than 15 per cent of the world’s population. If it achieves its rightful place, it should command at least 15 per cent of the total industrial gas market, or an annual turnover of around USD 12 billion. Chemical Engineering World
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and profitability depends on the growth and profitability of user industries. Hyper competition amongst small manufacturers and over-capacity also remains a problem coupled with the lack of financial resources of smaller players for technology up-gradation.
CEW Features Since liberalisation, GDP growth rate had been varying from 6 to 8 per cent per annum. It is estimated that the industrial gas market grew between 12-18 per cent per annum during that period. With the recent deceleration in growth, the industrial gases growth has come down to around 8 to 9 per cent. But, with the new government in place and with its attention on infrastructural development to push economic growth, the industrial gases growth is likely to go back to a double digit figure in near future. Industrial gas is required in every segment of manufacturing sector. With the development of integrated steel plants all over the country, there was a spurt in on-site tonnage plants and this had given a big push to industrial gases sales in terms of availability of low-cost surplus gas from captive plants. This trend is likely to continue. Medical sector had also been growing at around 18 per cent per annum. With the push towards medical service expected in rural sector, the medical gases demand may go up. If the new government gives a push towards infrastructure and clear pending projects like POSCO, Arcelor-Mittal, Jindal Steel, etc, these and their downstream industries would increase the demand for industrial gases further. The key driver for industrial gases growth will lie on the knowledge of the application development and application of gases in non-traditional areas like space research, food preservation and distribution, agriprocessing, etc. This paper looks at the challenges and opportunities associated with the industry and growth potential of industrial gases - both gaseous and liquid for industrial applications and future scope for non-traditional applications. Challenges Faced by the Industry There are a number of challenges being faced by the industry. Electricity is the main input to ASU gases industry. Yet the quality and cost of power remains a problem. The second issue is the length and breadth of the country. The distribution cost, 72 • December 2015
Challenges Faced by the Industry
Electricity
• Electricity is the main input to ASU gases industry • The quality and cost of power remains a problem
Length/breadth of Country
• The distribution cost, particularly for cylinder gases is high • It is not cost effective to serve long distances from a mother location
Safety
• Both high pressure cylinders and liquid tanks have safety issues and need skilled manpower for which there is a scarcity as there no established centres for providing skills
Opportunities Industrialgases Gasesisthrough particularly forofcylinder high. ItApplications is waterDevelopment and in coal gasification systems.
not cost-effective to serve long distances
It can also be used as a replacement of
Oxygen: Oxygen is required in steel melting, fabrication, copper smelting, medical applications, etc. paper oxygen and pulp to of fromuse a mother location. problem The of oxygen improvesThe thethird thermal efficiencychlorine of fuel. Asina result, is usedindustry as a method reduce pollution. is safety. Both high pressure cylinders better energy production from available fuel. Oxygenation in different furnaces including those for steel, copper,tanks cement production, etc will and improve efficiency in energy generation. Similarly, oxygen and liquid have safety issues can be used for hazardous waste clean-up, pollution treatment of water & in material coal gasification Nitrogen is an inert and need skilled manpower for which there is a Nitrogen: systems. It can also be used as a replacement ofis chlorine in paper and pulp industry to reduce used in heat-treatment to create a neutral scarcity as there no established centres for pollution.
providing skills. Yet another problem is atmosphere. It is also used for the removal of from contaminated minestohaving methane Nitrogen: is an product inert material and isairused in heat-treatment create a neutral that it is Nitrogen a consumable and not to avoid occurrence of fire. Huge quantities atmosphere. It is also used for the removal of air from contaminated mines having methane to avoid a stand-alone finished product. Being a nitrogen usedfurnaces in blastand furnaces occurrence of fire. Huge quantities of nitrogenofare used inareblast other and furnace derived demand, its growth and profitability applications to make use of its neutral properties. other It is also used applications as a source oftonitrogenous furnace make use offertiliser its depends on the growth and profitability of from Ammonia which is obtained from the synthesis of nitrogen with hydrogen. Ammonia is also the neutral properties. It is also used as a source user industries. starting point of chemicals like nitric acid, hydrazine and amines. Liquid nitrogen is used for of nitrogenous fertiliser from ammonia which cryogenic applications to take advantage of its low temperature properties in many applications like is obtained from the synthesis of nitrogen solvent tires, food Hyper extraction, competitionrecycling amongst small and pharmaceutical industry, hospitals, artificial with hydrogen. Ammonia is also the starting insemination, enhanced oil recovery etc. manufacturers and over-capacity also point of chemicals like nitric acid, hydrazine remainsArgon a problem coupled withgas'. the Itlack of not and Argon: is known as 'Noble does mix with oxygen and isnitrogen used in stainless amines. Liquid is usedand foralloy financial resources of smaller players for cryogenic applications to take advantage technology up-gradation. of its low temperature properties in many applications like solvent extraction, recycling Opportunities for Industrial Gases tires, food and pharmaceutical industry, through Applications Development hospitals, artificial insemination, enhanced Oxygen: Oxygen is required in steel oil recovery etc. melting, fabrication, copper smelting, medical applications, etc. The use of Argon: Argon is known as ‘Noble gas’. oxygen improves the thermal efficiency It does not mix with oxygen and is used of fuel. As a result, oxygen is used as a in stainless and alloy steel production, method of better energy production from MIG and TIG method of welding. Argon available fuel. Oxygenation in different is also used in light bulbs for creating an furnaces including those for steel, copper, inert atmosphere to increase the life of cement production, etc will improve tungsten filaments. efficiency in energy generation. Similarly, oxygen can be used for hazardous Acetylene: This is a gas made from waste clean-up, pollution treatment of calcium carbide, whose production needs Chemical Engineering World
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CEW Features a lot of electricity. Acetylene is mainly used for cutting mild steel and welding. Of course, carbide sludge from acetylene production being a pollutant, acetylene may be slowly replaced by LPG. Hydrogen: Hydrogen is presently made by the electrolysis of water and its production consumes a lot of energy. In spite of this handicap, it is used for the manufacture of edible oil fats like margarine from vegetable oils. Hydrogen is used to create a reducing atmosphere in heat-treatment furnaces. It is also needed for the manufacture of silicon chips. Liquid hydrogen is used as fuel in space shuttles. With the availability of hydrogen as a by-product from some chemical processes, its use has been growing. Many consider hydrogen as a future source of energy. Hydrogen is also used to remove sulphur from sour crude oil which is gaining ground because of emphasis on environmental protection. Carbon Dioxide: Carbon Dioxide is mainly used in food industry for carbonating beer, soft drinks, etc. Liquid carbon dioxide is used as a refrigerant in food industry. Carbon dioxide gas is used as a de-oxidant/insecticide for food preservation, foundry applications and firefighting. Solid and liquid carbon-dioxide is used in many cryogenic applications, as in blood storage. Helium: This is a very light gas and is nobler than Argon. It is used in deep sea diving, balloons and many other applications including high quality electric welding and leak detection. Liquid Helium is used in MRIs at hospitals for its supra-conductive characteristics. Electronic Gases: Some of these are elemental gases of extremely high purity with impurities in Parts Per Million (PPM)/ Per Billion (PPB) range. Some of the gases like Silane, Diborane, SF6, etc. are toxic and are not available in the country. This can be a good area for new product development. Nitrous Oxide: Obtained from the fractionation of Ammonium Nitrate, it is used as an anesthetic agent. 74 • December 2015
Speciality Gases and Gas Mixtures: Dopant gases like Arsine and Diborane are toxic gases and are used in semiconductor industry. Another gas, Silane, is used in solar photo-voltaic cells and semiconductor industry. These are hazardous gases. High purity gases with impurities in PPM and PPB range are also used in space research. Gas mixtures are used for calibration and research purpose. Some gases and mixtures find application in high-tech areas like submarine and battle tank manufacturing. Future Scenario We believe that the application of industrial gases will grow in all areas of manufacturing industry. Products like CNG, LNG and LCNG should join the portfolio since the nature of these products are similar. Shale gas is yet another area for growth of the industry. We think the country has challenges from 3Es, namely Energy, Environment and Eatables. These areas need a helping hand from the industrial gas industry to solve their problems. Energy: With the depletion of fossil fuel, there will be a need for energy conservation and efficient usage of existing fuel. Oxygen will play a dominant role here through oxygen enrichment. There may be a thrust towards production of steel using iron ore fines with direct reduction using oxygen and hydrogen to replace integrated steel production. Hydrogen and hybrid hydrogen like HCNG are likely to emerge as alternative clean fuels of the future. Environment: With societal clamour for clean environment, there will be stress on using oxygen in effluent treatment and hydrogen to remove sulphur from sour crude oil because of more and more stringent EPA norms. Eatables: With population growth and reduced productivity of used soil, there will be a shortage of food in India. Moreover, there is a tremendous wastage of food both because of loss during distribution and also due to cyclical availability of food products. About 25 to 30 per cent of food products are wasted which can be assisted by cold chain and use of gases like
Nitrogen and CO 2 for food preservation. Even export quality of frozen foods can be improved by cryogenic processes. Thus, use of liquid nitrogen, liquid carbon-dioxide, etc. will get a quantum jump. Three other areas where the industrial gas industry can play a meaningful part are: 1. Collaboration with the Defence sector to improve Manufacturing Excellence to make ‘Make In India’ programme of the Prime Minister a success. 2. Collaborative research through the Industrial Gases Association (AIIGMA) for developing technology relevant to Indian conditions in the areas of Production, Application and Distribution to reduce cost and increase the market size. 3. Collaboration of AIIGMA with NSDC for skill development so as to make skilled manpower available to improve quality, reduce cost and increase the employment potential. Conclusion Industrial gas is an important sector to contribute to a country’s progress. It appears to grow at double the rate of GDP. With the sophistication of economy, the usage of nitrogen and argon grow faster than that of oxygen. India is still in Oxygen era. With industrial sophistication, future growth may come from nitrogen and argon. With depletion of fossil fuel, application of hydrogen as an energy source might gain importance. Of course, application of oxygen for energy conservation and environmental protection and application of nitrogen for food preservation remains as immediate opportunities. The use of hydrogen for desulphurisation of sour crude oil might take the industry to greater heights. Simultaneously, LNG, CNG, LCNG and Shale Gas could be future product areas to grow. We believe that the industry will grow tremendously through traditional and non-traditional applications. Chemical Engineering World
ONE CHANGE
CEW
“WHAT is that ONE CHANGE in your view that can be the key enabler for India to realise the projected growth of chemical industry to reach 215 billion USD?” CEW asked key industry leader what according to them was that one change the industry needed the most to reach its full potentional.
PD Samudra, Managing Director, ThyssenKrupp Industrial Solutions (India) Pvt Ltd “At the outset, I would like to convey my heartiest congratulations to CEW for entering into its 50 th year of publication, which has been exclusively catering to the Chemical Industry as well as the Engineering Consultants, EPC Companies and the component manufacturers/ fabricators, for the process industry. Ever since I remember, the layout, quality of the magazine and the contents of CEW have always been impressive; especially the industry highlights and developments were very informative. The growth of the Indian Chemical Industry in the 50’s and 60’s took place in the Eastern part of the country, when coal was used as the main feedstock. In the late 60’s with the advent of the oil based industry, a number of refineries with downstream petrochemical units came up in the Western part of the country. However, it must also be noted that some of the oil refineries in the Eastern part of the nation are in operation for more than 100 years. The golden period for the Chemical Industry was seen when the Petrochemicals, Polymers plants and a number of refineries were set up in the ‘public’ and ‘private’ sectors; as well as when the Speciality Chemicals Sector gained momentum! The ‘oil and gas’ discoveries gave a further boost to the entire chemical sector. Although the Indian Chemical & Petroleum Industries increased the output and reached the annual outlay of USD 150 bio, still we represent only some 3 per cent of the world’s production! Considering that our population represents 17 per cent of the world’s population and we will be soon surpassing China to become number one in terms of population, our production of chemicals has to be increased substantially, considering the rising internal demands. The major constraints in my opinion are - high costs of oil and gas, threat of cheap imports of finished products from China and the Middle East, lack of enthusiasm in the private sector to set up Chemical plants, due to its high capital outlay and need for ‘forward and backward’ integrations, to remain competitive. What needs to be done urgently, in my opinion, is to install a gas pipeline between Iran and India, in addition to the LNG Terminals under implementation. Simultaneously, there should be an attempt to woo the international manufacturers of Speciality Chemicals, to invest in India; as well as to persuade the private sector companies to set up our fertilisers and petrochemical plants, by providing them with necessary infrastructure offsites including feedstock like natural gas from the gas network. I am sure India has very high potential, (although presently the scenario is rather dim), with the above important measures we can bounce back into the growth trajectory, once again.”
