Chemical Engineering World November 2019

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Contents CHEMICAL ENGINEERING WORLD RNI Registration No. 11403/66 Chairman Publisher & Printer Chief Executive Officer

Maulik Jasubhai Shah Hemant K. Shetty Hemant K. Shetty

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Xylem Water Solutions India Pvt Ltd -Bengaluru pH Correction of Cooling Water & Effluent Water: Comparison between Lime and Caustic Soda

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The Growth of an Organization is Not Only about the Leadership at Top, But across All Levels Ranjit Lala, Managing Director, Aerzen Machines (India) Pvt Ltd

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CEW News Vaisala Added Potential for Smart Industries by Bringing New Smart Probes for Dew Point and Moisture in Oil Measurement Vantaa, Finland: Vaisala – a g l o b a l l e a d e r i n w e a t h e r, environmental, and industrial measurements – has recently launched six new smart probes for its Indigo product family, optimized for demanding industrial applications. New options for dew point and moisture in oil measurements bring more possibilities for industries to save energy, optimize processes, and improve product quality. The new probes will improve customers’ process efficiencies by providing accurate and reliable measurement data for their industrial processes. The capabilities of the new probes are based on next-generation sensor technologies. The new Vaisala DRYCAP Dew Point and Temperature Probes DMP5, DMP6, DMP7, and DMP8 are optimized for low humidity and high temperature or pressurized environments. Dew point measurements are particularly important in various industrial drying applications, for example in ovens and compressed air systems. The dew point probes include Vaisala’s DRYCAP sensor, which is immune to particulate contamination, water condensation, oil vapor, and most chemicals. Its fast reaction time gives it unmatched performance even in dynamic and low dew point applications, and the sensor’s outstanding stability enables a long two-year calibration interval. The Vaisala HUMICAP Moisture in Oil Probe MMP8 extends the Indigo product offering to include heavy industry applications such as measuring moisture in transformer or lubrication oils to protect engines from wear and shutdown. Also introduced today, Vaisala HUMICAP Humidity and Temperature Probe HMP3 is a generalpurpose remote probe suitable for duct mounting in non-pressurized applications with moderate temperatures. The probe structure allows the sensor to be replaced in the field without tools, providing maintenance flexibility in demanding applications that might require periodic sensor replacement, such as paint booths. The HMP3 and MMP8 both include Vaisala HUMICAP thin-film capacitive humidity measurement technology, which has become the industry standard in humidity measurement. “With these new products, the Vaisala Indigo product family is getting stronger. The new probes add dew point and moisture in oil measurements to the existing parameters of humidity, carbon dioxide, temperature, and vaporized hydrogen peroxide. I am excited that we are now able to provide high-quality measurement data in a more flexible way to all industries. Contributing to smarter environments is something we at Vaisala are passionate about,” says product manager Jarkko Ruonala. 8 • November 2019

All six new smart probes complement Vaisala’s existing Indigo product family. The digital Modbus RTU connection enables both easy integration into other systems and standalone usage. The probes are also plug-and-play compatible with Indigo 200 transmitters, which offer various additional benefits such as a display for data visualization, easy access to probe configuration, and more options for connectivity, supply voltage, and wiring. For on-site configuration, diagnostics, and self-calibration, the Indigo probes can be connected to the Vaisala Insight PC software. The shipments of the new smart probes will start during December 2019.

Pietro Tomasi Succeeded Gary Kedgley of Romaco Group as Vice President, Sales & Service. Karlsruhe, Germany: Pietro Tomasi has been appointed as the new Vice President Sales & Service of the Romaco Group. He is going to succeed Gary Kedgley, who is going into retirement. Mr. Tomasi will be responsible for the Romaco Group’s sales and service activities worldwide. Gary Kedgley has held this position since 2006 and will be retiring at the end of the year. The Romaco Group management would like to thank him for his valuable contribution to the successful marketing of the pharmaceutical machinery manufacturer’s products. Mr. Tomasi has been at the helm of the Romaco Group’s global Sales & Service organisation since July 2019. He is responsible for expanding and developing both the international Romaco Sales & Service Centres (SSC) and the Group’s worldwide network of agents. The supplier is aiming to establish a strong presence around the globe in this way, so that customers can profit directly from the knowhow of a specialist for solid pharmaceuticals in their local region. Pietro Tomasi was born in the Italian province of Ravenna and began his professional career back in the eighties as a service technician at IMA in Bologna. In the early nineties, he joined the sales team at the Marchesini Group, an Italian supplier of pharmaceutical packaging machines. After several years in the UK, where he built up Marchesini’s British branch, he gradually took on more and more responsibility for expanding and organising international sales structures. Prior to joining Romaco, he spent nearly two decades as the Italian Group’s Commercial, Sales and Marketing Director. “We’re delighted to have Pietro Tomasi on board the management of the Romaco Group”, emphasised Jörg Pieper, CEO Romaco Group. “He’s a man who knows what he’s doing and what he’s talking about. Mr. Tomasi is thoroughly familiar with all the ins and outs of our industry and is very proactive when it comes to establishing the Romaco brand as a global player in the long term. He can draw on extensive managerial experience, an excellent knowledge of the market and broad technological expertise.” “As Vice President Sales & Service at Romaco, I’m ideally placed to make things happen”, said Tomasi when prompted to outline his motives for switching to the Romaco Group. “I firmly believe that a strong sales and service organisation makes all the difference in the market! And since the economic situation in the global marketplace is changing all the time, dynamic processes are increasingly crucial to generate sustainable growth. Suppliers like us have to anticipate what their customers want and satisfy tomorrow’s needs today.” Chemical Engineering World


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CEW News Siemens Expanded Their Additive Manufacturing Portfolio through Acquisition of Atlas 3D

build orientation and support structures are determined. Typically, designers don’t have the capabilities to consider such factors as part orientation, distortion, and heat extraction uniformity in their design. This puts the onus on engineering specialists to resolve such issues. Atlas 3D’s Sunata software solves this problem by giving front-end designers a quick, easy, and automated way to get much closer to a “right first time” build. Sunata is a GPU-accelerated high-performance computing additive manufacturing software solution that can deliver results up to one hundred times faster than other build simulation solutions on the market. GPU-accelerated computing is the employment of a graphics processing unit (GPU) along with a computer processing unit (CPU) to facilitate processing-intensive operations such as deep learning, analytics and engineering applications. The acquisition is due to close in November 2019. Terms of the transaction were not disclosed.

With Atlas3D, designers and manufacturing engineers can quickly gain insights into the optimal part build orientation in order to minimize supports, distortion, effort to remove supports, part material, and printing time.

Mumbai, India: Siemens announced that it has signed an agreement to acquire Atlas 3D, Inc., a Plymouth, Indiana-based developer of software that works with direct metal laser sintering (DMLS) printers to automatically provide design engineers with the optimal print orientation and requisite support structures for additive parts in near real-time. Atlas 3D will join Siemens Digital Industries Software, where its solutions will expand additive manufacturing capabilities in the Xcelerator portfolio of software. Sunata software uses thermal distortion analysis to provide a simple, automated way to optimize part build orientation and generate support structures. This approach allows the designer – rather than the analyst – to perform these simulations, thereby reducing the downstream analysis that needs to be conducted via Simcenter software to achieve a part that meets design requirements. Siemens plans to make the Atlas 3D solution available through its online Additive Manufacturing Network. “We welcome Atlas 3D to the Siemens community as the newest member of our additive manufacturing team. Our solutions industrialize additive manufacturing for large enterprises, 3D printing service bureaus, design firms, and CAD designers”, said Zvi Feuer, Senior Vice President, Manufacturing Engineering Software of Siemens Digital Industries Software. He added, “The cloud-based Sunata software makes it easy for designers to determine the optimal way to 3D print parts for high quality and repeatability. The combination of Sunata with the robust CAE additive manufacturing tools in Simcenter enables a ‘right first time’ approach for industrial 3D printing”. “Siemens is a leader in additive manufacturing, with the most integrated and functionally robust solutions in the industry, so we are excited to join the team”, said Chad Barden, Chief Executive Officer of Atlas 3D. “The power of Sunata is that it equips designers to more easily design parts that are printable, which helps companies to more quickly realize the benefits of additive manufacturing. As a part of Siemens, we look forward to introducing Sunata to customers who already have Siemens’ AM solutions and can achieve new efficiencies in their front-end design for additive process, as well as companies who have yet to start their additive manufacturing journey”. The high rate of 3D print failures is a key challenge companies face in leveraging additive manufacturing for high-volume production. Parts often need to go through several design and analysis iterations before the optimal 10 • November 2019

Siemens Digital Industries Software is driving transformation to enable a digital enterprise where engineering, manufacturing and electronics design meet tomorrow. The Xcelerator portfolio helps companies of all sizes create and leverage digital twins that provide organizations with new insights, opportunities and levels of automation to drive innovation. For more information on Siemens Digital Industries Software products and services, visit www.sw.siemens.com or follow us on LinkedIn, Twitter, Facebook and Instagram. Siemens Digital Industries Software – Where today meets tomorrow.

Thyssenkrupp and Paradeep Phosphates Signed Expansion Contract for Phosphoric Acid Plant Mumbai, India: Thyssenkrupp Industrial Solutions has recently been awarded a contract from Paradeep Phosphates Limited (PPL) for the expansion of their phosphoric acid plant in Paradeep, Odisha (India), based on the Di-hydrate technology from Prayon Technologies of Belgium. PPL is a leading fertilizer company in India and part of the Adventz Group. The project will increase the capacity of the existing plant from 1,000 tons to 1,400 tons of phosphoric acid per day. The phosphoric acid produced will be utilized by Paradeep Phosphates in the manufacturing of phosphate fertilizers such as DAP (diammonium phosphate) and NPK (compound/multi-nutrient fertilizers). The company is in the process of revamping their DAP- NPK facility as well. Thyssenkrupp Industrial Solutions will provide engineering and technical procurement services which will cover the plant’s reaction unit, filtration unit, dry rock grinding section, and an additional cooling tower cell. The project is planned to be completed within a period of 22 months from the Effective Date of the Contract. P D Samudra, CEO and Managing Director at Thyssenkrupp Industrial Solutions (India) said: “Paradeep Phosphates has been one of our earliest customers in India. Way back in the late eighties and nineties, we built for them what is still one of India’s largest cryogenic ammonia storage tank farms. We are proud to be assisting them in this prestigious fertilizer project, by leveraging our experience in the phosphatic fertilizer sector”. Ranjit Chugh, COO of Paradeep Phosphates said, “The setting up of this phosphoric acid plant is aligned with our plans for expanding our footprint in the phosphatic fertilizer industry. We are happy that Thyssenkrupp, who has considerable experience in the field is partnering with us in this project.”The project vindicates Thyssenkrupp’s experience in the fertilizer sector. The engineering major has recently commissioned a similar project for another fertilizer major in India. Chemical Engineering World



CEW News SGLTPL Collaborated with Hakka Sangyo

datasphere is set to grow to 175ZB by 2025, with nearly 30 percent requiring real-time processing. Aspen Enterprise Insights visualization and workflow management solution enable capital-intensive enterprises to analyze data throughout the asset lifecycle and across the entire value chain, delivering actionable insights to multiple users to increase operational excellence.