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Anand Pattani, Managing Director, Black & Veatch India “Many infrastructure projects, including those in the chemical sector, are affected by time over runs. These over runs can vary from a few months to as much as five or more years, placing project viability at risk. Delays in land acquisition and site handover are key reasons for schedule over runs during the pre-execution phase. For new projects, delays in land acquisition and forest and environmental clearances are reducing. The government has issued guidelines to speed-up the process plus an online clearance application system. It will help the chemical industry reach its projections for growth if government’s strategies to reduce delays are pursued with vigour nationwide. Poor project/ program management and execution coordination results in schedule delays during execution. Our experience in India’s oil and gas, fertiliser and sulphur processing sectors suggests such delays can be mitigated with the use of an engineer, procure, construct (EPC) contract model, delivered by an EPC partner able to apply world-class best practice that is tailored to the Indian market and delivered with local expertise.”
Bimal Goculdas, CEO, The Dharamsi Morarji Chemical Company Ltd. “Infrastructure bottlenecks are impediments to growth in India. One particular aspect, truly Integrated Chemical Complexes, can pave the way for growth. Today’s concept of simply allocating land and providing water and electricity is not enough. The complexes must have common utility plants with pipeline connectivity for steam, thermic fluid, nitrogen, chilled brine, etc. Large utility plants are more efficient and less polluting than several smaller ones. Effluent treatment must be common and capable of handling a range of components. Individual ETPs should not be required. Within the complex, there must be product flexibility subject to total effluent load. The lengthy clearance process should be abolished. Other allied services should be included such as: schools, residential complexes for workers and management, local transport, truck/tanker parking and driver rest areas, hospitals, industrial training institutes, road/port/rail connectivity. All these services can be charged for. The overall cost, when divided over a large user base, will be lower than the sum of individual costs. Industry does not mind paying, but we must get ‘plug-and-play’ connectivity so that we can focus on the core activities of manufacturing and marketing that are essential for growth. Then USD1 trillion can be the target, why USD 215 billion?”
Dr Peter Martin, Vice President, Business Value Solutions, Schneider Electric “One of the key advantages the Indian chemical market has over other geographic markets is the significant availability of highly trained and highly skilled engineers. The education system in India, especially technical education, has outpaced that of the rest of the world over the past 30 years. The Indian chemical market can benefit from the availability of this talent base in many ways that will provide competitive advantages. Trained and skilled engineers can be used to fill positions that had previously been filled by lower skilled labourers, such as operations and maintenance positions. This will bring new perspectives to these positions. Traditionally, operators and maintenance personnel have been minimally trained employees expected to monitor the operations and respond to failures. This perspective has resulted in chemical plants performing at a considerably lower level than is their potential. Having trained engineers fill these positions will enable chemical companies to rely on this talent base for better decisions. As the speed of industrial businesses continues to increase, a higher level talent base will enable chemical companies to transition these positions from simple monitoring labourers to true performance management positions. The result will be higher profits and increased safety.” 78 • December 2015
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Jeremy Hunter, President, Henkel Group, India “The Indian speciality chemicals market has witnessed a growth of 14 per cent in the last 5 years. Moreover, considering that there is a global shift towards Asia as the world’s chemicals manufacturing hub, India is bound to benefit. Recognising the chemical industry’s potential, the Government of India has also recognised the chemical industry as a key growth driver of the Indian economy. We, at Henkel, believe that the one trend that can change the dynamics of the chemical industry is ‘sustainability’. In 2011, Henkel introduced its Sustainability Strategy 2030. Central to this strategy is the simple but challenging ambition to triple our efficiency by either delivering three times more value with the same environmental footprint or reducing the footprint by one third while delivering the same value, in other words, achieving more with less. To achieve sustainability goals, the chemical industry has to work closely with its customers, suppliers and end consumers, so that it is able to find solutions to their design, efficiency and reliability challenges; look for ways to improve its existing technologies or products; and most importantly work on creating innovative products and solutions. Henkel is focused on creating the highest value for its customers at the lowest possible production costs. We also work with other value chain participants to develop viable solutions for the future, as by doing so, we will be contributing to every entities’ sustainable development and to our company’s economic success. Sustainability is a key enabler for fostering growth of the Indian chemical industry, as besides focusing on profit and planet, people’s occupational health and safety, and their development is also a vital parameter that it focuses on improving. India can emerge as one of the world’s major chemical manufacturers concentrate on improving efficiency as well as adhere to global environment and quality standards.”
Kevin Shah, Managing Director, Kevin Enterprises Private Limited The chemical industry sector in particular is susceptible to global movements, be they - commodity pricing pressures, currency fluctuations or geo-political fall outs. The fate of said three variables are further entwined to the vagaries of the financial systems, making it that much more difficult for planners to forecast, as often the change in direction is very sudden. Over last 7 years, we witnessed with aghast the sudden halting or folding up of chemical process industry projects after say, drop in oil price by less than half over a period of about just about one year and earlier due to the uncertainty over Euro Zone and still before that because of money supply squeeze and contagion effect in the banking sector immediately after the infamous ‘Lehman moment’ in 2008. So while it was prudent to look at the outside world to get a clue, it is now somewhat established that uncertainty is certain and anyway beyond our control. At such a time, there is wisdom in imbibing the adage by Alan Kay that “If you want to predict the future, you must invent it”. It is time to look inward but with a difference. Recall, an entire information technology industry in India was built just when the developed world was about to hit the Y2K wall. Going forward, what do we know with certainty? That global cooling practices is the order of the day, that there is going to be a conspicuous demand from our ever growing middle class population and that we have ‘adequate brains and inadequate technology’ - India’s proprietary oxymoron, if I may! India has traditionally sought process technology from outside and has also been playing catch up with respect to clean technology. We must now instead make a bold ‘Make-in-India’ push which will pay off in the mid term by taking the lead and by self imposing a higher benchmark for clean process ie, ahead of the agreed schedule at Climate Summit and eventually get the world to follow us. We must collaborate with world technology leaders and jointly develop cleaner processes for chemical plants and clean fuels with a commitment to be the first confirmed customers. Involving our process equipment manufacturers in development process will compound the advantage. That would be a sound investment disguised as an unaffordable cost! 80 • December 2015
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S C Mehta, Director, HPCL Indian Chemical Industry is set for rapid growth driven by factors like strong domestic demand, increasing purchasing power parity, youngest (@ 54 per cent under 25 age) population, higher urbanisation rate, low per capita consumption of plastic, skilled manpower etc. and the right ingredients to emerge as the global hub for chemical manufacturing provided the government is able to push thru PCPIR initiative. At present, India is the net importer of chemicals as huge investment is required in this sector . In addition, due to the inverted duty structure raw materials (inputs) are taxed at higher rate than the end product, discourages local manufacturing. Government has taken steps towards the duty structures and aiming to improve business environment by adopting transparent policy changes. ‘Make in India’ will play a pivotal role to stimulate growth and with roll out of GST chemical industry is likely to gain. ONE CHANGE which would make significant difference is ‘government support’ for business friendly policy in terms of duty and tax structure, development of infrastructure like ports, roads, railways for fast easy and competitive logistic, provision of common facilities like power and water at lower input cost, facilitation for availability of land are the key enables for Indian Chemical and Petrochemical Industry rapid growth to reach USD 215 billion.
Sudhir Shenoy, Chief Executive Officer, Dow India Despite feedstock and technology challenges, India’s share in global specialty chemical industry is estimated to grow from about 2.8 per cent in 2013 to 6-7 per cent in 2023 with market size in the range of USD 80-100 billion, according to a recent report on the sector by Mckinsey India. The committed investment from government in the Indian chemical sector, not just in terms of monetary investment, but resource investment in creating a competitive playing field in the sector is the key change that I would like to see. I believe there are four key dependencies that need to be addressed to achieve this growth - infrastructure development, investment in technology, partnering with industry to develop regulations and standards that will govern responsible and sustainable growth and implementing ‘zero duty’ on the import of value adding specialty chemicals to encourage the development of improved and sustainable solutions in downstream markets. The current reform initiatives by the Government of India, including ‘Make in India’ and ‘Smart Cities’, if implemented well, will also be immensely beneficial for the specialty chemical sector and give the Indian chemical industry a much-needed boost.
Vipul Shah, COO – Petrochemicals, Reliance Industries Ltd Life, as we know it currently, cannot be imagined without Chemicals! Chemicals and their end-applications in the downstream industry, are an integral part of our modern, comfortable, rich lives. Hardly any industry exists, which does not benefit from its quintessential advantage. Each one of the 80,000 different chemicals existing today make their products and services extremely useful for the intended target customers. Be it in Pharmaceuticals, Agriculture, Food Products or modern technologies like Computers, iPads, Smart Phones, Smart Cars, LED/OLED TV’s et al. No wonder, the global chemical industry output is currently valued at close to USD 5 Trillion and growing. Indian Chemical Industry has grown over the years to the current market size of appx. USD 150 billion. Even though, growing at a healthy 11 per cent per annum, it remains a miniscule single digit percentage in terms of our global market share. In my opinion, going forward, the single largest growth driver, for us to achieve a global stature with our Chemical Industry, would be a Focus on Speciality Chemicals using upgraded Technologies. It may necessitate working closely with upstream feedstock manufacturers for collaborative innovations or seeking out technology partnerships. It will potentially help our downstream businesses create and service new profitable market niches and address the downstream customer’s growing need for value-added products. Also, it would help insulate/ make them more competitive with respect to their global competitors. And what is more, it would also bolster our honourable Prime Minister’s ‘Make-in-India’ program through import substitution. 82 • December 2015
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Ashish Gharpure, Chief Operating Officer, Aker Solutions India The chemical processing industry does indeed have the potential to be one of the higher growth segments. India has the wherewithal to execute such projects at or better than global competitive benchmarks, both on the cost and schedule fronts. One of the major challenges facing any big ticket investment decision is a stable and supportive business environment. As with any industry, for the chemical processing industry too, the external environment plays an extremely important factor in deciding the final investment. The government should look at providing a long term stable investment climate to give assurance to such investors. All over the world, such industries have thrived and succeeded using the geographical clustering method. This should be strongly encouraged by all concerned stakeholders to take advantage of the current low input prices. In the long term, these measures will serve to develop a strong industry which has the potential to create a lot of direct and indirect employment opportunities.
Dr Arup Basu, President, Tata Chemicals The health of the chemical industry is a lead indicator of the health of an economy. For India to realise the projected growth of the chemical industry, true market forces should be at play. For this, in my view, the ONE change required is for the government to withdraw all incentives of any kind, form or shape whatsoever (for example subsidies of any kind, special economic zone status, tax holiday/exemptions, low interest loans, grants, preferential allotment of land parcels etc…) to participants in the formal economy. All such support should only be extended to individuals or entities that belong to the informal economy.
Uday V Kulkarni, Country Head – Offshore Business Development & Offshore Projects Operations Head, Technip India Ltd Bring new Technologies / techniques to help cost optimisation is a key enabler for India to realise the growth in the industry. The O&G Industry is ~50 years old in India. The biggest challenge in the market place is that the O&G producing Companies do not have focus on Conceptual development, FEED type Projects which can attract new Techniques and Technologies beneficial for the Companies , for the industry and the country as a whole. T here is no ‘Design competition’ during the bidding stage and generally the selection of the Contractors is through Commercial merits only. Therefore, World class Contractors do shy away from actively participating in the market place. This deprives the Clients of Good Quality/ technology driven products and Projects. Moreover, this make the Bidders become too cost conscious and likely to loose focus on Quality and Safety. The Myth of new Technology always mean ‘Extra’ cost needs to be broken. The technologies, apart from their obvious benefits, also help in achieving – • Cheaper developments through Standardisation and Early involvement. • More guaranties on Project execution One can now realise, in the current era of low Oil Pricing ( when the oil price is expected to hobble around USD 42-45 / bbl for quite some time) , the new technologies / techniques become so very essential!! 84 • December 2015
Chemical Engineering World
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ONE CHANGE
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M B Parekh, Chairman, Pidilite Industries “Identify key building blocks and intermediates for Chemical Industry and facilitate setting up capacities on a large scale which will make these available at competitive prices”.
Dr Raman Ramachandran, Head South Asia, Chairman and Managing Director, BASF India Ltd The one change that I would like to see is greater focus and investment into R&D and innovation to address specific challenges that we will face with population growth, resource limitations and climate change.
Yatinder Suri, Country Head, Outokumpu India has all the desired growth drivers as well as the FDI policy in place. In my humble view, the key enabler for investment and growth will be the GDP growth as well as GST passage. Unless a positive investment climate is seen by the domestic Indian players, foreigner investors will not be inclined to invest. So, it is the GDP growth and ease of doing business which are the key enablers in my view. It can only happen if political maturity dawns in Parliament and all hues of politicians decide to work unitedly for the sake of our nation. PM has an important role to play here as the leader of our nation to take everyone along. Sooner the better
Nadir Godrej, Managing Director, Godrej Industries India has very high prices of electricity and natural gas. This is a severe impediment to the growth of the chemical industry. Fortunately the cost of Solar Energy is coming down. If industry can be permitted to wheel solar energy without hindrance, the chemical industry will get a boost. Natural gas is both a raw material and a source of fuel for the chemical industry. The global prices have fallen but Indian prices are still very high. Ensuring global prices for the chemical industry will go a long way in supporting the industry. As chemicals are a major input to all industries supporting the chemical industry is essential for ‘Make in India’ to be a success.
86 • December 2015
Chemical Engineering World
15th Edition
Chemical | Pharma & Biotech | Oil & Gas | Pumps, Valves Pipe & Fittings | Filtration & Separation
Who’s Who is an ‘Exhaustive Listing and Fact Book on Chemical Process Pharma & Biotech, Oil & Gas, Pumps Valves Pipes & Fittings, Filtration & Separation Don’t miss this unbeatable brand building opportunity. Advertise in the biggest & best of the India’s Process Industry & watch your Company grow. We look forward to your participation in our 15th Edition. We would like you to know that Who’s Who has progressed by leaps & bounds over the last 14 editions. Thank you for your support. We are now in the process of compiling the 15th Edition. Who’s Who is an exhaustive listing & Fact Book on the process engineering companies in the Chemical, Pharma & Biotech, Pumps Valves Pipes & Fittings, Filtration & Separation. It also carries extensive information on the Oil & Gas Industries and Industrial & Process Automation. The database covers more than 10,000 participants at our ChemTECH Events. Who’s Who is an important part of the literature accessed by Purchase Managers from these industries for their research before procurement. It is also made available to visitors to our stalls at international expositions who evince interest in Indian products. The whole compilation rendered on CD is a big hit with these visitors. The international audience can also access Who’s Who at the libraries of Indian Trade Chambers abroad. Important Segments 2. Pharma Process Equipment / Packaging 4. Plant & Machinery 5. Pumps, Valves, Pipes & Fittings 6. Filtration & Separation 7. Industrial & Process Automation 8. Water & Waste Management 9. Materials Handling & Logistics 10. Engineering, Procurement & Construction 11. Oil & Gas 1. Pharma & Biotech
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Big Is Beautiful, Except For Condensers
A
major European chemical company increased production reliability by re pl a cin g she ll-a nd -t ub e (S& T) condensers with Alfa Laval Compabloc condensers. Utilising only half the space of the old shell-and-tube installation, the Compablocs solved a corrosion problem and at the same time generated considerable savings in capital cost. â&#x20AC;&#x153;Big is not beautiful anymore at this siteâ&#x20AC;?, says the plant engineer. In all capital-intensive industries, plant decisions are of major importance. This is nowhere more true than in the chemical industr y. A major European chemical company solved production problems, which were also having unacceptable environmental knock-on effects, by replacing existing shelland-tube (S&T) condensers with modern Alfa Laval Compabloc condensers. The plant upgrade increased reliability, showed a considerable capital saving over re-tubing the old S&T condensers and saved about half the space occupied by the old units. Process Plant One of the products of this company, which has a multi-billion Euro turnover, is hydroxylamindisulphanate (Hydramin) used in the production of Caprolactam. The process is exothermic and excess heat is removed in a normal refrigeration loop using ammonia as refrigerant. After evaporation and compression to between 14 bar(a), the ammonia was condensed in six parallell S&T condensers - three using cooling tower water and three using brackish dock water as cooling medium. Each had 1300 m2 of heat transfer area, consisting of 3000 tubes of carbon steel, with a corrosion-resistant coating. The ammonia was condensed on the carbon steel shell side. Corrosion Problems The water side needed to be cleaned by high pressure water jet every two years as performance deteriorated. This operation stripped off the protective coating which 88 â&#x20AC;˘ December 2015
allowed the tubes to corrode and led to ammonia leaking into the cooling water system, which was totally unacceptable. Drop In Production The condenser, which was giving trouble, had to be identified and taken out of operation while the corroded tubes where plugged. During the summer, loss of cooling capacity meant a significant drop in production. In addition, cooling capacity gradually reduced as tubes became plugged. Plant Comparison In 1996 the plant and process engineer began making price and perfor mance comparisons to solve the corrosion problems which were causing high maintenance costs and reducing plant efficiency. The cost of re-tubing three of the existing carbon steel S&Ts with AISI 316L stainless steel tubes was compared with installing three new Alfa Laval Compabloc condensers with plates in AISI 316L. Higher capacity at half the space like many sites in the chemical industry, the space available at the plant is very valuable. The Compabloc condensers having about 50 per cent higher capacity still only required half the space occupied by the original S&Ts. This gives options for plant modification or expansion in future years with minimum cost and disruption. Experience has shown that the heat transfer coefficient of Compabloc condensers are around two to four times higher compared to S&T condensers depending on application. Cost Savings In the price comparison, the Compablocs cost considerably less than re-tubing the carbon steel S&Ts with 316L stainless tubes. If the comparison is made between Compablocs and new S&Ts in 316L, the cost difference is even greater. For a Compabloc in titanium the savings are even greater compared to a S&T with
titanium tubes and a carbon steel shell. This is important because titanium condensers are needed when harbour water is used as cooling medium. One Compabloc in titanium is installed and two others are planned. Fully-Welded and Fully Accessible The Compabloc is fully-welded and is fully accessible for inspection and maintenance. There is a vent on the ammonia side to purge the system of nitrogen. This gas is used as a seal in the compressor to avoid compressor oil leaking into the ammonia. Operation The Compabloc units run 24 hours a day, 8400 hours a year with the ammonia at a pressure of 14 bar(a) and the cooling tower water at 3 bar(g). In August 1999, about a year after commissioning, they were inspected on the cooling tower water side and found to be clean. Since there have been no other problems, no maintenance has been required. The S&Ts were cleaned every two years.
For more information: Alfa Laval (India) Limited Office No. 301/401, Global Port Building, S. No. 45/1-10, Mumbai-Banglore Highway, Baner, Pune 411 045 T: +91 20 6734 1100 E: india.info@alfalaval.com W: www.alfalaval.com Chemical Engineering World
+91 - 80 - 4142 9900, 2783 2051 +91 - 80 - 41429903
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Explosive Dusts And Electrostatic Charging
W
hen two substance are brought into contact with one another, charge migrates across the points of contact. One substance becomes positively charged and the other negatively charged. As the substances are separated, electric fields develop and these have a tendency to drive the charges back across the remaining points of contact leaving the two substances neutral. If one or both of the substances is highly i n s u l a t i n g , c o n s i d e r a bl e a m o u n t s o f charge can get stuck and we have the phenomenon of electrostatic charging. Electrostatic charging is very common but it normally occurs totally unnoticed. But, when it occurs where there are flammable atmospheres it may lead to fires or explosions. A great many process industries handle large volumes of dusts/powders, the majority of which are flammable. Handling dusts and powders is unavoidable and can result in electrostatic discharges creating a risk from fires and explosions in the workplace. Many dust/ powders are highly insulating. This can happen not only when they are dispersed in air, but also when they are in contact with surfaces. Even some solid materials which have conductive properties in a solid state can develop insulating property when converted into powdered form. Depending upon its Minimum Ignition Energy (MIE) these flammable dusts/ powders can be ignited even by a small electrostatic discharge which could then lead to a violent explosion. An initial dust explosion could stir up dust lying on surfaces and this could then lead to a secondary explosion which can be more damaging than the initial one. An appropriate ‘Basis of Safety’ has to be established for the process where there is a potential of electrostatic charge 90 • December 2015
Barton Solvents Explosion, July 2007 Barton Solvents Explosion, July 2007
and flammable dust/powder. To develop the most suitable ‘basis of safety’, it is essential to determine the flammability properties of the dusts/powders involved in the process. Sigma-HSE have extensive experience in establishing the electrostatic properties of dust/powders and a dedicated laboratory to test a range of materials from powders, liquids, clothing to FIBC’s. Our specialist Process Safety Consultants are also very familiar with powder handling processes that can create electrostatic potential in dust/powders, from vessel charging to conveying and can work with manufacturers to identify and mitigate fire and explosion risk. Some of the studies being: • Electrostatic Hazard Assessment can be carried out to cover the possibility of electrostatic charge generation, charge accumulation and discharge mechanism. Adequate measures are suggested in order to minimise risk due to electrostatic charges • Dust Explosion Risk Assessment is carried out to assess potential Dust Explosion hazards in powders handling areas of the plant & to recommend
appropriate practical measures for eliminating and/ or controlling potential Dust explosions and dust emissions. • ATEX Assessment involves qualitative a s s e s s m e n t o f r i s k o f va p o u r ( s ) / gas(es)/ dust(s) fire & explosion and establishing basis of safety for reducing the r isk to As Low As Reasonably Practicable level (ALARP).
For further information, contact our Business Development and Marketing team on safety-india@sigma-hse.com T: +91 9599042429. W: www.sigma-hse.com. Chemical Engineering World
Over 1 million Users since its introduction Introducing HI98100 Checker Plus
The next generation of the original Hanna Checker pH tester.
HI98100 Checker®Plus pH Tester
• Economical • One button operation • Two point auto calibration • Replaceable pH Electrode • Long battery life
Hanna Equipments (India) Pvt. Ltd.
HI180 mini stirrer with Speedsafe™ technology sold separately
Kharghar, Navi Mumbai - 410210 +91 22 27746554/55/56 09321911190 / 07498360234 water@hanna-india.com, Web: www.hannaindia.in
Brilliant technology Italian quality Saurus939: High quality, versatile and long life vacuum pump for continuous recovery of the solvents extracted. Fit & forget!
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Your vacuum drying specialist marketing@italvacuum.com | italvacuum.com
Vac Enterprises India LLP, Mr. Jayant Joshi B 102 Shubh Sarita, Appasheb Sidhaye Road Shree Krishna Nagar, Borivali (East) Mumbai 400 066 Tel. 02228975275 | Mobile 9820047858 info@electromechengineering.com
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About Economy
E
conomy Refr igeration Pvt. Ltd., established in 1926, offers Vacuum Systems, Lobe Blowers, Process Gear Pumps , Liquid flow meters, Food and packaging inspection systems and Process equipment. Economy designs and builds complete customised skids for Process and Vacuum requirements for varied applications across industries. Economy with its Corporate office in Mumbai and main branches in Chennai,Nasik, Delhi, Hyderabad and a countrywide Dealer network reaches out to customers located across the Indian sub-continent. The Company owned warehouse in Bhiwandi , Thane stocks finished equipment and spares available for quick response t o c u s t o m e r r e q u i r e m e n t s . We h ave
established a strong and dynamic sales, ser vice and dealer network emerging as one of the largest companies in our segment.Our offices in UAE and Saudi Arabia through our associate Company Rotative Process Systems FZE offers support across the Middle East. Economy has an experienced, dedicated and technically skilled team to service our growing number of customers. Along with commissioning of our systems, we are equipped to provide prompt after sales service with a dedicated team of Engineers and Technicians. We have supplied a large number of Vacuum Systems, Blowers, Pumps and Flow meters to several industries in India as well as overseas. These systems are satisfactor ily perfor ming in industr ial
segments like Auto, Cement, Chemicals, Food Processing, Gas Process, Paint, Pharmaceutical, Steel, Sugar, Solar and Water Treatment Solutions etc. Economy supplies equipment to major OEM's throughout India. We are approved by many Engineering /Project consultants. Economy team welcomes opportunities f r o m c u s t o m e r s t o o f fe r c u s t o m i s e d engineered solutions for their Process, Vacuum and Inspection requirements. For further information, contact our Economy Refrigeration Pvt Ltd, A16/1, Harihar Corporation, Mankoli Village, Dapoda, Off Mumbai Nashik By Pass, Bhiwandi, District Thane - 421302 T: 91-2522- 662746 E: sales@erplindia.com W: www.erplindia.com
Now : Mobile App of CHEMICAL ENGINEERING WORLD For Android & Apple Platforms
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Chemical Engineering World
Over 1 million Users since its introduction Introducing HI98100 Checker Plus
The next generation of the original Hanna Checker pH tester. Manufacturers of: FDA approved Food grade Hoses and Hygienic valves, Ball, Gate, Globe, Check valves, Mascon Diaphragm valves, Diaphragm operated pumps, Dairy Sanitary valves & Fittings, Deltech butterfly valves.