Hyderabad, India: Standard Glass Lining Technology Pvt Ltd (SGLTPL), a leading manufacturer of Chemical and Pharmaceutical equipment, is going to establish a new manufacturing location at Jinnaram, Hyderabad with the investment of ` 35 cr. Mr. Kundala Nageswara Rao, Managing Director of Standard Group, has informed that it shall start commercial operations at their new location from April 2020. Currently SGLTPL has two manufacturing units located in Jeedimetla, Hyderabad set-up with an investment of 35 Crores, manufactures reactors with capacity of 63L to 20KL. With the opening of new manufacturing location, SGLTPL expects to make about 200 reactors every Month and also undertake production of vessels up to 32KL. SGLTPL has 400+ clients and have supplied to customers in Oman, Turkey, and Dubai. It has supplied 4000+ rectors till date. In 2018-2019, the turnover of the company has been ` 80 Cr and expects to achieve a turnover of ` . 140 Cr in the Current Financial year. SGLTPL announced their recent business collaboration with Japan’s pioneer in manufacturing of Glass Lined Equipment, M/s. Hakko Sangyo Co Ltd of Nakatsu, Japan. With this collaboration, SGLTPL intends to launch Conductivity Glass Lined Reactors for the first time in India. With these reactors, the accidents that occur due to static discharge would not happen. These reactors would be in market from December 2019. Along with Jeedimetla, the new branch is also going to manufacture the same. Even the reactors with a capacity of 32,000 liters would also be manufactured in Jinnaram plant. So far SGLT has supplied over 4000 reactors to more than 400 clients. Oman, Turkey, and Dubai also have their own clients. Very soon they will start supplying to Russia as well. SGLT is a part of the Standard Group of Companies and their current group turnover is of 330Cr in FY 2018-19 with 8 manufacturing companies and an R&D unit in the UK. In FY 2019-2020, the group is expected to achieve ` 400 cr turnover. Within a span of 5 yrs, they are targeting to achieve ` 1000 Cr.

Aspen Technology Brings New Levels of Performance Insight to Drive the Smart Enterprise Massachusetts, USA: Aspen Technology Inc, the asset optimization software company, has recently announced the launch of Aspen Enterprise Insights, a visualization and workflow management solution that aggregates and analyzes data from across the enterprise to deliver insights & actionable information, and drive better collaboration & decision-making within organizations. Organizations struggle to identify, analyze, and derive value from their data lakes, and that challenge is set to grow. According to IDC1 the global 12 • November 2019

Aspen Enterprise Insights creates and weaves a “digital thread” within the enterprise to connect smarter processes and push the boundaries of productivity. The technology, now part of the AspenTech portfolio following the acquisition of Sabisu in June 2019, is a proven hybrid-cloud-based solution that brings enterprise-level performance management across the organization. It can enable informed strategic decision-making by identifying the high-value data needed to provide insights and drive informed actions, to enhance existing business processes, and to assist organizations in creating new ones. “The accessibility of accurate data analysis is critical when seeking greater levels of efficiency and optimization. Aspen Enterprise Insights will give our customers a flexible visualization and collaborative workflow management solution to support real-time strategic decision-making across the enterprise”, said Antonio Pietri, President and CEO of Aspen Technology. “As the Industrial Internet of Things expands, visualization of heterogeneous data sources becomes critical to the success of a digital transformation strategy. Aspen Enterprise Insights can help our customers achieve greater levels of efficiency throughout the asset lifecycle, driving towards the automation, collaboration, and insights that are required by the smart enterprise”. According to Peter Reynolds, Senior Analyst, ARC Advisory Group, “Aspen Enterprise Insights offers what appears to be a unique combination of experience data and operational data with a workflow engine. When digitalization is top of mind for industry, this solution could help drive a new level of collaboration with the potential to create higher value work processes for customers.”

Glenmark Pharmaceuticals Received ANDA approval for Adapalene and Benzoyl Peroxide Gel, 0.1 percent and 2.5 percent Mumbai, India: Glenmark Pharmaceuticals Inc., USA (Glenmark) has been granted final approval by the United States Food & Drug Administration (USFDA) for Adapalene and Benzoyl Peroxide Gel, 0.1 percent and 2.5 percent, the generic version of Epiduo 1 Gel, 0.1 percent and 2.5 percent of Galderma Laboratories LP. According to IQVIATM sales data for the 12 month period ending September 2019, the Epiduo® Gel, 0.1percent|2.5 percent market2 achieved annual sales of approximately $33.7 million*. Glenmark’s current portfolio consists of 163 products authorized for distribution in the U.S. marketplace and 45 ANDA’s pending approval with the U.S. FDA. In addition to these internal filings, Glenmark continues to identify and explore external development partnerships to supplement and accelerate the growth of its existing pipeline and portfolio. 1All brand names and trademarks are the property of their respective owners. 2Market includes brand and all available therapeutic equivalents *IQVIATM National Sales Perspectives: Retail & Non-Retail, September 2019 Chemical Engineering World



CEW News Indian Firms Won Maximum Number of Safety Oscars This Year

award. To secure the award, organizations have to be fully committed to both excellent standards and continuous improvement. The British Safety Council is one of the world’s leading health, safety, and environmental organizations. It has been helping companies across the globe to look after their people for over 60 years. Its aim is to keep all workers as safe and healthy as possible through campaigning, training, and practical guidance.

London, UK: As a major boost to workplace safety in India, Indian companies have recently won the maximum number of the prestigious Sword of Honour and Globe of Honour Safety Awards given by the British Safety Council. The count for winning Indian organizations is 41 against the total participation of 84 organizations from across the globe for the prestigious Sword of Honour award by the British Safety Council. Nine global companies were also in the Globe of Honour winning list. Each year, the British Safety Council presents this Sword of Honour to companies around the world for excellence in health and safety management, and the Globe of Honour for excellence in environmental management. This year the award ceremony is scheduled on 22 November at Merchant Taylor’s Hall in the City of London. The large number of Indian winners is the evidence that Indian companies have begun to prioritise safety for their employees. This has not always been the case. Studies have stated that limited budgets have been one of the top challenges for Indian companies to drive workplace health, safety, and wellbeing initiatives. In India, around 80 percent of the estimated workforce counting to approximately 465 million is not protected by the existing health and safety legal framework. The situation seems to be slowly changing, as reflected by the growing number of award winning Indian companies this year. The winning organisations came from a wide range of industry sectors in India, the UK, Europe and the Middle East, thus covering a host of sectors including education, energy construction, food and beverage, leisure, logistics, manufacturing, retail and transport, etc. The Indian companies, which won the Sword of Honour award, were: Adani Power Rajasthan Ltd (APRL), Asian Paints Ltd (Rohtak Plant), Shriram Alkali and Chemicals, sites of DLF Power & Services across India, sites of JK Tyre & Industries Limited, GMR Warora Energy Limited - Maharashtra, sites of L&T, Mindspace Hyderabad and SRF Limited - Packaging Film Business, Bagdoon, Pithampur etc. Hemant Sethi, Country Head, British Safety Council India, said, “The Sword of Honour and Globe of Honour awards recognize and reward the organizations that demonstrated the best health and safety performance, or environmental management, or both in the case of a few companies. These organizations are leading the global efforts to make all workplaces safe, healthy, and sustainable. They have demonstrated a proven track record of excellence in managing risks to workers’ health and safety and/or to the environment from the organisations’ activities to an independent adjudication panel. I would like to congratulate all the winners on behalf of the British Safety Council.” Organizations from around the world who have achieved the top grade in the British Safety Council’s Five-Star Audit are eligible to apply for the 16 • November 2019

Winners List India Sword of Honour 2019 • Adani Power Rajasthan Limited (APRL) • Asian Paints Limited (Rohtak Plant) • Shriram Alkali and Chemicals – (A unit of DCM Shriram Ltd) • DLF Power & Services Ltd – The Chanakya • DLF Power & Services Ltd – Cyber Green Hanging Floor South 4th Floor Cyber City (Office Complex) • DLF Power & Services – DLF Mall of India • DLF Power & Services Limited – IT Park, Chandigarh IT Park • DLF Power & Services Ltd – Cyber City Chennai • DLF Power & Services Limited DLF Cyber City • DLF Power & Services Ltd Cyber Hub, Gurgaon • DLF Power & Services Limited Emporio, Vasant Kunj, New Delhi • DLF Power & Services Limited DLF IT PARK–1& DLF IT SEZ, Kolkata • DLF Power & Services Limited DLF Centre Sansad Marg • DLF Power & Services Ltd Multi Level Car Parks (Capitol Point, Baba Kharag Singh Marg & South Square, Sarojini Nagar) New Delhi • DLF Power & Services Limited Promenade Mall, Vasant Kunj, New Delhi • DLF The Lodhi Hotel • Eon Free Zone (Eon Kharadi Infrastructure Pvt. Ltd) • GMR Warora Energy Limited – Maharashtra • JK Tyre & Industries – Cavendish Industries Limited • JK Tyre & Industries Limited – Chennai • JK Tyre & Industries Ltd. Mysore Unit VTP, RTP, OTR • JK Tyres & Industries Ltd – Banmore Tyre plant • L&T B&F IC – Emerald Isle Phase 2 Project Powai Mumbai • L&T Salsette 27 Peninsula Project – Mumbai • L&T B&F IC – Business Tower Phase 1 Powai • L&T B&F IC – Oberoi Sky City Project Mumbai • L&T Grasim • L&T Rustomjee Crown Project • Larsen & Toubro Limited, Transportation Infrastructure, Railway SBG, WDFC, EMP – 4 Project • Larsen & Toubro Construction, Buildings and Factories Independent Company, WIPRO IT SEZ Project, Gopanpally, Hyderabad • L&T Shipbuilding Ltd, Kattupalli • L&T IICC New Delhi • L&T APTIDCO Projects Krishna District – Andhra Pradesh • L&T AIIMS Project Mangalagari Guntur • Mindspace Hyderabad • Mindspace (Commerzone) Pune excluding Amenity building and MSEDCL switching station • Shapoorji Pallonji Bumi Armada Offshore Private Limited – FPSO Armada Sterling • SP Armada Oil Exploration Private Limited – FPSO Armada Sterling II • SRF Limited – Packaging Films Business, Bagdoon, Pithampur • SRF Limited – Packaging Films Business, Indore SEZ, Pithampur • Torrent Power Limited (AMGEN) Chemical Engineering World



CEW News Cook Compression Opened Satellite Service Centre in Italy

Ellesmere Port, UK: Cook Compression celebrated the grand opening of its satellite service facility in Sicily, Italy sometime ago. The service facility supports the rapid reconditioning of compressor valves for ISAB S.r.l, a part of Lukoil Oil Company, and other refineries in the region. ISAB has awarded Cook Compression a multi-year contract to provide technical support, reconditioning and upgrades for reciprocating compressor valves. “We are proud to provide our valve expertise and local support to the ISAB refinery,” commented Dean Lewis, Cook Compression VP Aftermarket, Europe & Russia. “This service facility represents our commitment to building lasting partnerships that help our customers improve compressor performance and minimize equipment downtime.” Service personnel received in-depth training from the Cook Compression European Operations headquarters in the United Kingdom, and ISAB has completed a full audit of the repair facility. Cook Compression provides expert valve repair for any make or model valve and guarantees as-new performance and service life for the reconditioned valve. Rigorous inspection, best-in-class procedures and quality replacement components return valves to original specifications. Cook Compression also has the application knowledge and technical expertise to recommend valve upgrades for improved reliability and efficiency. Highly qualified in-house engineering teams optimize valves for the end user’s specific operating conditions, applying a range of proven designs. From the creation of the original radiused-disc Manley® valve to the extreme reliability of the patented MOPPET® valve, Cook has pioneered developments in valve designs and materials that yield meaningful improvements in performance. The Cook Compression global service portfolio includes reconditioning, replacements and upgrades for compressor sealing components, packing cases, pistons, rods and cylinders, as well as valves, providing proven solutions for emissions management and equipment optimization. The Sicily service facility has room to expand its capabilities in support of the region’s compressor service, repair and upgrade needs.

PCPIR Rejuvenation Study Has Been Launched at Summit on Global Chemicals & Petrochemicals Manufacturing Hubs in India 2019

Mumbai, India: In its endeavor to strive robust advancement in the Indian Chemical & Petrochemicals industry, Federation of Indian Chambers of Commerce & Industry (FICCI) jointly with the Ministry of Chemicals and Fertilizers, Government of India today launched 18 • November 2019

the PCPIR Rejuvenation Study at the ‘Summit on Global Chemicals & Petrochemicals Manufacturing Hubs in India 2019’. The PCPIR Rejuvenation Study, by FICCI and their knowledge partner Mott MacDonald, highlights the continuous development of Petroleum, Chemicals and Petrochemicals Investment Regions (PCPIR), its current scenario and government’s roadmap for policy interventions to rejuvenate investment in PCPIRs. It has stated that India is the sixth largest producer of chemicals in the world and contributes 3.4 percent to the global chemical industry. The chemicals market in India has grown at 3 percent over the last decade. The industry comprises of 13.38 percent of manufacturing GVA and 2.39 percent of National GVA which employs about 2 million people. The Government of India adopted a policy in 2007 to set up Petroleum, Chemicals and Petrochemicals Investment Regions (PCPIR). Currently there are four identified regions - Dahej (Gujarat), Vishakhapatnam (Andhra Pradesh), Paradip (Odisha) and Cuddalore (Tamil Nadu). However, due to a wide range of issues (ranging from overall infrastructure development to project financing), attracting investment to Vizag, Paradip and Cuddalore has been relatively challenging in comparison to Dahej. Considering the overall scenario, the government has now planned for policy interventions to rejuvenate investment in PCPIRs. Speaking about extraordinary role of Chemicals and Petrochemicals Industry in shaping the other industries, Mr. D.V. Sadananda Gowda, Minister of Chemicals & Fertilizers, Government of India said, “The Indian Chemical & Petrochemical Industry is currently witnessing a rapid expansion. The untapped potential of this industry needs to be addressed which holds the power to bring a revolution in the country. The industry is expected to grow at a CAGR of 9.3 percent from USD 163 billion to USD 304 billion market by 2025, which not only emphasizes the important role it can play in the growth of Indian economy but to become the global leaders in petrochemicals and emerge itself as world’s next manufacturing hub. We are honoured to partner with FICCI to host first of its kind Summit on Global Chemicals & Petrochemicals Manufacturing Hubs in India 2019.” Commenting on the significance of the report launch, Mr. Deepak C. Mehta, Chairman – FICCI Chemical Industry Committee and CMD, Deepak Nitrite Ltd. said, “It is my privilege to be a part of Summit on Global Chemicals & Petrochemicals Manufacturing Hubs in India 2019 and meet the entire industry fraternity at this important event. The Indian Chemical and Petrochemical industry is an integral part of the Indian economy and possess huge unrealized potential to strengthen the Indian economy. The PCPIR Rejuvenation Study connotes the chemicals market in India has grown at 3 percent over the last decade, current development and policy interventions to rejuvenate investment in PCPIRs.” “The government’s initiative towards successful implementation of Petroleum, Chemicals and Petrochemicals Investment Regions (PCPIR), shoring up existing infrastructure to world class level is truly commendable. We at FICCI are really obligated to Department of Chemicals & Petrochemicals, Government of India for their valuable support and guidance in organizing the first ever summit of its kind.” he added. Across the summit, eminent speakers from the industry like Mr. Nikhil Meswani, Executive Director, Reliance Industries Limited, Mr. R Mukundan, Managing Director & CEO, Tata Chemicals Ltd., Mr. Sanjeev Gandhi, Members of the Board of Executive Directors, BASF SE, Mr. Walmir Soller, CEO, Braskem Europe, Mr. Prabh Das, Chairman - FICCI Petrochemical and Plastic Industry Committee, MD & CEO, HPCL Mittal Energy Limited, amongst others were a part of it. Chemical Engineering World



CEW News Praj and IISER Pune Joined Hands to Scale-up Nation’s Biggest Science Quiz – Mimamsa

the recycled water back to process, for further reclamation of good water, making the Sakarwadi site’s continuous compliance to ZLD.

Pune, India: Praj Industr ies and IISER Pune have signed a Memorandum of Understanding (MoU) with the objective to scale up Mimamsa, a nation-wide intercollege science competition held annually. As per the MOU, to begin with, Praj will lend technical as well as financial assistance to Mimamsa for three editions. Mimamsa 2020 will be the first of the revamped contest.

With the inauguration of the new facility, GBL’s Sakarwadi plant will be compliant to the stringent future Environmental norms, guidelines to be applicable.

Over the past decade, Mimamsa has gained recognition as the country’s most acclaimed science competition that is based on the concepts of science and their interdependence. Mimamsa is a two-tiered event -- Prelims and Mains -- where teams across India compete under scientific and critical ways of thinking with zero emphasis on memorization. The quiz questions are designed to stimulate debate within the teams and encourage discussion with judges, rather than simply arriving at an answer. Previous winners have been IISc Bengaluru, IIT Mumbai, BITS Hyderabad and Institute of Bioinformatics and Biotechnology, Pune. At the MOU signing, Prof. Jayant Udgaonkar, Director- IISER Pune, said, “I am happy that a progressive company like Praj has chosen to associate itself with and promote Mimamsa. Mimamsa is a tough unique competition and the support of Praj will only lead to a further improvement in its high quality.” Speaking at the event, Pramod Chaudhari, Executive Chairman - Praj Industries, said that collaboration between industry and academia benefits institutes, quality of research and business in several ways. “We are pleased to collaborate with IISER in this novel project that fosters investigation, deliberation and critical thinking in the fundamental sciences among the future academics and industrial researchers. India’s vast talent in science and technology has the potential to spur innovation and drive socio-economic change in the country. We believe Mimasa is the ideal platform for budding undergraduate science enthusiasts to showcase their talent”, he said. As an event with no registration fee and prize money of INR two lakhs, Mimamsa 2020 is expected to elicit participation from over 1,700 institutions across 22 cities. This will mean over 13,000 participants since inception. The preliminary round will be held on January 18, 2020 and the grand finale will take place at IISER’s Pune campus between March 21-22nd 2020.

Godavari Biorefineries Limited (GBL) Inaugurated Its Upgraded State of the Art Set-up “Zero Liquid Discharge” and Continued Compliance of ZLD Facility at Its Plant in Sakarwadi, Maharashtra. Mumbai, India: Godavari Biorefineries Limited (GBL) inaugurated its upgraded state of the art set-up “Zero Liquid Discharge” (ZLD) facility at its plant in Sakarwadi, Maharashtra. To attain ZLD, effluents are subjected to biological treatment, ultra-filtration, reverse osmosis, multiple evaporation techniques and agitated thin film drying to enable purification and removal of contamination at various stages. GBL’s Recycling Unit comprising of intricate systems like Ultra Filtration & Two Stage RO helps in reusing 20 • November 2019

The ZLD facility will enable GBL’s growth strategy for its manufacturing facility at Sakarwadi, Maharashtra while ensuring focus on sustainability and environment protection. The set-up shall help meet new norms that have been under discussion which may be implemented in future. Also any site expansion that may be done in due course after receiving required statutory approvals, too shall benefit from the set up. GBL Sakarwadi unit recently participated and won the (Platinum Award) in “Environment Health & Safety (EHS) category” Excellence Award’19 in “Envosafe – The EHS Excellence Award,2019” championed by Deputy Director Industrial Safety and Health (DISH), Ahmednagar in coordination with Mutual Aid Response Group (MARG). GBL received a special note of appreciation from Hon’ble Shri Swapnil Deshmukh, Dy. Director of Safety & Health Department, Ahmednagarfor the site’s good upkeep and safe practices focused on EHS in a chemical plant. Said Mr Samir Somaiya, Chairman & Managing Director, “Our commitment is to provide sustainable solutions for our stakeholders and the communities we operate in. The investment in the ZLD facility adds one more milestone towards our effort to uphold a greener economy”. The Sakarwadi site has ICC Responsible care Logo certification that helps meet customer expectations and ensures the deliverance of the highest quality products and production standards in line with ISO 9001: 2015 and RC 14001:2015 guidelines.