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• Economical • One button operation • Two point auto calibration • Replaceable pH Electrode • Long battery life
Hanna Equipments (India) Pvt. Ltd.
J-209, MIDC Bhosari, Pune 411Kharghar, 026. Navi Mumbai - 410210 +91 22 27746554/55/56 Mobile : 9881236139, 7722076899, 7722092473, 7722092472 09321911190 / 07498360234 HI180 mini stirrer with Speedsafe™ technology sold separately water@hanna-india.com, Web: www.hannaindia.in Email : pramod@parth-valves.com/ sales@parth-valves.com /marketing@parth-valves.com Web : www.parth-valves.com
Brilliant technology Italian quality SE Brilliant technology Italian quality Saurus939: Versatile and long life vacuum pump for continuous recovery of the solvents extracted Saurus939:
SAMARTH ENGINEERS Criox System: Patented rotary vacuum dryer with electric lump-breakers
any other vacuum
• Uncontaminated vacuum technology
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• Environment friendly • ATEX zone 0
Frankfurt (Germany), 15-19 June
AN ISO 9001 : 2008 Certied Stand B44, hall 4.0 Company
Versatile and long lifevacuum vacuum • Uncontaminated pump for continuous recovery of • Operational costs lower than the solvents extracted • lower than • Operational Simple andcosts cheap any other vacuum maintenance technology
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Specialist in
· Pressure Vessels & Heat Exchanger · Manhole Planex System: · Process Equipment Design · Blenders Multi-patented paddle vacuum & Fabrication · Storage Tanks ® planetary dryer with ZeroFriction Planex System: · Agitator Tanks · Fabrication & Machine Work movement eccentric agitator Multi-patented paddle vacuum · Distillation Column dryer with ZeroFriction® planetary· Manufacturing of Flow · Condensers movement eccentric agitator venture tube
Fabrication In Inconnel – 600 / 625 / 690 Aluminium Hastalloy Copper
CosmoDry System: Paddle vacuum dryer with concentric Titanium
CosmoDry System: agitator, fitted with a shaft dismountable S. S.with Duplex Steel 300 Paddleinvacuum dryer concentric sections. agitator, fitted with&a 400 shaft Series dismountable in sections. Mild Steel
Carbon Steel
Agent for vacuum pumps Agent for vacuum pumps
EMJAY Unit – I : J – 415, MIDC, Bhosari, Pune – 411026, Tel. No. : (020)ENGINEERS, 66300305. Mr. Jayant Joshi B/102, Shubh Sarita CHS, Shrikirshna Nagar, Unit – II : Plot No. 4/18, Sector No. 10, PCNTDA, Bhosari, Pune – 411026, No.Near : (020) 66146033. EMJAY ENGINEERS, Mr.Tel. Jayant Joshi Appasaheb Sidhaye Marg, Borivali (East), Your vacuum drying Unit–specialist III : J-414, MIDC, Bhosari, Pune - 411026 B/102, Shubh Sarita CHS, Near Shrikirshna Nagar, Mumbai 400066 Mobile : 98600 98706, 97663 26240, 7776025551 Appasaheb Sidhaye Marg, Borivali (East), Your vacuum drying specialist marketing@italvacuum.com Tel.400066 02228975275 Mobile 9820047858 E-mail : sanjayraut21@hotmail.com | sanjayraut22@gmail.com Mumbai marketing@italvacuum.com italvacuum.com Website : www.samarthengineers.com, www.samarthengg.in E-mail:electromech.engg.entp@gmail.com Tel. 02228975275 Mobile 9820047858 italvacuum.com E-mail:electromech.engg.entp@gmail.com
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When others stop, Saurus939 carries on
S
aurus939 has all the Italvacuum experience, a vacuum pump that guarantees unrivalled performance in all the main chemical and pharmaceutical processes, ensuring total recovery of extracted solvents, even in severe operating conditions.
• Bio-science • Waste management.
A simply designed machine, that combines traditional robustness and reliability with the most evolved technology.
Features The design is simple and traditional. The great added value is Italvacuum’s consolidated experience that year after year has perfected, innovated and improved the Saurus939 vacuum pump, guaranteeing optimum operation in all chemical and pharmaceutical processes, such as drying, distillation, reaction and crystallization.
Saurus939 has always been the core business of Italvacuum, one of the leading manufacturers of vacuum pumps as well as a worldwide reference point in the design and manufacture of vacuum dryers Resistance, strength and consumption of oil virtually eliminated thanks to the innovative LubriZero system, that guarantees perfect operation and optimum results with total respect for the environment.
Processes: Vacuum dr ying, reaction, distillation, crystallization, filtration, evaporation and polymerization.
Saurus939 can intake both the vapours of common solvents (methyl alcohol, ethylic alcohol, chloroform, acetone, ethyl acetate, methyl chloride, benzene, toluene, isopropyl alcohol , ethyl ether, heptane) as well as those of more aggressive solvents
(hydrochloric acid, acetic acid, chlorobenzene, dimethylfor mamide, acr ylonitrile, dichloroethane,cyclohexane, pyridine, dimethyl sulfoxide, dichloromethane). Construction details Cylinder, pistons, piston rings and head are made of special anti-acid cast iron. The other components are made of cast iron, special steel and PTFE with special charges. The pump is completely sealed: a characteristic that makes it extremely reliable and efficient for a long time, even in damp and dusty environments. The discharge valves have automatic openings and are available in different materials, including Hastelloy. Cooling is by air. Saurus939 has two completely separate, independent lubrication circuits: • one circuit for the process part, with metered injection of fresh oil, thanks to
Saurus939 has no fear of aggressive and corrosive solvents, powders and condensates, nor distillation by-products. But above all it does not fear confrontation because it is designed and manufactured to work 24 hours a day with a constant excellent performance and minimum operating costs, thanks to a low-energy motor, negligible oil consumption and easy, immediate maintenance. Powerful, efficient, but absolutely safe: Saurus939 guarantees optimum safety through the whole process and complete purity of the final product. In other words, ensures an uncontaminated vacuum. Applications The Saurus939 vacuum pump has a vast range of uses, as it can be used in the following sectors: • Chemicals • Pharmaceuticals • Cosmetics • Oil and gas • Plastic and rubber 94 • December 2015
Saurus939_double stage with all accessories
Chemical Engineering World
st@koerting.de Your vacuum drying specialist
Appasaheb Sidhaye Marg, Borivali (East), Mumbai 400066 Tel. 02228975275 Mobile 9820047858 E-mail:electromech.engg.entp@gmail.com
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Marketing Initiative the LubriZero system • one circuit for the mechanical part with recirculated oil. LubriZero System Saurus939 is equipped with the exclusive L u b r i Z e r o s y s t e m t h a t e n s u r e s b e st possible performance with truly negligible oil consumption, completely compatible with the environment. The LubriZero system combines the metered injection of oil with a kit of new materials in PTFE with special charges that are not only resistant to corrosion, but require virtually no lubrication. This also allows for the use of synthetic FDA approved oils.
Yearly operation costs
The metered flow of a few drops of fresh oil (about 10 g/h) guarantees an effective barrier from even the most aggressive solvents, considerably increasing the duration of the perfect cylinder-piston coupling and hence the working life of the vacuum pump. Uncontaminated vacuum Powerful, resistant, efficient, but also completely safe: Saurus939 guarantees maximum safety throughout the whole process and complete purity of the final product. In other words, guarantees uncontaminated vacuum. In fact, during the entire work cycle, not even one molecule of oil reaches the processed product. This is certified by the Department of Material Science and Chemical Engineering at the Politecnico of Torino, as part of specific research carried out on a complete process of vacuum drying. The results leave no space for doubt: the final product is absolutely pure with no risk of oil contamination in the process. Best results Better quality is never an expense: it’s an investment. And investment is always rewarded with good results. Over time the Saurus939 vacuum pump, achieves more, lasts longer and has lower running costs with respect to other main technologies for vacuum systems. The use of oil not only avoids any contamination in the process, but also improves performance 96 • December 2015
Break-even
and increases pump life, reducing maintenance costs, even in the presence of very aggressive solvents. The choice of materials, technology employed and the appropriate solutions taken by Italvacuum in every design detail make Saurus939 the best in the sector, with reliability and results beyond comparison. Range Saurus939 range includes single stage and double stage models. Double stage models are also available with one or two compressor roots in order to increase the pump rotation speed and reach lower final pressures (high vacuum levels). Accessories The high quality of Saurus939, not only in the unquestionable reliability of the vacuum pump, but also the wide range of accessories, allows
for turn-key installation of the entire vacuum group: 1) Atmospheric post-condenser for the recovery of solvents from the pump outlet 2) Condensate recovery tank from the postcondenser outlet 3) Pump suction filter with particle centrifuge separation and metal filtering cartridge 4) Control panel board, also available in compliance with ATEX DIRECTIVE 94/9/EC 5) Support base for easy, fast installation. Certifications Saurus939 complies with the requirements of the most demanding European Directives : • MACHINERY DIRECTIVE 2006/42/EC • ELECTROMAGNETIC COMPATIBILITY DIRECTIVE 2004/108/EC Chemical Engineering World
Brilliant technology Italian quality SE Brilliant technology Italian quality ncept
SAMARTH ENGINEERS s o Frankfurt (Germany), 15-19i June AN ISO 9001 : 2008 Certied Company Stand B44, hall 4.0
C
Matter How ANo Custom-Designed Viscous your Fluid Is! Peristaltic Pump? Versatile and long lifevacuum vacuum • Uncontaminated pump for continuous recovery of • Operational costs the solvents extracted lower than
Criox System: Patented rotary vacuum dryer with electric lump-breakers
any other vacuum • Uncontaminated vacuum technology
• lower than • Operational Simple andcosts cheap any other vacuum maintenance technology
Criox System: Patented rotary vacuum dryer with electric lump-breakers ®
Specialist in rvices Se
• Simple and cheap • maintenance ATEX zone 0
En g i n e eri ng
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Frankfurt (Germany), 15-19 June Stand B44, hall De4.0
gn
Saurus939: Versatile and long life vacuum pump for continuous recovery of the solvents extracted Saurus939:
· Pressure Vessels & Heat Exchanger · Manhole Planex System: · Process Equipment Design · Blenders Multi-patented paddle vacuum stirrers keep moving& Fabrication • Cole-Parmer ATEX zone 0 · Storage Tanks ® planetary dryer with ZeroFriction Planex System: · Agitator Tanks · Fabrication & Machine Work movement eccentric agitator Multi-patented paddle vacuum • Constant speed · Distillation Column dryer with ZeroFriction® planetary· Manufacturing of Flow Unique built-in counter reaction maintains · Condensers movement eccentric agitator venture tube constant rpm even with viscosity changes
OEM Services Creates It • Environment friendly
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• Precise control Microprocessor allows precise control of speed and temperature
CosmoDry System:
Paddle vacuum dryer with concentric Inconnel – 600 / 625 / 690 Titanium CosmoDry System: agitator, fitted with a shaft dismountable • Safe to use Aluminium S. S.with Duplex Steel 300 Paddleinvacuum dryer concentric sections. Hot surface warning remains lit until top plate cools Hastalloy agitator, fitted with&a 400 shaft Series dismountable below 50˚C in sections. Copper Mild Steel • Chemically resistant Carbon Steel Agent for vacuum pumps Corrosion-resistant ceramic-coated top plate is suitable for a variety of high temperature applications Agent for vacuum pumps
Get the pump design to meet +91-22-6139-4444 r o f ll a C +91-22-6139-4444 your needs with our Dual pricing EMJAY ENGINEERS, Mr. Jayant Joshi Unit – I : J – 415, MIDC, Bhosari, Pune – 411026, Tel. No. : (020) 66300305. l includes ia B/102, cEMJAY Collaborative OEM process • Uniform temperatures SpeBhosari, Shubh Sarita CHS, Shrikirshna Nagar, Unit – II : Plot No. 4/18, Sector No. 10, PCNTDA, Pune –duty 411026, No.Near : (020) 66146033. 1-800-266-1244 ENGINEERS, Mr.Tel. Jayant Joshi custom
Pricing
Rugged aluminum alloy delivers optimal heat transfer Your vacuum drying Unit–specialist III : J-414, MIDC, Bhosari, Pune - 411026
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Appasaheb Sidhaye Marg, Borivali (East), exempt B/102, Shubh Sarita CHS, Near Shrikirshna Nagar,
response@coleparmer.in
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prices Mumbai 400066 Mobile : 98600 98706, 97663 26240, 7776025551 Appasaheb Sidhaye Marg, Borivali (East), Your vacuum drying specialist marketing@italvacuum.com Tel.400066 02228975275 Mobile 9820047858 E-mail : sanjayraut21@hotmail.com | sanjayraut22@gmail.com Mumbai marketing@italvacuum.com italvacuum.com Website : www.samarthengineers.com, www.samarthengg.in E-mail:electromech.engg.entp@gmail.com Request yourTel. FREE catalog today!Mobile 9820047858 02228975275 italvacuum.com E-mail:electromech.engg.entp@gmail.com
Brilliant technology Italian quality
4143_CPI_ChemEngWorld_SpAd_1215.indd 1 4121_Chemcan EnginWorld_India spad 0815_17.5cmx12cm.indd 1
Saurus939: Versatile and long life vacuum pump for continuous recovery of the solvents extracted
12/4/2015 10:10:46 9:01:15 AM AM 8/4/2015
Criox System: Patented rotary vacuum dryer with electric lump-breakers
Planex System: Multi-patented paddle vacuum dryer with ZeroFriction® planetary movement eccentric agitator
CosmoDry System: Paddle vacuum dryer with concentric agitator, fitted with a shaft dismountable in sections.