BASF India Limited Announced Results for the Second Quarter 2019 Mumbai, India: BASF India Limited registered sales of ` 20,743.3 million in the second quarter of 2019 which ended on September 30 compared to ` 16,755.7 million in the corresponding quarter of the previous year, representing an increase of 24 percent. Profit Before Tax (before exceptional items) came in at ` 140.8 million, compared to ` 118.8 million in the prior-year quarter. An increase in merchandise sales, which was mainly due to a change in the business model from erstwhile agency business, contributed to the increase in the topline result. Subdued demand from automotive and consumer durables focused businesses continued to impact margins. “By pursuing growth projects with our customers, we overcame the overall slowdown in the manufacturing sector. Our Agricultural Solutions and Nutrition & Care segments saw good growth compared to the corresponding period of last year. A lower demand from the automotive market had an impact on the related businesses. We remain committed to growing faster than the market by working closely with our customers”, said Narayan Krishnamohan, Managing Director, BASF India Limited. For the half-year which ended on September 30, 2019, the Company registered sales of ` 36,880.8 million, as compared to ` 33,026.8 million for the corresponding period of the previous year, an increase of 12 percent. Profit Before Tax (before exceptional items) stood at ` 316.4million for the half year, compared to Profit Before Tax (before exceptional items) of ` 469.6 million for the corresponding period of the previous year. Profit After Tax (after exceptional items) came in at ` 105.2 million in the second half of 2019, compared to Profit After Tax (after exceptional items) of ` 338.3 million posted in the corresponding period of the previous year. Chemical Engineering World



CEW News LANXESS India Added to Employability through Its Vocational Skill Centre

to provide skills to such youth that will help them sustain a decent livelihood. We see this project as a small gesture in contributing positively to the country’s skill development goals.” D Sattaiah, CEO & MD of B-ABLE said, “It is a gratifying experience to see these young boys and girls becoming self-confident and securing gainful employment with our training. We are fortunate to have partnered with LANXESS for this extremely productive and positive skill development programme. I am sure we will do exceedingly well going ahead, also.”

Haldor Topsoe Won the 2019 IChemE Oil and Gas Global Award for its TIGAS™ Gas-to-Gasoline Technology

Thane, India: LANXESS India Private Limited established a skill development centre in Thane as part of its Corporate Social Responsibility programme to provide training to aspiring candidates looking for suitable employability. The LANXESS B-ABLE SKILL CENTRE was set up in association with BASIX Academy for Building Lifelong Employability Limited (B-Able) who is the implementation partner for the project for a period of three years covering Thane, Jhagadia and Nagda. At a brief event in Thane, LANXESS AG Board of Management members Dr. Rainier van Roessel and Dr. Anno Borkowsky along with Mr. Neelanjan Banerjee, Vice Chairman and Managing Director, LANXESS India, presented a cheque of ` 5 million to Mr. D Sattaiah, CEO & MD of B-Able for project implementation in the second year.

Lyngby, Denmark: It was a proud Topsoe delegation who accepted the award on behalf of the larger group of excellent scientists, engineers, and other Topsoe employees involved in development of the unique TIGAS™ technology over many years.

In its first year, LANXESS India successfully trained 129 candidates in its centre in Thane wherein the candidates were given training under the categories of Sewing Machine operators and Call Centre executives. The courses started in January 2019 and after completion, candidates were assisted with placements. A total of 96 candidates which is 78 percent of the total enrolments, have been placed in companies or have started their own business after the project concluded. LANXESS has supported B-Able on this project with the cost of mobilization, training, human resource, rent for the facility etc.

“To us, the Oil and Gas award 2019 is the culmination of decades of complex catalyst development, pilot testing, reactor design, and process engineering. The triumph with TIGAS™ today has only been possible by sharing competences and experience across our entire company. And the result has been spectacular: The successful design, commissioning and start-up of the world-scale and only natural gas-to-gasoline facility in Turkmenistan. And we are extremely happy to receive this recognition from the renowned IChemE organization and peers in the industry,” says Kim Knudsen, Executive Vice President of Topsoe’s Sustainables Business Unit.

The project is focused on providing skill development training for the youth who are unskilled, semi-skilled, school drop outs and come from the underprivileged sections living in and around LANXESS India’s operations. LANXESS India has funded the project to provide sustainable livelihood to such underprivileged youth. This program has been designed for three years starting from Thane in the first year, Jhagadia in the second and Nagda in the third year with nearly 125 candidates being trained each year.

The Turkmenistan TIGAS™ plant has a name plate capacity of 15,500 barrels per day of on-spec RON 92 gasoline. Several other companies around the world have shown interest in the technology.

For the current financial year, an on-ground survey in and around Jhagadia in Gujarat found that the most popular employability choices for the local youth with lower academic qualification was that of a retail trainee associate. Taking a lead from the survey conducted by B-ABLE, LANXESS has financially supported the project in Jhagadia this year. The first batch of candidates has already commenced with batch strength of 25 participants. Commenting on the project, Neelanjan Banerjee, Vice Chairman and Managing Director, LANXESS India said, “Lack of higher education due to any reason should not be a hindrance in employability opportunities for the underprivileged youth of our nation. Through this project we have attempted 22 • November 2019

TIGAS™ is a viable technology in regions with abundant gas resources where it represents an attractive option to monetize natural gas by producing synthetic gasoline that complies with the highest environmental standards, contains no sulfur and very little unwanted byproducts, which can be sold into a local or export market. Topsoe’s proprietary end-to-end TIGAS™ solution is based on industryproven Topsoe technology platforms and catalysts, the key being Topsoe’s proprietary SynCOR Methanol™ and Gasoline Synthesis technologies. Topsoe offers all catalysts and technology for the process, which allows for valuable process optimization and further development. The TIGAS™ process can also be adapted to produce gasoline in compliance with varying national specifications. Apart from Topsoe, the finalists in the Oil and Gas category were ExxonMobil Chemicals, Flour, PETRONAS Penapisan, Saudi Aramco (three entries), and University College London. Chemical Engineering World


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CEW News B&R Introduced Powerful PC for Outdoor Applications: More Processing Power for Mobile Machinery Pune, India: B&R has added a powerful PC with Intel Core i processor to its portfolio of mobile machinery. The full-fledged PC with IP69K protection is specially designed for use in harsh environments. Its high performance makes it optimally suited for smart machines that communicate with each other and with the cloud. The PC for mobile machinery features a 7th-generation Core i processor from Intel. Its performance can be scaled from a 2.2 GHz Celeron processor to a 2.8 GHz Core i7. It offers up to 16 GB RAM and 480 GB of flash memory, and is equipped with a TPM module. It also supports standard operating systems like Windows 10 IoT Enterprise and Linux. The PC's computing performance enables implementation of semi or fully autonomous machine functions. Smart machines: The PC can also be used as an edge controller, collecting large volumes of data from one or more mobile machines, preprocessing it and then sending it to higher-level systems or the cloud. For machine-tomachine and machine-to-cloud communication, B&R offers the widely used OPC UA and MQTT protocols. They allow data packets to be transferred reliably even in cases where the network connection has low bandwidth or is intermittently unavailable. Used in harshest industrial environments The PC's rugged design is resistant to shock, vibration, salt, UV light and oil. Despite the housing being completely sealed, it is also fanless. The zero-maintenance PC has a specially developed temperature management system that allows it to be operated from -40 °C to +85 °C surface temperature. Modular expansion: The PC is insensitive to voltage fluctuations. In addition to a broad standard voltage range from 9 to 32 V, it also has integrated load dump protection. This compensates for peaks in the supply voltage to protect the electronics and ensure uninterrupted operation. Two internal slots allow the PC to be expanded modularly with additional communication interfaces. B&R has added a powerful PC with Intel Core i processor to its portfolio for mobile equipment.

North American EtherCAT Plug Fest Offered ‘Great Opportunity’ to Participants Denver, USA: Numerous ETG member companies met for the 2019 North American EtherCAT Plug Fest, which was hosted in Denver, Colorado by Beckhoff Automation. With more than 35 participants, the event was a great success. In addition to the highly productive learning environment, the participants particularly liked the fact that they were able to meet so many high-ranking manufacturers of EtherCAT devices. The participants tested a total of seven controllers from different manufacturers and 16 EtherCAT field devices, and three different tools were also used. In addition to extensive interoperability tests, many discussions took place with the EtherCAT experts in attendance. The opportunity to exchange technical ideas during the development phase is one of the major benefits of EtherCAT Plug Fests. “The 2019 North American EtherCAT Plug Fest was very productive and successful for everyone involved,” says Robert Trask, P.E., North American Representative for ETG. “The ETG was glad to welcome many new Plug Fest 24 • November 2019

participants as well as those who have attended multiple events.” One of the participants adds: "It was my first time at an EtherCAT Plug Fest in North America. Everything was very well organized and I'm impressed that so many well-known ETG members were there." And another adds: "The Plug Fest was a great opportunity to test the interoperability of numerous field devices all at once. Although we have been using the same EtherCAT controller for many years, there’s always something new to learn." EtherCAT Plug Fests take place several times a year all over the world. All information about dates and participation can be found online at www. ethercat.org/events.

MOL Group Acquired Aurora Group, Strengthened Position in Recycled & Sustainable Plastics Compounding Segment Budapest, Hungary: Following satisfaction of customary transaction approvals, MOL Group announce that effective 31 October 2019, it has acquired 100 percent shareholding in Aurora, a German plastic compounder company. As a result of the acquisition, MOL Group is strengthening its position in recycled, sustainable compounding segment and in the automotive supplier industry. MOL Group is a well-established virgin polymer supplier, continuously looking for opportunities to extend its petrochemical value chain towards higher added-value products. To reach this goal, MOL aims to widen the synergies with its current polymers product portfolio via both organic and inorganic developments, to gain expertise and high-end capabilities in both virgin-based and recycled plastic compounding. With the acquisition of Aurora, MOL Group is further expanding its product portfolio with Aurora’s excellence in engineering plastics and polypropylene recyclate-based compounds. Aurora with its innovative products and business model are greatly complementing MOL Group’s current petrochemical portfolio and also contributes to its sustainability objectives. Aurora, with production plants located nearby automotive manufacturing and plastics conversion clusters in Baden-Württemberg, Germany has a unique and lean closed-loop business model. Aurora collects the industrial plastic waste, recycles it and then upgrades the properties of the material into an enhanced plastic that suits the requirements of the customers in the car manufacturing industry. By combining MOL Group’s experience and Aurora’s exceptional know-how, the long-term objective is to accelerate further market growth while relieving the burden on the environment. The acquisition is another important milestone in MOL Group’s transformational journey to become the leading chemical player in CEE, after the partnering with German APK in plastic recycling. With Aurora in the portfolio MOL Group can increase its footprint in the automotive, a strategic segment for MOL, while addressing the increasing needs of its customers towards more sustainable products. “The recyclate-based products of Aurora greatly complement our current product line, underlining our increasing efforts towards sustainable development. As we strive to strengthen MOL Group’s presence as an automotive supplier, we recognized compounding as a key activity which we want to integrate in our business portfolio.” – said Ferenc Horváth, Executive Vice President of MOL Group Downstream. Leading ESG (environmental, social and governance) rating agencies, including Dow Jones Sustainability Indices (where MOL is the only emerging European member), MSCI and Sustainalytics have confirmed MOL’s efforts in the area of sustainability and the transition to a low-carbon economy. Chemical Engineering World