Agent for vacuum pumps
Your vacuum drying specialist marketing@italvacuum.com | italvacuum.com
ADVERTISE TO EXPAND ADVERTISE TO ADVERTISE TO EXPAND Brilliant technology Italian YOUR REACH THROUGH YOUR REACH THROUGH
EMJAY ENGINEERS, Mr. Jayant Joshi B/102, Shubh Sarita CHS, Near Shrikirshna Nagar, Appasaheb Sidhaye Marg, Borivali (East), Mumbai 400066 Tel. 02228975275 | Mobile 9820047858 E-mail:electromech.engg.entp@gmail.com
quality
Marketing Initiative • Uncontaminated vacuum and complete purity of final product • Lower operating costs than any other vacuum technology • LubriZero system with negligible oil consumption • Extremely limited environmental costs • Low-energy motors • Easy and economical maintenance • Absence of warm-up cycles and waiting times • Physical separation between process and mechanical parts • Unrivalled performance in the constant recovery of extracted solvents • Low noise (<70 db) and low operating speed (250 rpm) • Low average working temperatures. • ATEX certification up to zone 0. Innovative by tradition Saurus939_double stage + 2 root
• ATEX DIRECTIVE 94/9/EC. The standard version, CE x II 2G T4/T3, is suitable for installation in an area classified as ZONE 1-GAS and temperature Class T4 (135°C). The Saurus939 special version can be supplied with ATEX certification up to ZONE 0-GAS (internal pump), ZONE 1-GAS (external pump) with three different classes of temperature T4 / T150°C / T3.
Strengths • Complete robustness in any wor k environment • High resistance against corrosion • H i g h r e s i s t a n c e a g a i n s t p o w d e r, condensates and distillation by-products • Continuous recovery of the extracted solvents • Unlimited use over the entire vacuum range
Pushing forward the frontier of innovation every day. This, from the very beginning, has been Italvacuum’s mission, among the world’s leading manufacturers of vacuum pumps and vacuum dryers for the chemical, fine chemical, pharmaceutical and cosmetics industry. Italvacuum is able to realize cutting-edge equipment, particularly suitable for production processes under controlled atmosphere. Top quality, safety and productivity in any application, with a special care for sustainability and total respect for the environment. A reliability guaranteed by an established presence all over the world, with a constantly growing number of installations in both consolidated markets and emerging areas, and by a prestigious collection of national and international patents. In India for vacuum pumps Italvacuum c o o p e r a t e s w i t h E M JAY E n g i n e e r s , consolidated company based in Mumbai and well rooted in the whole country. ◘
Saurus939_single stage
98 • December 2015
Chemical Engineering World
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Live Ch@t with Your vacuum drying specialist us Today! marketing@italvacuum.com | italvacuum.com
response@coleparmer.in Shree Krishna Nagar, Borivali (East)
ColeParmer.in/3125 Brilliant technology Italian quality
4076_CPI_ChemEngineer_SpAd_0515.indd 1
Saurus939: Versatile and long life piston vacuum pump • Uncontaminated vacuum • Operational costs lower than any other vacuum technology
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5/11/2015 3:13:03 PM
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Agent for vacuum pumps
Your vacuum drying specialist marketing@italvacuum.com italvacuum.com
EMJAY ENGINEERS, Mr. Jayant Joshi B/102, Shubh Sarita CHS, Near Shrikirshna Nagar, Appasaheb Sidhaye Marg, Borivali (East), Mumbai 400066 Tel. 02228975275 Mobile 9820047858 E-mail:electromech.engg.entp@gmail.com
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Industrial Solvent Recycling Machines – FORMECO (Italy)
A
lmost all industries, which are using Solvents, face problems of regular purchasing of costly solvents, costly disposal of hazardous /toxic waste (not reusable in production). FORMECO has solved solvents problems in over 50,000 companies worldwide. It is a unique system which helps in protecting environment by reducing handling volume of disposable hazardous/ toxic wastes. Formeco units use the Principal of distillation, which allows the recycling, and reuse of degreasing and washing solvents. Through this simple distillation process, they separate the contaminants (resins, polymers, pigments, paints, oil, etc.,) from original solvents. The condensed solvent is collected in an tank ready for its reuse. The characteristics (composition, purity, concentration, colour, effectiveness etc,) of the processed solvent are not altered by the process which can be repeated indefinitely. Formeco units are compact and skid mounted with complete internal connections of pipes , electrical wires, safety and control systems, etc., It is a factory fitted, tested and ready to use at site, it does not require much space. The distillation cycle is fully automatic. It is available in standard models: capacity 7 litres to 230 litres, with or without scrapper blades. FORMECO – Solvent Recovery Systems (Distillers) allows: • Polluted solvent recycling – immediate reuse of solvents flushed in original production. • Cutting solvent purchasing cost almost to zero.. • Cuts expenses on waste disposal. • S o l ve n t s t o ck i n g r e d u c e s, w h i c h r e d u c e s t h e c h a n c e of accidents. FORMECO - Solvent Recovery Systems are used in various industrial sectors for various applications. FORMECO has been supplying these units in Mechanical, Auto body-shop, Paints, Woodworking, Fiberglass, Metal Works, Electronic, Chemical, Pharmaceutical, Plastic Materials, Gold Smith, Printing and Graphics arts etc. In India our machine aremarketed by M/s Neotech Equipments Pvt, Ltd, and have been installed at all major two wheelers companies and can further find its use in any industry where Industrial Solvents such as Acetons, Xylene, White Spirit, MIBK are wasted on a regular basis. For further details, please feel free to contact us. Case Study: A leading 2 wheeler manufacturer in the country has a daily wastage of Purging solvent, utilised for cleaning of equipments during 100 • December 2015
colour changes to the range of 800 to 900 litres on a daily, Each Litre of Solvent costs them ` 110 ie ` 88000.00 Daily, using FOREMCO’s Solvent Recovery Model D 230 Ax 3-4 Cycles a day they are able to recovery 80 per cent of the waste solvent ie Solvent Worth ` 70,000.00, the machine cost has been recovered by the company within a span of 7 Months, which is a highly attractive R.O.I Period.
For further information, contact our NEOTECH EQUIPMENTS Pvt. Ltd. 401, Gagandeep – 12, Rajendra Place, New Delhi -110008. E: mail@neotechworld.com T: +91 9540062568 W: www.neotechworld.com Chemical Engineering World
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24-12-2015 12:03:43
Marketing Initiative
Progressive cavity pump optimised for the installation space The nature of critical liquids as well as the advancement of production processes are constantly posing new challenges on existing pump technology. Often, gear pumps are no longer sufficient for the dosing and dispensing of such critical liquids. Furthermore, companies are now paying an increasing amount of attention to the optimisation of costs and space-saving properties of a system at the time of purchase. With robots in particular, these properties are especially significant since centrifugal forces during dynamic movements can have an enormous effect on the pumps. Beinlich Pumpen GmbH has developed a progressive cavity pump which is not only optimised in regard to installation space, but is also easy to assemble and handle.
T
he nature of critical liquids as well as the advancement of production processes are constantly posing new challenges on existing pump technology. Often, gear pumps are no longer sufficient for the dosing and dispensing of such critical liquids. Furthermore, companies are now paying an increasing amount of attention to the optimisation of costs and space-saving properties of a system at the time of purchase. With robots in particular, these properties are especially significant since centrifugal forces during dynamic movements can have an enormous effect on the pumps. Beinlich Pumpen GmbH has developed a progressive cavity pump which is not only optimised in regard to installation space, but is also easy to assemble and handle. Gluing and sealing applications set extremely challenging and specific demands on the applied pumps, since exact dosing is essential here. Too much mater ial can cause an uncontrollable time delay in the through hardening process. The components to be glued would potentially not adhere sufficiently or even loosen during transport. Too little material also prevents sufficient adhesion force of the substrate, meaning individual parts will not stick together properly. In addition, spillage or stringing due to excess bonding material can obstruct the machine or result in waste if cosmetic limits are not observed. 102 â&#x20AC;˘ December 2015
Viscosity and pressure can pose problems for the pump When selecting the pump unit, the respective viscosity of the media must be taken into account. Viscosity is known to be dependent on temperature and pressure, whereby some systems which cannot function volumetrically, cannot achieve accuracy. Time/pressure systems are inaccurate because they have to dispense a quantity with pressure Px within a certain time frame. Since pressurised a i r i s c o m p r e s s i bl e a n d v i s c o s i t y i s dependent on the factors named, material to be dispensed is lost due to inaccuracy. This can be expensive for the company when, for instance, gold or silver particles are used. Pumps are often installed in a spacesaving manner, whereby for mini-pumps, the housing is already ver y small and the required system pressure is correspondingly high. With regular startup of the pump in particular, the pressure as well as the flow rate must be built up very quickly. Highly viscous media make for high friction losses, however, meaning high inlet pressures are not uncommon. Some shear-sensitive materials separate,
thereby losing their proper ties. Often, these media must be transported through tight profiles or dispensing needles and vo l u m e - o p t i m i s e d l i n e s . T h e m a r ke t expects sturdy and long-lasting solutions for the exact dosing of such media. The principle of the progressive cavity pump Progressive cavity pumps work with a displacement system in which a helix is installed. The slope of the helix edges and the excenters are the most important p a ra m e t e r s h e r e. W i t h r e g a r d t o t h e displacement pump based on the helix, the rotor/stator principle is relevant, whereby displacement is endless and continuous. If the rotor rotates within the stator, a vacuum is created through which media are sucked according to their viscosity. An exactly-defined chamber or cavity forms according to the slope of the edges. The counterpart (stator) must have double the slope so that the helices can rotate and a cavity can form. If the cavity is filled with a medium, this medium must be exactly dispensed by the rotating movement of the edge surfaces both forwards and backwards, according to the direction of rotation. Chemical Engineering World
Körting Hannover AG
Agent for vacuum pumps
30453 Hannover/Germany Tel.: +49 511 2129-258 st@koerting.de Your vacuum drying specialist
EMJAY ENGINEERS, Mr. Jayant Joshi B/102, Shubh Sarita CHS, Near Shrikirshna Nagar, Appasaheb Sidhaye Marg, Borivali (East), Mumbai 400066 Tel. 02228975275 Mobile 9820047858 E-mail:electromech.engg.entp@gmail.com
www.koerting.de marketing@italvacuum.com italvacuum.com
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Marketing Initiative motors without transmissions can be assembled, thus reducing the weight and the installation length.
Pressure and installation space optimisation through adapted geometries The potential disadvantages of previous displacement pumps and progressive cavity pumps in particular are primarily the installation lengths and the joint used. Since the progressive cavity pumps have to convert an excentric movement, a corresponding space is needed in the pump housing. A long joint requires a large volume of the suction housing and must be especially sturdy to transmit the necessary force. B e i n l i c h P u m p e n w o r k e d t o p e r fe c t the geometr ies of the pump and the compensation of the inlet pressure in p a r t i c u l a r w h e n d eve l o p i n g t h e n ew VISCO.pump ® progressive cavity pump. The objective of this development was and is considerably reducing the installation space and thereby introducing a light and space-saving product onto the market. With the adaptation of the rotor and stator geometries, Beinlich has already managed to design the VISCO.pump ® to be significantly smaller than earlier systems. This makes the progressive cavity pump particularly well-suited for use in small dosing robots, since the centrifugal forces in fast, dynamic traverse paths cannot influence the pump. Moreover, the wall thickness of the rubber must be adapted to the counterpressure so that the pump can function at optimal pulsation. The adapted geometry of the displacer reduces the necessar y starting torque, whereby small, dynamic 104 • December 2015
Dosing accuracy and simplicity of the application saves money The newly developed VISCO.pump ® is able to accurately dispense liquids and pastes with up to 60% filler content, whereby the exter nal integration of the dosing pump is made possible independently of pressure regulators.
dam-and-fill processes, underfilling, for sealing housings, greasing motor shafts, applying cooling paste on chips or for dispensing PU. The development of the VISCO.pump ® together with the range of proven gear dosing pumps makes Beinlich Pumpen an expert supplier and forerunner of solutions for your dosing needs.
The dosing quantity can be set to be absolutely linear; the standard deviation (as per 6σ) of dosing accuracy as well as repeatability is ± 1% and less. An absolutely precise cavity as well as the optimal volumetric efficiency factor of the dosing pump enable a "Plug&Go" control s y s t e m . T h i s c o n s i d e ra bl y fa c i l i t a t e s operation and handling for the user, which also reduces costs for installation and commissioning. The VISCO.pump ® can be used anywhere, even if existing systems have to be modified. Recognition due to corporate design In addition to the optimisation of the i n d i v i d u a l c o m p o n e n t s, B e i n l i c h h a s focused on creating a corporate design for the pump, as this is a decisive factor for the recognition value of the pump and the company. As a rule, competing products look similar, since the core components are designed in a similar fashion when all physical characteristics are already known and have been exhausted. Beinlich Pumpen therefore made it its mission to develop an ergonomic design and adapt the colours to fit the company image. Application areas of the technology The newly-developed pump can be used in many areas of industry. It is principally designed for precise dosing, such as bead and dot dispensing as well as filling cavities. Fur thermore, it is well-suited for adher ing magnets for motors and loudspeakers, for LED strips, glob topping,
For further information, contact our BEDA FLOW Systems Pvt. Ltd. W-7, Sector-XI, Noida -201301 E: info@bedaflow.com M: +91-9871842066 Work: 0120-4329990 F: 0120-4080022 W: www.bedaflow.com Chemical Engineering World
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Get an Appropriate Drying Solution .......from Toshniwal
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ffective drying is often the crucial step in many operation. In a simple terms, these are just two conditions for drying methods - atmospheric and vacuum. Atmospheric Drying Toshniwal Mixer cum Dryer is a modification of the mixer design into a drying unit. It is especially suitable for powder products, granulates and filter cakes. The product is dried by mixing energy and product in the best possible way. The mechanical fluidisation ensures that all particles are surrounded by the drying medium (cold/ warm/ hot air, inert gas etc.) and an effective transmission of energy occurs. Moisture is thereby extracted from the product. The reliable and repeatable process gives the same perfect quality product for each batch. Open System: The drying system is designed as an open system where the ambient air is blown in to the drying system. The air is warmed up in a heater then blown into the drying chamber and the hot air is inserted on both side towards the paddles in the dryer. The paddles will bring the air through the material in the fluidized zone where the particles can be lifted and create a larger surface area which will increase the drying rate. The moist air will be blown out of the dryer with fine particles which are then collected in the filter bags, which is kept in the exhaust side of the dryer. Close System : Heated air is blow into the mixer and mixed with moist product. During the heat exchange, the moisture will evaporate from the product which makes Moist air passes through the filter before it is sucked into the fan. The air is thereafter blown through the cooler for condensation before it is reheated. When drying moist products the wet product is mixed with dry product 106 • December 2015
as to ensure the fluidisation and the high drying rate. Advantages : • No local overheating • No local overdrying • Gentle drying • Low drying temperature possible • Good correlation between product temperature and exhaust temperature • The integrated mixing technology always ensures a homogeneous batch Vacuum Drying Process The drying operation will be carried out at low temperature under vacuum, it is economical and efficient especially for dying sensitive material. A. Toshniwal Paddle Vacuum Dryer The Toshniwal Single/ Double Paddle Vacuum Dryer is a cylindrical jacketed vessel with central Shaft having specially designed blades. These blades are designed to create efficient homogeneous mixing of the ingredients and also for all particles come in contact with the heated surface. B. Orion Rotary Cone Vacuum Dryer The Orion Double Cone Vacuum Dryer is completely jacketed and heat transfer fluid (either hot water or oil, stream or vapour) is circulated throughout the jacket to meet various Industrial Drying requirement for temperature sensitive materials. The heat source (for example, low pressure steam or thermal oil) pass through the sealed jacket. The heat will be transmitted to raw material to be dried through inner shell. Under driving of power, the tank is rotated slowly and the raw material inside it is mixed continuously. The purpose of reinforced drying can be realized. The raw material is under vacuum. The drop of steam pressure makes the moisture
(solvent) at the surface of raw material become saturation and will evaporate. The solvent will be discharged through vacuum pump and recovered in time. The inner moisture (solvent) of raw material will infiltrate, evaporate and discharge continuously. The three processes are carried out unceasingly and the purpose of drying can be realized within a short time. Advantages • Low Product temperature with vacuum for low temperature product drying • No oxidation while drying. • No dust development with powdery product • Reduced hazard of explosion • Large drying surface Features • Lowest energy consumption compared to any other batch type dryer due to high differential temperatures. • High Thermal Efficiency. • Heating Temp: From 30° C to 350° C • Shear Maker is provided for delumping /deagglomeration. Guidelines to select the appropriate, Toshniwal Drying equipment by studying the operational parameter as atmosphere/ vacuum drying is as follows. Conclusion : A unique opportunity for the Test Facility in Toshniwal’s Drying equipment are available, Hence the customer can be able to determine the processing advantages and efficient of the equipment without large commitments of research and development funds. For more information Toshniwal 267 Kilpauk Garden Road Chennai - 600010 T: +91 44 26445626 /8983 E: sales@toshniwal.net W: www.toshniwal.net Chemical Engineering World
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We have QC Solution in • Automated Measurements • Layer Thikness Measurements • Surface Smoothness • Count, Measure, Track • Scratch Detection • Measure Taper • Drills, Contouring • Dimensions (LxWxH) • CAD Comparison • Colour Coding / Recognisation
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For further information, contact our 187, G/Block, 1st Floor, Thermax Chowk, MIDC Above Renault Showroom, Chinchwad, Pune - 411019 T: +91-2066304033 M: +91-8551091333 E: sales@nihva.com W: www.nihva.com Chemical Engineering World
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Peristaltic Hose Pump
Ferolite, an ISO/TS 16949:2009 and ISO 14001:2004 company, is India’s No: 1 manufacturer of compressed asbestos, non-asbestos jointing gasket sheets and gland packings as per National and International Quality Standards at its state-of-the-art plant located in Ghaziabad. Ferolite is supplying its products to all the process industries (refinery and petrochemicals, oil and gas, chemical, fertilizers, paper, sugar, power, engineering) and OEMs such as pumps, valves, compressor manufacturers, etc, and having Regional Offices in all metro cities with nationwide dealer network. The company is also exporting sheets and gland packings all over the world.
Moniba Anand Electricals offers peristaltic hose pump (with supported hose) in the capacity range of 20 to 30,000 LPH, head range of 40 metres and more, and electrical motor of 0.5 to 10 HP for transferring liquid, paste, viscous liquid, abrasive and corrosive liquid in almost every industry including fruit salad, dairy product, paper and pulp, animal feed, bentonite, lime wash, manure slurry, rubber latex, etc. Hose tube is suitable for liquid where the end connector is in SS-316/PP/UHNW titanium and outer casing of CI/aluminum roller SS-316 with bearing bush/ball bearing. It is a self-priming, seal less, good for slurry pump with capability of running dry where hose tube is the only item that comes in contact with the liquid and can handle solids too. It has a reversible rotation to clean the pipe line and the pump.