CEW News Features

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rundfos Demand Driven Distribution (DDD) system provides constant and stable water pressure for the end users in Kauniainen, a small town in the metropolitan area. The Helsinki Region Environmental Services HSY, which maintains area’s water distribution network, has been able to save energy and running costs as well as to decrease non-revenue water in the area with this initiative. ”We have received significantly less complaints from our customers regarding low water pressure than before”, says the Waterworks Operating Manager Pertti Luukkonen from HSY, “It means that the system works”. His comment refers to the new system implemented in Kauniainen during 2014. The old control method of the pumping station enabled only using pumps on constant pressure. This system was replaced with Grundfos

Demand Driven Distribution system, which alternated pressure at the booster station according to demand. The system has provided comfort for the end users and increased the stability of the water distribution network. ”Our pipe network is 28 kilometers long with challenging terrains and altitudes. The demand for pressure varies greatly depending on the time of day. Additionally the local ski center with snow making machines adds unpredictability to the overall water demand. We were keeping high pressure all the time so that we could provide water even at peak hours which we did not know when they would occur.” “The idea of the traditional pressure boosting has really changed. Keeping the system over pressurized increased our energy consumption unnecessarily, caused additional leakages, and the risk

for pipe failures was always present”, Luukkonen said. HSY was looking for ways to optimize the old water distribution system and Grundfos was simultaneously looking for a pilot project to try out the new Demand Driven Distribution (DDD). The implementation of the controller and remote pressure sensors was commissioned in 2014. The late summer and autumn were used to find the optimal level for required pressure. Local industry needs were also taken into account. “The lowest possible pressure which would still satisfy each customer comfortably was found in a trial period.,Should the pressure demand suddenly increase, the system has also a backup reserve that can be used. DDD can be adjusted and monitored from an online service through GPRS, but HSY is looking forward for an option to be able to monitor the system in real time. HSY waterworks engineer Miia Hyttinen confirms that the advantages of the system are substantial. “We have been able to reduce our energy consumption by 15-20 percent. We have also noted a significant decrease in leakage water especially during nights when the pressure is lower. The main point for us is that our customers are content with their water pressure”, Hyttinen added.

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Grundfos Pumps India Pvt Ltd (Grundfos India) Tel: +91-44-4596 6800 Web: www.grundfos.in 26 • November 2019

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CEW Features

Role of Digitization in Smart Water Management Digitization is the talk of the time, and smart water management is the need of the hour to solve various water related issues. This article narrates how digitization does foster smart water management. Not only is that, the article also exhibits various solution instances as brief business cases.

I

ndia is the second most populous country in the world. It has over 17 percent of world population, but has only 4 percent of fresh-water resources. Nearly half of India’s population is facing severe water crisis. The water crisis hampers economic growth, well-being of the nation, and sustainability of the ecosystem. Managing critical assets and aging water infrastructure pose serious challenges and require significant investments. Most of the investments that are done in these areas are reactive and are generally driven by emergencies, causing disruption, and a major loss of productivity. Hence there is a need for an intelligent system that is able to foresee and predict the emergency situations well in advance. Digital technologies in water sector utilize sensors, automation, and artificial intelligence to predict failures or operational issues, thereby driving better system performance. It empowers key stakeholders to take better decisions regarding future capital and operational investments. Smart Water ,or Digital Water, or Internet of Water refers to the use of these advanced technologies and forms a vital component of Smart Cities. According to the analysis report by McKinsey Global Institute on “Smart Cities: Digital Solutions for more livable future”, the range of digital application in Smart Cities could cut the greenhouse gas emission by ~15 percent, reduced water consumption by ~30 percent, and solid waste per capita by ~20 percent. Various enabling technologies for digital solutions in the water sectors are as follows: 1) Deployment of sensors, analytic tools, remote sensing, geographic information systems (GIS) technologies, and visualization tools can help in monitoring and forecasting of various parameters related to water quality, infrastructure, weather, and system performance. These technologies can prepare key stakeholders of water resource departments and utilities against any unforeseen incidents like storm water flow

28 • November 2019

or drought, water quality deterioration, sewer blockage, water pipeline leakages, and other challenges. 2) Data processing by using Artificial Intelligence (AI) helps in better prediction of failures and operational issues. AI can be paired with software as a service (SaaS) platforms, sensors, and communication networks to create Digital Twins of assets, systems of processes, thereby allowing strategic and costeffective operation of utilities. This is due to better planning and execution of projects, better system level performance, better tracking and understanding of resource-loss in real time, more efficient collection & distribution networks, and maximum revenue capture & customer satisfaction. Digital twins can also be used to simulate different scenarios for better planning for emergencies. 3) Augmented and virtual reality can be used for training projects & service teams by providing holographic representation of pipelines, cables, and other cost intensive assets. Block chain applications for water 4) provide possibility of direct, safe, and easy transaction between the service providers, consumers, and other players. The digitization in water has various associated benefits. Various benefits derived out of the digital water are as follows: Community • Increased availability and affordability of water. • Better customer experience. • Reduced risk of overflows and emissions, thereby protecting the environment.

Xylem is a leading water technology company that is committed to solving water. We possess an array of products and services that is helping utilities, communities and industries to solve water. Our solutions span the entire water life cycle. From collection & distribution to reuse and return to nature, our highly efficient water technologies, industrial pumps, and application solutions not only use less energy and reduce life-cycle costs, but also promote sustainability. Xylem also provides a leading portfolio of smart metering, network technologies, and advanced infrastructure analytics solutions for water, electric, and gas utilities. Here are a few examples of how various digital water solutions provided by Xylem have created an impact on our customers at a global scale. Improved performance through predicting failures & operational issues : • Pengurusan Air Selangor Sdn Bhd, Malaysia, partnered with Xylem to proactively detect leaks and pipe bursts on over 3,725 miles of critical pipes. Data from high resolution pressure and acoustic sensors have enabled important insights into the operation of the network and the nature & distribution of leaks on the trunk mains. In the first year alone,

Operational Financial Long-term Resiliency • Accurate data • Reduced • Increased resilience reduces errors and operational and to weather related enhances efficient maintenance costs. emergencies. decision making. • Proactive approach • Development of • Reduced downtime reduces breakdown workforce. and predictive and improves cash • Increased innovation. maintenance of flow. critical assets. • Improved revenue. • Reduced emergencies and better regulatory compliance.

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CEW Features 70 major leaks and bursts have been successfully detected and repaired. • Howard County, Maryland was looking to optimize their capital program to reduce leaks and main breaks. Partnering with Xylem, the team implemented an artificial intelligence supported risk model that prioritized the riskiest pipes and recommended appropriate management strategies to minimize risk. Since the beginning of the program, the County has achieved planned levels of service at 75 percent of the cost of conventional methods. • A private utility in Singapore was experiencing leaks and breaks on approximately 9 miles of new steel trunk main and was not able to determine the cause. By implementing high sampling rate pressure sensors and advanced analytics in large magnitude, damaging pressure transients were quickly detected, located and mitigated, eliminating the issue and generating approximately USD 15 million in savings. Better visibility optimization :

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performance

• Thames Water in the United Kingdom wanted to understand the nature of their water source to support the optimization treatment. Using Xylem’s automated systems, they were able to generate vertical profiles of water quality at key locations in their drinking water reservoirs. This visibility allowed them to optimize intake selection and mixing protocols to mitigate taste and odor problems and reduce the release of potential cyanotoxins, thus reducing treatment requirements, costs, and customer complaints. • The City of Houston, Texas, wanted to assess and maintain its 100,000 distribution system valves to establish and ensure system control. Together, Xylem and the City established a robust valve assessment program. To date,

4,700 valves have been found in the incorrect position, creating over 8,000 “dead-ends“, which often increase water age in distribution systems. Correcting this issue has improved water quality, increased fire flows, eliminated nearly 200 miles of “dead-ends”, and enhanced the accuracy of the City’s GIS. • Baltimore County, Maryland, was looking to use data to manage their critical force mains. Working with Xylem, they implemented a comprehensive force main assessment program using a combination of SmartBall®, PipeDiver®, and PureRoboticsTM inspection technologies. These assessments determined that 3.5 percent of pipes showed signs of deterioration, with only 0.5 percent requiring the repair. The program has empowered the County to safely and cost effectively manage its system while avoiding unnecessary replacements. • Denver Water in Colorado faced the challenge of integrating information between their Customer Billing System, Computerized Maintenance Management System (CMMS), and GIS to support their over 300 field staff. Xylem’s KonaTM solution provided a flexible mobile frontend where dispatch and field staff can see all work being conducted in one view, powered by a robust and seamless back-end integration platform. This implementation enabled information to flow between major back office systems while preserving the source system data structures and removing the need for expensive middleware. Over the course of 10 years, Denver Water has saved over USD 20 million by increasing staff efficiency across dispatch and field functions and IT integration costs. Better resilience weather events :

against

Conclusion Availability, quality, and affordability are the key challenges being faced by the water sector today. Xylem is uniquely positioned to address these complex water issues through the use of advanced technology. Let’s Solve Water – is Xylem’s tagline, as well as goal. Xylem possesses Smart Digital solutions that help to proactively manage water related assets in efficient, effective, and economical way. It increases the impact of the capital investment, while lowering the risk of system failure. These products and solutions are backed up by the global brands and many years of expertise. These solutions have been implemented across the globe and significant benefits have been realized by the water utilities, communities, and customers.

Reference:

1) Composite Water Management Index Report by Niti Aayog, August 2019 2) McKinsey Global Institute on Smart Cities: Digital Solutions for more livable future 3) Digital Water Report – The International Water Association (IWA) (https://iwa-network. org/wp-content/uploads/2019/06/IWA_2019_ Digital_Water_Report.pdf )

extreme

• The City of Fountain Valley, California, sought to increase its drought resilience by deploying advanced metering

According to the analysis report by McKinsey Global Institute on “Smart Cities: Digital Solutions for more livable future”, the range of digital application in Smart Cities could cut the greenhouse gas emission by ~ 15 percent, reduced water consumption by ~30 percent, and solid waste per capita by ~20 percent. 30 • November 2019

Infrastructure. The city selected Xylem’s Sensus Smart Utility Network solution, which enabled their team to monitor high volume consumption and identify leaks, resulting in a 23 percent decrease in water consumption and the achievement of ambitious conservation goals.

For more information Xylem Water Solutions India Pvt Ltd Bengaluru Karle Town Center- SEZ, Hub#2 , 4th floor, Survey# 61/1, 61/2 Kempapura Main Road Bengaluru, Karnataka 560045 Tel: +91 80 66794000 Email: indiasales@xyleminc.com Web: www.xylem.com/india Chemical Engineering World


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pH Correction of Cooling Water & Effluent Water: Comparison between Lime and Caustic Soda Author, here in this article, provides a comparative account for pH correction of cooling water and effluent water by using lime and caustic soda, for industrial benefit

G

enerally industrial cooling water tends to have a pH of more than 7.5 to 8 due to the presence of bi-carbonates or other alkaline compounds in it. As such pH correction is not required for Cooling Water. Effluent water can have a pH less than 7.0, thus pH correction is required here for further treatment. However, due to condensate water mixing from various sources, in specific industries (as in sugar industry) – the pH value for circulating cooling water revolves around 5.0. Lime treatment is very favored here for pH management by the industry, basically due to lower cost of lime. Therefore, some other industries also find it easy to use lime for same or similar purpose. This is with specific reference to cooling water treatment in sugar industries. Sodium hydroxide is not so favored, because of its price. However, the author here explained that how ultimately sodium hydroxide is more economical & the very suitable treatment option to increase pH, thus making the plant operation simple. Disadvantages of Lime Treatment: 1. Contrary to general perception, Lime is not suitable for pH treatment as its solubility is very low i.e. approx 1.73 g/lt water.

2. Due to low solubility, the balance Ca(OH) 2 settles as sludge in the cooling tower or effluent treatment tanks.

pH level of saturated lime solution goes to 12.4. 5. Ca(OH) 2 having higher reactivity replaces the dissolved salts into Casalts. Also, we know that Ca-salts have low solubility. 6. Removing this sludge is very tedious & often requires lot of manpower. 7. Lime further forms carbonate while coming in contact with air (CO 2 ), and which is sparingly soluble in water. These carbonates get deposited on fills of cooling tower & effluent tanks. Problem with Calcium Hydroxide: 1. Large quantities of dissolved Calcium Hydroxide are needed for pH treatment, if sludge formation is to be avoided. 2. Sludge formation in cooling tower can be difficult to handle or to remove. 3. Sludge settling on splash fills can break them and thus affect the splash fill area for heat transfer. 4. Lime is dosed manually, inadvertently the dosage is far in excess, resulting in sludge formation. 5. Calcium salts form scaling on heat transfer surfaces. Advantages of Caustic Soda Treatment: 1. It has a very high solubility of 1000 g/lt. 2. All sodium salts are soluble in water, thereby forming no scales.

temperature,

3. Small amount of NaOH causes a high rise in pH i.e. 0.4g of NaOH crystals in 1 litre of water causes a pH rise from 7 to 12.

4. Due to this low solubility, the maximum

4. With increase in temperature, the solubility of NaOH increases.

3. With increase in solubility decreases.

32 • November 2019

Results & Discussion: For Comparison, if we take a saturated solution of Lime & 20 g of Caustic Soda each in 1 litre of water to change the pH from 5 to 8 at different flow quantities.

Dosing Rate Flow Quantity (m3/day)

Lime (lit./day)

Caustic Soda (lit./day)

20

4.705

0.44

50

11.763

1.1

75

17.644

1.65

350

82.341

7.7

1000

235.25

22.0

Although Lime is cheaper than Caustic Soda, it is not appropriate for pH treatment of Cooling Water or Effluent water. Conclusion: 1. Caustic Soda eliminates the problem of scale formation. 2. Problem of Sludge can be avoided using caustic soda for pH correction, which in turn reduces other operational cost. 3. Automatic dosing with Caustic Soda is a simple way for pH correction.

Author Details Atul Krishna Sahoo and Rajat Palkar AB-ChemTECH chemtech.ab@gmail.com chemtech.ab@rediffmail.com Chemical Engineering World


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ChemTECH SPECIAL SOUTH WORLD EXPO 2019

Ceecons Process Technologies (CPT-PRAVAH)

C

eecons Process Technologies (CPT-PRAVAH) is engaged in the design and manufacture of mixing equipment like agitators and solid mixing equipment since 1990.

Ceecons Process (CPT-PRAVAH) is one of the handful of companies worldwide with expertise to optimally design mixing equipment to suit specific process task from mining to space research with infrastructure to R&D, build and test the equipment. Ceecons Process (CPT-PRAVAH) cater to Major Chemical, Fertilizer, Food, Pharma, Brewery, Specialty Chemicals, Bulk Drug, Oil and Gas, Petrochemical, Paper and Pulp, Mineral and Ore, Polymer, Cement and Construction Chemical based industries in India and also export to Bhutan, Nepal,

Bangladesh, Egypt, West Africa, South Africa and Gulf countries. Ceecons Process (CPT-PRAVAH) makes various types of agitators from portable table top Model to 1-MW industrial mixer. Agitators are made from AISI304, AISI316, AISI317, AISI410, AISI904L, Titanium, Hastalloy, Duplex, Wood and Fluropolymers.

For details Contact :

Ceecons Process Technologies (CPT-PRAVAH) (Manufacturing Facility and Registered Address) SP-66, 3rd Main Road, 4th Street, Ambattur Indl Estate (South), Ambattur, Chennai 600 058 Tel: 044-26242436 E-mail: nagaraj@ceeconsprocess.com ramesh@ceeconsprocess.com ceeconsprocess@gmail.com Website: www.ceeconsprocess.com Ceecons Process Technologies (CPT-PRAVAH) (Business Development & Technical Services Hub-Chennai), Ambattur, Chennai E-mail: nagaraj@ceeconsprocess.com aarathi@ceeconsprocess.com ccons@vsnl.com ceeconsprocess@gmail.com Ceecons Process Technologies (CPT-PRAVAH) (Business Development & Technical Services Hub-Mumbai), Nerul, Navi Mumbai E-mail: anand@ceeconsprocess.com ccons@vsnl.com 34 • November 2019

Chemical Engineering World


Brilliant Italian quality quality Brilliant technology technology Italian Saurus939: Saurus939: Saurus939: The The vacuum vacuum pump pump made made The vacuum pump made to to live live longer. longer. Unique Unique in in to live longer. Unique in reliability, reliability, performance performance and and reliability, performance and consumption. consumption. consumption.

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ChemTECH SPECIAL SOUTH WORLD EXPO 2019

Dynavac India Pvt Ltd

D

ynavac is a manufacturer of industrial and commercial cleaning equipment and dust collection systems for professionals, companies and businesses. Started operations 25 years ago in 1989 and was the first industrial vacuum cleaner manufacturer in India. Over the last 15 years, Dynavac has expanded its product portfolio to manufacture diverse range of dust collectors as well. Dynavac is committed to total customer satisfaction by providing effective

solutions to meet the specific needs when needed. Their wide network of service engineers around the country allows them to provide their customers with unmatched service. They strive hard to respond to every request immediately. Dynavac is committed to help you keep your industrial environment safe and clean. In addition to their expansive range of standard industrial cleaning and pollution control equipment, they also offer custom vacuum equipment to meet your specific needs, custom-design multi-point suction capable centralized vacuum cleaning solutions, reusable material recovery systems, vacuum tables and more. If one is looking for a blower manufacturer, fume extractor, vacuum loader, paint booth manufacturer, industrial vacuum cleaner manufacturer or dust collector manufacturer, Dynavac is the one that offers their products and services. Their team has a passion for excellence and a commitment to hard work. They not only offer equipment; they provide solutions to every need, help their customers increase profitability and productivity while maintaining a safe and clean industrial environment. Dynavac has provided solutions to the various problems arising in cleaning of various engineering, textile, pharma and trading industries, offices, car service centres, jewel manufacturing industries, water treatment plants, etc.

36 • November 2019

Their range of industrial vacuum cleaners has been designed to match the wide variety of cleaning requirements that different industries face today. One can view their complete range of products that matches ones specific cleaning requirement needs by clicking on their website. Certain models are also available with flame-proof and stainless steel options.

For details Contact : Dynavac India Pvt Ltd 302 ALG Farms Nambialaganpalayam Vedapatti Post, Coimbatore Tamil Nadu 641 007 Tel: 0422-4525555 E-mail: sales@dynavac.org Website: www.dynavac.in Chemical Engineering World


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Italvacuum Agent: Vacuum Drying Technology India LLP, Mr. Jayant Joshi - B 102 Shubh Sarita, Appasaheb Sidhaye Marg Nr Shrikrishna Nagar, Borivali East - Mumbai 400 066 Phone No 9820047858/9819982801 info@electromechengineering.com marketing@italvacuum.com | italvacuum.com

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CEW

ChemTECH SPECIAL SOUTH WORLD EXPO 2019

PH1 Industries Pvt Ltd

P

H1 Industries Private Limited is one of the reputed manufacturers and suppliers of an unlimited assemblage of Virgin & Anti-static PTFE / PFA / FEP Lined Pipes, ELBOW, EQUAL TEE, Reducing TEE, Equal Cross, Reducing Cross, DIP Pipe, Blind Flange, Concentric Reducer, Eccentric Reducers, Bellows, Flexible Hoses, Reducing Flanges, Sight Glass, Manifolds, Jacketed Pipes and Fittings, Machined Items, View Glass, Strainers, Instrument Tee, Dampners, Valves, etc that are massively admired for their quality and flawlessness. The company has wide range of liner materials which includes PTFE, PFA, FEP, etc.

• The company is focused on catering to the exact needs of their valued patrons with high quality standards. • The high demand of the PTFE Lining division in pharma sectors has lead the company to manufacture the PTFE/FEP/ PFA lined pipes, fittings, and various lining materials. • PH1 is an ISO 9001 accredited company and is dedicated to deliver innovative, reliable, and safe products to the customers worldwide. • The rapid advances in technology have made today’s manufacturing environment increasingly stringent and complex.