For details contact: Ferolite Jointings Ltd C-178. Site-1, Bulandshahr Road Indl Area Ghaziabad, Uttar Pradesh 201 001 Tel: 0120-4051500, 2702655 | Fax: 91-0120-2701002, 4051550 E-mail: dgmsales@ferolite.com / sales@ferolite.com vp@ferolite.com
For details contact: Moniba Anand Electricals Pvt Ltd 5 Saphire Bldg, Tirupati Park Opp: Professional Couriers, Sativalli Road, Village: Waliv Tal: Vasai (E), Dist: Thane, Maharashtra 401 208 Tel: 0250-6450425, 6450426, 6450427 E-mail: moniba83@gmail.com
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Magnetic Drive Pump KBL offers magnetic drive pumps - ROMAK Pump Series. This includes ROMAK (RMK) process pumps that are used for handling various types of clear/clean chemical liquids without any suspended particles by various process industries. RMK pump is magnetic drive pump comprising permanent magnets. A magnetic drive pump uses a balanced magnetic field to create the rotation of the fluid impeller. A mag-drive pump eliminates the direct drive mechanism and replaces it with a magnetic field. Magnetic drive pumps can be easily substituted for DIN/ISO pumps without modifications at sites. Moreover, they have a lower life cycle cost compared to solutions with double mechanical sealed pumps. RMK are available in different sizes varying between 32 to 100 mm with a total discharge capacity of up to 300 m 3/hr. They are made for various applications in process industries and handling liquids which have a temperature between -50 to +180 oC. The Series has total 22 models in innovative designs. ROMAK pumps have a centerline delivery with self-venting. The back pullout type design makes the installation of these pumps easy. These pumps are designed for suction pressure 5 kg/cm 2. These magnetic drive pumps have a leak-proof coupling between the motor and the pump body. This in turn reduces the need for unexpected shutdowns. For details contact: Kirloskar Brothers Ltd Global Headquarters Yamuna, Survey No: 98/(3-7), Baner, Pune, Maharashtra 411 045 Tel: 020-27214444 or Circle Readers’ Service Card 3
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Products CEW Intelligent AutoCAD-based 3D Plant Design Solution Intergraph Process, Power & Marine (PP&M), part of Hexagon offers CADWorx 2016, an AutoCAD-based intelligent 2D and 3D plant design system, features significant enhancements including capabilities for greater control of material assignment at the specification level, management of all specification content across all versions, the ability to facilitate the use of highly specialized components with combination of different end-types and much more. Intergraph CADWorx & Analysis Solutions’ offerings allow design and engineering to share relevant information seamlessly, thereby maintaining accuracy and improving efficiency. These include CADWorx Plant Design Suite, for AutoCAD-based intelligent plant design modeling, process schematics and automatic production of plant design deliverables; CADWorx DraftPro, a free solution for intelligent 2D design and layout; CAESAR II, the world’s most widely used pipe stress analysis software; PV Elite, for vessel and exchanger design and analysis; TANK, for the design and analysis of oil storage tanks; GT STRUDL, one of the most trusted, adaptable and fully-integrated structural analysis solutions in the world; and Visual Vessel Design, a comprehensive pressure vessel, shell and tube exchanger, and boiler design and analysis solution. For details contact: Intergraph Corp 19 Interpro Road, Madison, AL 35758, U.S.A. E-mail: jerry.felts@intergraph.com or Circle Readers’ Service Card 4
Retractable Sensor Housings Mettler Toledo has developed the InTrac 781/784 Series of retractable sensor housings, which are designed to tolerate extreme process conditions. They combine rugged design with installation versatility and ease of use to meet the demands of chemical, petrochemical, pulp and paper or utilities applications. An intelligent locking system ensures operating safety at all times. Without the presence of a sensor the housing’s insertion rod cannot be deployed into the process. And the locking system makes it possible to remove the probe only when the insertion rod is fully retracted. This avoids any unintended sensor removal when it is in the measuring position. InTrac781 and 784 housings allow sensor maintenance and exchange without any interruption to the running process. The SS version of the housing allows sensor deployment or retraction in up to 16 bar with no compromise to operator safety. Four spray nozzles ensure thorough cleaning of the sensor tip, and the large chamber bore size means dirt and particles are thoroughly flushed out. Operation with Mettler Toledo’s EasyClean systems is possible for fully automatic sensor cleaning, flushing and calibration (for pH sensors). Wetted parts are available in different materials (SS 1.4404, Alloy C-22, polymer PP, PEEK or PVDF), offering suitability with a wide range of applications. Various immersion lengths and type of process connection are also available. The new housings meet major International Standards including installation in ex-classified area and pressurized equipment directive (PED 97/23/EC) requirements. For details contact: Mettler-Toledo India Pvt Ltd Amar Hill, Saki Vihar Road, Powai, Mumbai 400 072 Tel: 022-42910111 Extn: 256/115 or Circle Readers’ Service Card 5
Chemical Engineering World
December 2015 • 111
CEW Products Butyl Rubber Sheet
Digital Differential Pressure Transmitter
Butyl rubber has low permeability to air and other gases. It has excellent resistance to ozone, oxidation and sunlight, with an excellent temperature range of -45 to 120 oC, Butyl has a low resilence, which makes it ideal for vibration damping and shock absorption applications but offer a moderate resistance to abrasion and compression set. With careful compounding, butyl compound can be made to acquire good tensile strength. It is resistant to most mineral acids and alkaline. Kiran Rubber Industries do not recommend its use to application where resistance to oil and hydrocarbon is required. The company can offer halogenated butyl rubber sheets for spcified applications.
DDPT-10.0-XXIS designated for measuring differential pressures in the air and in nonaggressive gases. The transmitter can be applied in the fields of pneumatics, process engineering and building engineering. As a result of completely digital realisation it is possible to change over the measuring ranges and to return to zero position after installation. Thus offset errors can be compensated by position of installation. The transmitter can be delivered with or without 4 place LCD display. The range of values is freely selectable. The access to data in digital form is possible optionally and up to 120 transmitters of this Series can be operated with one bus. Connection is made by bus coupler modules. Further measuring values are available in the digital Series.
For details contact; Kiran Rubber Industries 135 Shiv-Krupa Indl Estate LBS Road, Opp: Raj Legacy Vikhroli (W), Mumbai 400 083 Tel: 022-42637400 | Fax: 91-022-22-7499 E-mail: info@kiranrubber.com or Circle Readers’ Service Card 6
For details contact: Jupiter Electronics A-401 & G-414-416 Kailash Indl Complex B/h Godrej Colony, Parksite, Vikhroli (W), Mumbai 400 079 Tel: 022-67551606, 25185464 | Fax: 91-022-25170867 E-mail: sales@jupiterelectronics.co.in or Circle Readers’ Service Card 7
Model Development Process Maplesoft offers MapleSim, an advanced system-level modeling and simulation platform, together with important updates to many of the specialized component libraries and connectivity tools in the MapleSim family of products. The latest release provides a variety of new features that further support the creation, simulation and analysis of multidomain, system-level models. Enhancements include advanced diagnostic tools, expanded component libraries and other improvements requested by customers. The advanced diagnostic tools help engineers identify the source of problems in their models and simulations, and improve their model’s efficiency and robustness. Other improvements include the addition of over 50 new components in the magnetic, thermal, electrical, and signal block libraries, and a new connections manager that makes it easier to keep track of connections and port variables, and allows new types of connections to be made. Improvements were also made to many of the other members of the MapleSim family of modeling and simulation products. The specialized component libraries for batteries, drivelines, and tires provide improved modeling power and scope. As well, toolchain connectivity has been enhanced with improvements to the MapleSim Connector, for connectivity with Simulink, and the MapleSim Connector for FMI, which allows engineers to share high-fidelity, multidomain models created in MapleSim with other modeling tools. Both connector products now provide more detailed run-time error reporting to assist in trouble-shooting on the target platform. As part of this release, Maplesoft has also introduced a new product, the MapleSim CAD Toolbox, which helps engineers understand and improve their mechanical designs by making it easy to import CAD models directly into MapleSim and understand how they behave as part of a larger system. For details contact: Maplesoft 615 Kumpf Drive Waterloo, ON N2V 1K8 Canada or Circle Readers’ Service Card 8
112 • December 2015
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ChemTECH Gujarat 2016 Dates: 10-12 February, 2016 Venue: Ahmedabad, India Details: World meet of chemicals, petrochemicals, pharma and process industry in India encompassing exhibition and conferences. Contact: +91 22 40373636 Email: sales@jasubhai.com Website: www.chemtech-online.com
India Chem 2016 Dates: 1-3 September, 2016 Venue: Bombay Exhibition Centre, Mumbai Details: Event of chemicals and petrochemicals industry in India in its 9th edition Organiser: FICCI Contact: +91 22 2496 8000 Email: vishal.ganju@ficci.com Website: www.indiachem.com
20th Annual ARC Industry Forum Dates: 8 - 11 February, 2016 Venue: Orlando, USA Details: Discover what companies are doing to prepare for the new age of industrial innovation and how they expect to improve their business performance by doing so. Organiser: ARC Advisory Group Contact: +1 781-471-1175 Email:pking@arcweb.com Website: www.arcweb.com
Best Practices for Chemicals Dates: 14-16 March 2016 Venue: Texas, USA Details: The premier industry conference for organizations using SAP. Organisers: SAP, The Eventful Group and ASUG Contact: +1 877 411 4675 Email: sarah.carr@theeventfulgroup.com Website: www.sapforindustries.com
Chemspec 2016
ORPEC 2017
Dates: 7-8 April, 2016 Venue: Bombay Exhibition Centre, Mumbai Details: Meeting and networking with existing and potential partners and business facilitators Organiser: Quartz Businesss Media Ltd, Contact: +91 22 240 44472 Email: rohit@chemicalweekly.com Website: www.chemspecevents.com
Dates: 13-15 May 2017 Venue: Muscat, Oman Details: Designed to deliver key buyers to Oman’s growing refining and petrochemical industries creating a forum aligned with the government’s growth plans Organiser: OMANEXPO LLC Contact: Mr Ebrahim Taher Email: info@omanexpo.com Website: www.omanexpo.com
Automation 2016
The 2016 Automation Summit
Dates: 22 - 25 August 2016 Venue: Bombay Exhibition Center, Mumbai Details: Automation 2016, a four day automation event is set to introduce new and upcoming technology this year Organiser: IED Communications Ltd Contact: 91 22 22079567 Email: jyothi@iedcommunications.com Website: www.iedcommunications.com
Dates: 27-30 June, 2016 Venue: Las Vegas, USA Details: Siemens Automation Summit – A User Conference. All areas of industrial automation will be covered including factory, process, motion, and drives. Organiser: Siemens Industry, Inc Contact: +1 800 241 4453 Email: rich.chmielewski@siemens.com Website: usa.siemens.com/summit
Chemical Engineering World
December 2015 • 113
CEW Project Update
New Contracts/Expansions/Revamps The following list is a brief insight into the latest new projects by various companies in India. • CHEMICALS Globex Laboratories (R&D) proposes a pigments manufacturing unit at village: Dabhasa, district: Vadodara, Gujarat. According to MoEF sources, the project will come up in the existing land on 9,312 sq m. Kadam Environmental Consultants, Vadodara is the environmental consultant. The project will entail manufacture of 40-TPM red pigments, 40-TPM yellow pigment and 450-TPM dilute phosphoric acid. Environment clearance has been obtained for the products – red pigments and yellow pigments. Construction work has begun, as EC and NOC have been received. Effluents generated will be treated in effluent treatment plant having MEE. The company has applied for Amendment in Environmental Clearance dated 26th September 2012 for change in fuel from LDO to agro waste briquettes and addition of one raw material, ie, phosphoric acid and generation of dilute phosphoric acid (25 per cent basis) as by-product. Bohra Industries is implementing an expansion of its chemical and fertilizer manufacturing unit at Umarda, district: Udaipur, Rajasthan on 14,500 sq m of existing land. The project will entail expansion of single super phosphate capacity from 400-TPD to 600-TPD, granulated super phosphate from 200-TPD to 300-TPD and addition of new products namely 150-TPD triple super phosphate, 550 - TPD synthetic gypsum, 30-TPD di-calcium phosphate, 160-TPD phosphoric acid, 0.3-TPD potassium fluoride, 150-TPD H2SO4 and 0.3-TPD Sodium Tri Polyphosphate (STPP). Machinery has been ordered from China. Civil work is in progress. The project is scheduled for completion in 2018. Ami Lifesciences proposes expansion of its synthetic organic chemicals manufacturing unit (viz, pharmaceutical bulk drugs and drug intermediates) from 65.70-TPM to 131.60-TPM in Padra, district: Vadodara, Gujarat.The estimated cost of the project is ` 87.046-million. Environmental Consultant to this project is Envisafe Environment Consultants. According to MoEF sources, total plot area is 23,760-sq m (existing 10,270-sq m and 13,490-sq m for expansion). The unit currently manufactures 2-TPM 1-Acetyl Naphthalene, 1-TPM 2-Acetyl Naphthalene, 6-TPM itopide HCl, 1.20-TPM loxapine succinate, 0.30TPM amoxapine, 6-TPM venlafaxine, 6-TPM progunil HCl, 6-TPM CB-2-L-Valine, 0.60-TPM nateglinide, 0.60-TPM quetiapine, 24-TPM carbomazepin and 12-TPM oxacarbomazepin. The expansion will involve addition of new products. Water requirement from ground water source will be increased from 34.53-cu m/day to 181-cu m/day after expansion. Effluent generation will be increased from 9.35-cu m/day to 79.5-cu m/day after expansion. Highly concentrated effluent will be sent to captive incinerator for incineration. Remaining effluent (70-m3/day) will be treated in the ETP comprising primary, secondary and tertiary treatment. Treated effluent will be sent to CETP for further treatment. ETP sludge, inorganic residue and incineration ash will be sent to TSDF. Spent carbon, organic residue will be sent to incinerator. 114 • December 2015
Adi Finechem is planning a 40-TPA specialty products manufacturing project on a 2-acre land at an estimated cost of ` 400-million in village: Chekhala, district: Ahmedabad, Gujarat. The project is waiting for environmental clearance. RSPL is planning a 1,500-TPD soda ash plant and 40-MW captive power project in village: Kuranga, district: Jamnagar, Gujarat. Land acquisition is in progress. 85 per cent of land has been acquired. The project is waiting for environmental clearance. The entire project is planned for completion in 5 years from zero date. Superhouse is planning an expansion of its chemical mixmanufacturing project from 200-kg/day to 500-kg/day in UPSIDC Industrial Area, district: Unnao, Uttar Pradesh. The product will be used in leather tanneries. The project will involve installation of containers. The project is in planning stage. Stellar Chemical Laboratories is planning an expansion of its organic chemical manufacturing project from 7.1-TPM to 84.1-TPM in village: Derol, district: Panchmahals, Gujarat. Machinery is yet to be ordered. Work on the project is expected to commence after receipt of environmental clearances and the completion date is yet to be finalized. • MINING Aryan Ispat & Power is planning an expansion of its coal washery in village: Bamoloi, district: Sambalpur, Odisha. The project will come up in the existing 204.65-acre integrated steel plant premises. The capacity of the project is to be augmented from 0.70-MTPA to 5.70-MTPA. The cost of the project is ` 600.7 million. The project is awaiting environmental clearance and planned for completion in 1-year from zero date. According to MoEF sources, the expansion is based on heavy media cyclone (wet process) technology. The washery will produce washed coal of an average ash around 34% (GCV 4,350-Kcal/kg), middling (ash content about 58%) of GCV around 2,350-Kcal per kg useable as fuel in FBC boilers. The proposed expansion will be the state-of-the-art with close circuit water system, classifying cyclone, high frequency screens, thickener and multi-roll belt press filters. Power requirement of 5-MVA will be sourced from its own power plant connected with the Grid Corporation of Odisha. NTPC is planning the Kudanali-Luburi coal mining project in district: Angul, Odisha. The company has signed an agreement on June 15, 2015 with Jammu and Kashmir State Power Development Corporation (JKSPDCL) for promoting a joint venture company with 67:33 equity participation for undertaking exploration, development and operation of jointly allocated Kudanali-Luburi Coal Block at Odisha by the Ministry of Coal. Chemical Engineering World
Project Update CEW DSP Associates is planning a 15,17,600-TPA sand (minor mineral) mining project in the mines of Tikola-1 Sand Unit at village: Tikola, district: Gurgaon, Haryana. Mining lease area is 42.50-hectare. The estimated cost of the project is ` 55-million. The project is waiting for environmental clearance. Mining work is expected to commence soon. According to MoEF sources, out of the total area, 31.50-hectare area falls in the river bed and 11-hectare area falls in agricultural land (outside river bed). Method of mining will be opencast semi-mechanized without drilling and blasting. The mine will be excavated out in layers up to a depth of 3-m in riverbed and 9-m in agricultural field. Letter of Intent (LOI) for mining contract has been granted for a period of 9 years. Barmer Lignite Mining Company, a JV between Rajasthan State Mines & Minerals and Raj West Power, a subsidiary of JSW Energy is planning an expansion of the Kapurdi Open Cast Lignite Mining project from 3.75-MTPA to 7-MTPA in Kapurdi, district: Barmer, Rajasthan at an estimated cost of ` 18,000-million inclusive of a new lignite mining project at Jalipa mines. The project is waiting for environmental clearance. â&#x20AC;˘ NON-CONVENTIONAL ENERGY Hubli Electricity Supply Company is planning solar RTPV grid connected power plants in district: Belagavi, Karnataka. E-tenders have been floated to design, manufacture, supply, installation, testing and commissioning of solar RTPV grid connected power plants on the roof-tops of 31 of HESCOM office buildings in Belagavi Zone Jurisdiction for total load of 136-KWp including operation and maintenance for a period of five years. The approximate amount put to tender is ` 18.62-million. Karnataka Renewable Energy Development is planning a 10-MW solar power project at an estimated cost of ` 600-million (approximately) in village: Tingloor, taluka: Madhugiri, district: Tumkur, Karnataka. Surana Telecom And Power has received Letter of Award (LoA) for development of the project. Maharashtra State Power Generation Company is planning a 50-MWp solar photo voltaic power project in Gangakhed, district: Parbhani, Maharashtra. The company is scouting for land. Other details are yet to be finalized. Azure Power India is implementing a 10-MW solar photovoltaic power project in taluka: Hiriyur, district: Chitradurga, Karnataka. PPA has been signed with Bangalore Electricity Supply Company (BESCOM). Civil work and panel installation work is in progress.
Government of Odisha is planning a 20-MW solar power plant in Manmunda, district: Boudh, Odisha. Green Energy Development Corporation of Odisha is the nodal agency. According to reports, the nodal agency has identified about 120-acre of land at Manmunda for establishment of the project. The land has been allotted to the agency from the industrial park area earmarked by Odisha Industrial Infrastructure Development Corporation (IDCO).The EPC tender is for development of the power plant and maintenance for a period of 10 years. Apart from the Boudh project, the agency is in the lookout for additional land in Koraput, Kantamal and Bolangir areas for installing about 200-MW solar energy capacity.
ACME Solar Energy is planning a 30-MW solar photovoltaic independent power project at a cost of ` 2.4-billion in Chhattisgarh. The company is a JV between ACME Cleantech Solutions, EDF Energies Nouvelles (EDF EN) and EREN, Luxembourg. PPA is yet to be signed with Chhattisgarh State Power Distribution Company (CSPDCL). The project is in planning stage. The project is planned for completion in 1-year from zero date. Chemical Engineering World
December 2015 â&#x20AC;˘ 115
CEW Ad Index Sr. No.
Client’s Name
Page No
Sr. No.
Client’s Name
Page No
19
20
Horiba India Pvt Ltd
Inside Cover I
21
Horizon Polymer Engineering Pvt Ltd
Avians Innovations Technology Pvt Ltd
49
22
HRS Process Systems Ltd
4
Beda Flow Systems Pvt Ltd
83
23
ImageGrafix Engineering Services Pvt Ltd 111, 113, 115, 117
5
Bonfiglioli Transmissions Pvt Ltd
41
24
IMI Norgren Herion Pvt Ltd
55
6
Busch Vacuum India Pvt Ltd
73
25
Impart International Pvt Ltd
51
7
Cole-Parmer India
97
26
Indo Seals Pvt Ltd
89
8
CRI Pumps Pvt Ltd
79
27
Integral Process Controls India (P) Ltd
67
9
Dalal Engineering Pvt Ltd
17
28
International Combustion (India) Ltd
95
10
Dow Chemical International Pvt Ltd
Back Cover
29
Kevin Enterprise Pvt Ltd
37
11
Economy Refrigeration Pvt Ltd
11
30
Kirloskar Brothers Ltd
12
Emjay Engineers
91
31
KSB Pumps Ltd
25
13
Evergreen Technologies Pvt Ltd
47
32
Lubrizol Advanced Materials India Pvt Ltd
59
14
Ferolite Jointings Ltd
105
33
Mazda Ltd
99
15
Garlock India Pvt Ltd
27
34
Moniba Anand Electricals
95
16
GEA Process Engineering (India) Pvt Ltd
9
35
Nhiva Technologies Pvt. Ltd
13
17
Goodie International Pvt Ltd
85
36
Neotech Equipment Pvt Ltd
103
18
Hanna Instruments Equipments (I) Pvt Ltd
91
37
Paharpur Cooling Tower
31
19
Hi-tech Applicator
3
38
Parth Enterprises
93
1
Alfa Laval (India) Ltd
2
Atomic Vacuum Company (Exports)
3
116 • December 2015
101 7 & 62,63 5
Inside Cover II
Chemical Engineering World
Ad Index CEW Sr. No.
Client’s Name
Page No
39
Polyplast Chemie Plants (I) Pvt Ltd
77
40
PPI Pumps Pvt Ltd
99
41
Premium Transmission Ltd
35
42
Proactive Engineering Services
23
43
R K Dutt Concerns
44
Rasaii Flow Lines Pvt Ltd
81
45
Rathi Transpower Pvt Ltd
61
46
Ravel Hiteks Pvt Ltd
47
Ross Process Equipment Pvt Ltd
43
48
Samarth Engineers
93
103
103 It is time to Migrate to an advanced Structural Analysis Software
Easy User Interface Conformancee to nuclear industry QA/QC - NRC
49
Shanbhag & Associates
35
50
Sinocalci (India) Technology Pvt Ltd
15
Integration with smartPlant 3D / Tekla / STAAD.Pro Validation & veri�cation for more than 5000+test problems Base plate modeling & analysis
51
SPX Flow Technology (India) Pvt Ltd
71
Linear and Non linear Static-Dynamic analysis Steel Frame & reinforced concreate design
52
Suraj Ltd
97
53
SYP Engineering Company Pvt Ltd
53
54
ThyssenKrupp Industrial Solutions (India) Pvt Ltd
65
55
Ultrafilter (India) Pvt Ltd
89
56
Uni Klinger Ltd
75
CIS/2 analysis data interface Comprehensive & detailed user documentation Offshore structure analysis & deisgn
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UNP Polyvalves (India) Pvt Ltd
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December 2015 • 117
CEW Book Shelf Hazardous Waste Management Authors Price Pages Publisher
: Michael D LaGrega, Phillip L Buckingham, Jeffrey C Evans : USD 130.39 : 1232 (Hardcover) : Waveland Pr Inc
About the Book :Hazardous waste management is a complex, interdisciplinary field that continues to grow and change as global conditions change. Mastering this evolving and multifaceted field of study requires knowledge of the sources and generation of hazardous wastes, the scientific and engineering principles necessary to eliminate the threats they pose to people and the environment, the laws regulating their disposal, and the best or most cost-effective methods for dealing with them. Written for students with some background in engineering, this comprehensive, highly acclaimed text does not only provide detailed instructions on how to solve hazardous waste problems but also guides students to think about ways to approach these problems.
Welding: Principles and Applications Author Price Pages Publisher
: Larry Jeffus : USD 124.44 : 976 (Hardcover) : Cengage Learning
About the Book : Now nearing its 30 th year of publication, Welding: Principles & Applications (WP&A), 7 th Edition is the authoritative introduction to the subject of welding. It’s designed for students in a wide range of academic and workforce training programs who want to pursue careers as skilled welders and welding supervisors. The text also supports the needs of learners who need to achieve a basic level of proficiency in welding in their chosen skilled trade. While covering the procedural and safety information all students need, Welding: Principles & Applications also explains underlying theories. The combination of hands-on information with clear explanations of theory is a hallmark of this book. The depth of coverage allows it to be used as the core text in a multi-course welding curriculum, generally starting with shielded metal arc welding, and then covering other basic processes and more advanced techniques.
Industrial Gases Processing Editors & Translators Price Pages Publisher
:Heinz-Wolfgang Häring, Christine Ahner : USD 151.18 : 310 (Hardcover) : Wiley-VCH
About the Book : Almost every modern manufacturing process relies on industrial gases, and sales of such gases are expected to rise by around 45 per cent over the next five years. Here, experienced and authoritative experts from one of the two world’s largest producer of industrial gases impart their knowledge on atmospheric, noble and synthesized gases, carbon dioxide, LNG, acetylene and other fuel gases, as well as special and medical gases. Modern applications, eg, the use of hydrogen in fuel cells, are included as well. This practical text is rounded off by a section on logistics. 118 • December 2015
Air Pollution Control: A Design Approach Authors Price Pages Publisher
: C David Cooper, F C Alley : USD 80.41 : 839 (Hardcover) : Waveland Pr Inc
About the Book : A 25-year tradition of excellence is extended in the Fourth Edition of this highly regarded text. In clear, authoritative language, the authors discuss the philosophy and procedures for the design of air pollution control systems. Their objective is twofold: to present detailed information on air pollution and its control, and to provide formal design training for engineering students. New to this edition is a comprehensive chapter on carbon dioxide control, perhaps the most critical emerging issue in the field. Emphasis is on methods to reduce carbon dioxide emissions and the technologies for carbon capture and sequestration. An expanded discussion of control technologies for coal-fired power plants includes details on the capture of NOx and mercury emissions. All chapters have been revised to reflect the most recent information on U.S. air quality trends and standards. Moreover, where available, equations for equipment cost estimation have been updated to the present time. Abundant illustrations clarify the concepts presented, while numerous examples and end-ofchapter problems reinforce the design principles and provide opportunities for students to enhance their problemsolving skills. Chemical Engineering World
R.N.I. No. 11403/1966 Date of Publication: 29 th of every month. Postal Registration No: MCS/095/2015-17 Posted at Patrika Channel Sorting Office, Mumbai 400001, on 29th & 30th of every month. Total Pages No.: 120
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