• To meet these requirements, PH1 has implemented systems to improve efficiency and quality of products. Service Offerings / Product Lines: The Company caters to many Pharma plants with full-fledged services in the pipe line sector. A few are mentioned below: 1. MS/SS PTFE LINED PIPES 2. MS/SS PTFE LINED ELBOWS 3. MS/SS PTFE MACHINED BELLOWS 4. MS/SS PTFE EXPANSION BELLOWS 5. MS/SS FEP/PFA LINED CONCETRIC/ ECCENTRIC REDUCERS 6. MS/SS FEP/PFA LINED REDUCING FLANGES 7. MS/SS FEP/PFA LINED EQUAL TEE 8. MS/SS FEP/PFA LINED REDUCING TEE/ UNEQUAL TEE 9. MS/SS FEP/PFA LINED BALL VALVES 10. MS/SS FEP/PFA LINED BUTTERFLY VALVES 11. MS/SS FEP LINED FLUSH BOTTOM VALVES 12. MS/SS FEP LINED DIAPHRAGM VALVES 13. MS/SS FEP LINED Y-TYPE STRAINERS 14. MS/SS FEP/PFA LINED BLIND FLANGES 15. MS/SS FEP/PFA LINED INSTRUMENT TEES 16. PURE TEFLON SOLID SPACERS 17. MS/SS FEP/PFA LINED EQUAL CROSS 18. MS/SS FEP/PFA LINED REDUCING CROSS/ UNEQUAL CROSS

19. MS/SS FEP/PFA LINED SIGHT GLASSES 20. MS/SS FEP/PFA LINED BALL CHECK VALVE 21. MS/SS FEP/PFA LINED DIP PIPES 22. MS/SS FEP/PFA LINED MANIFOLDS (2-WAY & 3-WAY HEADER) 23. MS ANTI-STATIC PTFE LINED PIPES & FITTINGS 24. PTFE CORRUGATED HOSES 25. SS BRAIDED PTFE CORRUGATED HOSE 26. TEFLON GASKETS

Market Positioning: PH1 is a listed company amongst the foremost manufacturers & suppliers in the market. They have been operating through a quality management system certification qualifying to national & international standards. We have wellequipped in-house testing facilities. The parameters we can bank on, are: • • • • •

Qualitative product range Ultramodern infrastructure facility. Consistent improvements to the products. Experienced professionals. Efficient logistics and widespread distribution network. • Cost-effective prices. • Timely delivery. • Ethical business practices. Future Business Outlook: PH1 is planning to manufacture PTFE Lining pumps, various lining materials, and a wide range of mechanical equipments in different Material of constructions. The company is following the philosophy of evolving in to various sectors and coming with solutions accordingly. Their expansion has been taking place through Extension of their branch-offices and worldwide product export. For details Contact :

Ph1 Industries Pvt Ltd Reg. Off: No 13-59, Indiragandhi Nagar HMT Road, Balanagar Hyderabad 500037, INDIA.

Works: Plot No. 149, Road No. 4 IDA – Medchal, R.R. Dist, Telangana, India Tel : +91-7207067457 E-mail : sales@ph1.in 38 • November 2019

Chemical Engineering World


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Micro Pneumatics Pvt Ltd “MICRO PNEUMATICS PRIVATE LIMITED” founded in 1986 with a clear vision of excellent quality, reliability and customer satisfaction. The company earmarks themselves as a One Stop Solution For Valve And Valve automation Systems Under One Roof.

Micro Pneumatics follows a certified Quality Management System as per ISO 9001:2015 by Bureau Veritas Quality International with UKAS accreditation and Quality Management System implemented as per API Spec Q1.

Journey of Micropneumatics:

“MICRO” Valves are successfully tested accordance with API – 6FA (Fire Test) by DET NORSKE VERITAS AS (E), Flow by Fluid Control Research Institute Palakkad; 1 Million Cycle Test by Projects & Development India Ltd. (PDIL); and CE marking for Ball Valves, Butterfly Valves & Actuators. “MICRO PNEUMATICS” have 3-A Certificate for Cavity Filled Flush Bottom Ball Valves and Cavity Filled TC End Ball Valves with its patent registered, SIL – 3 for Ball Valves & Actuators, and IBR Certification for Ball Valves & Butterfly Valves. Micro Pneumatics Pvt Ltd is a Member of KITZ Group Japan, which is the 3rd largest manufacturer of Valves & Valves Automation in the world. As of worldwide, the KITZ group has 36 consolidated subsidiaries. With its 100 percent takeover by Valve Giant KITZ Group, Japan in February, 2015, Micro & KITZ have come together under the name Micro Pneumatics Pvt. Ltd – A member of KITZ Group. The company sees this merger as an important milestone which brings them one step closer to accomplish their goal; and also enables them to have a strong relationship, mutual trust, and an aim to build high quality & noble business to the world.

Launch of Actuators in 1986

Offset Design Butterfly Valve in 2000

Flush Bottom Valves in 2003

40 • November 2019

Launch of Ball Valves in 1987

TC End Ball Valves in 2003

For details Contact : Micro Pneumatics Pvt. Ltd A Member of Group Plot 133 – 134 Vasai Municipal Industrial Area, Umela Phata, Papdy, Vasai (W), Dist: Palghar Mumbai, Maharashtra, India. Email: info@micropneumatics.in Website: wwwmicropneumatics.in Chemical Engineering World


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KEP Engineering Services Pvt Ltd

T

he genesis of KEP can be traced back to 2010 when a group of technocrats, with years of experience in diverse fields, decided to pool their combined talent and to create an engineering company that would be a projection of their personality to

Zero Liquid Discharge System

Evaporator with ATFD

Evaporator with Crystallizer & Pusher Centrifuge 42 • November 2019

achieve their goals. KEP commenced its operations at Jeedimetla in Hyderabad, providing technological consultancy to diverse industries while commencing manufacture of a range of evaporators, distillation columns and dryers. In a short time, the company established itself as one of the leading manufacturers of Evaporator, ATFD, Distillation column, Heat Exchanger etc. Our approach is based on knowledge, concept, design, planning, and execution, especially when it comes to specialized Falling Film Forced Evaporator and Thin Film Evaporation technologies. The organizational competencies cover the entire gamut of Zero Liquid Discharge System, Multi Effect Evaporator, and ATFD technologies allowing KEP to design and to deliver solutions to meet their client needs.

Pharmaceutical & Drug Industries, Chemical Industries, Fertilizer Industries, Beverages Industries, Food Industries, Textile Industries, Petrochemical Industries, and Metal Industries

The present offerings include: Zero Liquid Discharge, Multi Effect Evaporators, Agitated Thin Film Dryer, Effluent Treatment Plant, Reverse Osmosis, Distillation Columns, Heat Exchanger Crystallizers, and Mechanical Vapour Recompression Evaporation (MVRE).

For details Contact :

Company’s technical expertise caters to the following industries:

Stripper Column Evaporator with ATFD

KEP Engineering Leads by virtue of superior engineering design capabilities, manufacturing excellence and a project based approach for commitment to delivery with high performance for total evaporation solutions customized to client’s requirement.

Mr T. Sairam Manager Business Development KEP Engineering Services Pvt Ltd Mobile: +91-9100444811 Email: proposal@kepengg.com business@kepengg.com Chemical Engineering World


ChemTECH SPECIAL

CEW

SOUTH WORLD EXPO 2019

Mascot Systems Pvt Ltd

M

ascot Systems Pvt. Ltd. is an Engineering Solutions company that provides specialty products for the Chemical, Petrochemical, Oil & Gas, Pharmaceutical, Fertilizer, Power, Water and Food industries. The broad range of engineered solutions includes Pumping, Sealing, Compression, and Safety technologies. The Company is located in six major locations in India catering to length and breadth of the country. Majority of the products are stocked in the Navi Mumbai warehouse and can be delivered to customers’ place with ease in the shortest possible time. Product Overview: For the products mentioned below, the company is the sole authorized channel partner for the Indian region: DuPont Kalrez Perfluoroelastomers DuPont’s KALREZ Perfluoro-elastomers (FFKM) O-rings and custom shapes- are widely used in mechanical seal as well as other equipment including Pumps, Valves etc. in various process plants handling corrosive chemicals, solvents, amines etc. and are suitable for CIP / SIP cleaning. Kalrez offer corrosion resistance to over 1800 Chemicals and are suitable to handle high working temperatures (up to 327 Deg C). Kalrez Valve Stem Packing (KVSP®) systems can significantly reduce fugitive emissions and improve process control. 100 Percent Genuine Viton Range of Elastomeric O-rings Mascot Systems Pvt Ltd is the channel partner for DuPont Kalrez Perfluoroelastomers in India and also supplies 100 percent genuine Viton O-rings. We have a rich experience that can help you with your demanding sealing requirements. Rembe GmbH Rupture Discs and Explosion Safety products REMBE® rupture discs are high precision safety devices that incorporate state-of-the-

Chemical Engineering World

art technology. REMBE® rupture discs are technically sophisticated safety devices, which are individually manufactured and tested for each application. They open at a precisely predefined pressure, relieving that pressure from the system. Rembe® rupture discs can be used as primary or secondary relief devices. In combination with a safety valve they are often an economically attractive option which protects the valve against product contamination or corrosion damage. The Explosion Safety product portfolio includes Ø Explosion Vents for Silos, Chambers, Coal Mills, Dust Collectors, Spray driers etc. Ø Flame-less Venting devices - Q Rohr-3 and Q-Box-II suitable for indoor venting of Dust collectors, chambers & Mills etc. Ø Explosion Isolation valve - Q-FLAP and EX-KOP with controller for isolation of flame propagation from Dust collector to aspiring equipment Ø Explosion Suppression System – Q Bic for Spray dries / chambers etc. Esco Couplings: Esco Couplings & Transmissions Private Limited (ECTPL) is a 100 percent technical subsidiary of Esco Couplings NV Belgium. It’s an ISO 9001 company and the world’s leading industrial flexible Gear & Disc types coupling manufacturers with a manufacturing facility in Bangalore. Escodisc couplings are being developed to ensure infinite lifetime while transmitting the highest torques at high misalignment, temperatures, and speed, even in aggressive and dusty atmospheres. These couplings are reliable and require no lubrication. Their discs assemblies are fretting corrosion-free, maintenancefree, and meet the most diverse application requirements of diverse industries such as petrochemicals, cement, test benches, power generation, and more. Escogear couplings, designed and optimized with the highest quality multi-crown gearing,

allow the transmission of the highest torque under the highest misalignment conditions using their large bore capacity. Being robust, efficient, and built for a long service life, they are the ideal solution for heavy duty machines catering to some specific industries such as steel, power generation, pulp & paper, marine, dredging, and more. Kito Armaturen GmbH: Kito’s product range includes flame arresters – Deflagrationproof, Detonation-proof, Flame arresters and Pressure/Vacuum Relief Valves. Being manufactured in Germany, Kito’s products meet the latest International standards, offering customers a safe process environment. Marque Bearing Seals: It’s a noncontact, non-wearing, and permanent bearing protection device. Marque Bearing Seals ensure that maintenance costs are significantly reduced and productivity is increased. BHDT GmbH: BHDT is a technologically qualified manufacturer and supplier of High pressure equipment and components including pumps, valves, vessels, and fittings for Chemical and Petrochemical industry – with specialization in Urea, LDPE, and EVA. Manufactured in Austria, BHDT products are world-renowned with more than 60 years of service across the globe.

For details Contact :

Yoganand Nannapaneni Mascot Systems Pvt Ltd 801, Ambience court, Plot 2 Sector 19D , Palm beach road, Vashi , Navi Mumbai - 400709 Tel: +91 022-41226500/01 /02 /03 E-mail: sales@mascot-systems.com Web: www.mascot-systems.com November 2019 • 43


CEW Paints & Coatings

Pipeline Corrosion & its Control The most important and acceptable method of transporting crude oil and gas from the exploration site, and a large number of hydrocarbons from refineries to storage areas is – by underground pipelines. Water pipelines are both underground and above-the-ground, while crude and gas transporting pipelines are mainly underground. One of the reasons for the same is the safety. Earth acts as the first defense towards safety. Corrosion is a serious problem. Internal corrosion of pipelines depends mainly on the type of fluid, while external corrosion depends on the soil conditions. For underground pipelines, the internal corrosion is not a very serious problem and is usually tackled by injection of inhibitors; however, external corrosion is a real threat which is controlled by a combination of coatings and cathodic protection. Here, in this article, the author narrates the various factorials and aspects of pipeline corrosion along with how to arrest it. His discussion here is limited to pipeline systems transporting crude, gas, hydrocarbons, and water.

P

ipelines are important constituent of our day to day life. They control our daily life cycle to a great extent. The very basic requirement of life – the water – reaches our home through pipelines; essential ingredients of our life such as petrol, diesel, and many other important hydrocarbons reach us through pipelines; natural gas, which is used in running several power plants and fertilizer plants, is being transported through pipelines. Cooling water for condenser of a power plant requires a robust pipeline to transport sea water at very high volumes. Sewage disposal from residential buildings and industrial plants is also carried out effectively using a very strong network of pipelines. We cannot think of a system without a pipeline link to take care of our essential requirements in our home and industry. Not only is that, ships and other commercial vehicles also use complicated pipeline network to supply fuel & cooling water to run the engine. In this context, it’s noteworthy that all piping systems have one common problem of corrosion.

Above-the-ground pipelines, in fact, face even larger threat of corrosion due to – changing climatic conditions, pilferage from people, and natural disasters such as thunderstorms, tree falling, building or structure collapse, etc; but do not pose a security threat as opposed to underground pipelines, which carry inflammable materials. Our discussion will mainly focus on ‘Underground Pipelines’. UNDERGROUND CROSS COUNTRY PIPELINES (UCCP): There is a huge network of underground pipelines across the globe. The UCCP lines are made to transport the crude and gas which are

inflammable and can catch fire if released due to some accidental leak or damage. That is why the first and foremost safety factor considered for UCCP is the earth itself, which acts as the first defense against fire or the release of the inflammable material to the environment. Usually, the pipelines are kept 6 feet below the earth level and nicely protected by gravel & mud to insulate them from outside environment. Different countries have these pipelines with different lengths and capacity spread across various land terrain varying in softness, hardness, sandy, or rocky nature and may be full of minerals or moisture. These terrains can be the under-sea, river

Classification of Pipeline Systems: In this classification, the pipelines can be divided into two broad categories: • Underground pipelines carrying crude, gas, and water. • Above-the-ground pipelines carrying hydrocarbons (within an industry’s boundary), and water (either for dinking or for fire-fighting applications). From the corrosion point-of-view and its protection strategies, underground pipelines are very important and a lot of systematic information is already available. 44 • November 2019

Figure 1: Network of Oil pipe line in India [3]

Chemical Engineering World


Paints & Coatings CEW been improved in the last three decades to various modified compositions (X46 to X100) to take care of specific corrosion related problems and strength. These several modified alloy compositions are listed in table 1, along with their tensile strength and yield strengths [4] Corrosion of UCCP: Though steel has excellent properties in terms of its strength, ease of fabrication, as well as its low cost, the most important drawback it has – is of getting corroded. Therefore, the steel needs the corrosion protection at wherever it is being used. This is a very important subject; and galvanization, coating by paints, use of inhibitor chemicals, etc are some of the primary methods towards protection.

Figure 2: Network of gas pipe line in India [3]

the crude and gas; and the rest belongs to refined product. These pipelines are spread across several states and are passing through various cities, towns, villages, and riverbeds. Figure 1 and 2 give a network of various pipelines for crude and gas respectively, spread across the country [3]. This does not include a network of compressed natural gas distribution lines, already working in many big cities such as Mumbai, Delhi, Ahmadabad, Baroda, Chennai, and Bangalore.

beds, brackish water, etc. Thus the first step in laying underground pipelines is the selection of laying route as per right of way permissions from several agencies in that state or county. There are more than 6500 offshore oil and gas installations in some 53 countries around the world. More than 50 percent of these installations are in the US Gulf of Mexico [1]. The next five largest areas are Asia, Middle East, North Sea, West Africa coast, and South America in descending order [2]. These six regions account for the majority of the existing offshore oil and gas installations. The installations are built for exploration (drilling) and production (including preparing water or gas for injection, processing oil or gas, cleaning produced water for disposal, and various accommodations).

Steels used for UCCP: The most common material for pipeline construction is the Steel, because it is the cheapest structural material, available in large quantities with the most suitable properties; and also, it is easy to fabricate into various shapes and sizes. There is, however, significant variation in the composition of steels being used for UCCP. The most primitive composition is X42, which has gradually

India has more than 25000 Km of UCCP, with more than 50 percent transporting Element /Grade

C

Mn

X42

0.09

0.84

X46

0.09

X52

It is easy to understand the corrosion when the pipeline is exposed to environment; however, it is not so easy for the underground pipelines. The earth or terrain at which a pipeline is buried, varies considerably from place to place. The soil under earth can be soft mud, sandy, rocky, or – with lots of minerals and moisture, brackish water, marshy land, or a river bed. All these create different local environment, which in turn causes the corrosion of underground pipelines. The corrosion occurs because of formation of differential corrosion cells on the pipelines due to the presence of soils with varying oxygen levels, or the steel pipes exposed to a soil of varying compositions viz sandy vs clayish texture, etc. The soil with different moisture levels will also create anodic and cathodic areas resulting the corrosion in steel pipelines from stressed areas (welded areas) to unstressed areas [5]. Corrosion is one of the major causes of pipeline failure. Courtesy to American gas pipeline data in 2011, about 22 percent failure of pipelines are due to corrosion

Cr

Cu

Ni

Mo

Al

Si

Nb/Ti

Yield Strength (MPa)

Ultimate Tensile Strength

0.013 0.004

0.07

-

0.02

0.02

0.03

0.22

-

290

414

1.28

0.014 0.009

0.02

-

0.03

0.03

0.02

0.25

-

317

434

0.09

1.31

0.012 0.006

0.01

-

0.07

0.003

0.03

0.25

-

359

455

X56

0.12

1.27

0.017 0.004

0.07

-

0.14

0.19

0.02

0.26

-

386

490

X60

0.12

1.48

0.013 0.004

0.01

-

0.09

0.02

0.008

0.27

-

414

517

X70

0.13

1.71

0.012 0.001

0.07

-

0.07

0.02

0.05

0.30

-1

483

565

X100

0.064

1.56

0.024 0.002

-

0.38

0.54

0.28

0.03

0.13

0.089/ 0.011

690

760

P

S

Table 1: Chemical Composition of Various Steels Used for Underground UCCPs

Chemical Engineering World

November 2019 • 45


CEW Paints & Coatings carbonate layer so formed remains protective at temperatures higher than 40oC and upto 80-100 oC, and hence the corrosion rate falls down. The de Waard and Milliams model is to predict the sweet corrosion [8,9]. They developed this model to investigate the corrosion of pipeline carrying wet natural gas containing CO2. The relationship between pH and Carbonic acid concentration is given below: pH(pCO2 = 1) = 4.17 x 10-3 T+371

(6)

Subsequently, they derived a simple equation to predict corrosion in sweet system log Ccorr”=5.8-1710/T+ 0.671 log(p CO2 ) (7)

Figure 3: Causes of pipeline failure in 2011 [6]

alone, which is slightly less than the material failure as exhibited in fig. 3 [6]. Methods of UCCP Corrosion Protection: Pipeline corrosion is of both internal and external. As per the schematic in Fig 4, the internal corrosion is due to the fluid flowing through the pipeline (viz. crude, gas, or water), whereas the external corrosion is due to the soil interruption as explained in penultimate section. Internal corrosion is not that serious unless the crude is sour (i.e. when H 2S level is more than 500 ppm) in nature. In case of sweet crude or gas, the internal corrosion is usually being treated by inhibitor addition into the pipelines. At times, a 50 µm epoxy coating is being applied to take care of the pipe’s drag problems. External corrosion problems are comparatively serious and require high class protective coatings, followed by additional cathodic protection. Internal Corrosion in UCCP: Corrosion on to the internal wall of a natural gas pipeline can occur when it is exposed to water and gas contaminants such as H 2S, CO 2, or chlorides. The nature and the extent of such damage are the function of the concentration of various corrosive constituents, such as CO2, H 2S, water/moisture entrapment, pH, present within the pipe as well as at the operating conditions of the pipeline [7]. 46 • November 2019

For example, gas velocity and temperature in the pipeline play a significant role in determining the corrosion damage and its location. In other words, a particular gas composition may cause corrosion only under some specific operating conditions. Therefore, it would be difficult to develop a precise definition of the term “corrosive gas” to be applicable universally under all operating conditions. The main effect of CO2 is to dissolve in water and to form carbonic acid, which dissociates and changes the pH, and which in turn causes corrosion. H 2O+CO2I H2CO3

(4)

H 2CO3IH + + HCO3-

(5)

Usually upto 40oC, a non-protective carbonate layer is formed. But the

External Corrosion taken care by Coating and CP

Where Ccorr is the corrosion rate, T is the temperature in oC, and pCO 2 is the partial pressure of CO2. They further simplified the nomogram and included a ‘scale correction factor’ to account the decrease of corrosion rate due to the formation of surface layer (Fig.5). Furthermore, they have also estimated the effect of total pressure, and temperature. At scale temperature Tscale, corrosion rate starts to decrease. It depends on the flow rate i.e. higher flow rates lead to higher scaling temperature Tscale=

2400 6.7+0.6log (fCO2)

(8)

The situation changes drastically when H2S is also present with CO 2 . This is explained as per the model explained by Srinivasan model [9]. The effect of H 2S depends on its partial pressure. At the partial pressure of H2S less than 0.01 psi, CO 2 is the dominant corrosive species; and the corrosion rate and surface layer formation are function of FeCO3 concentration. When the partial pressure of H 2S is higher than 0.01 psi and pCO2/pH2S is greater than 200, an iron carbonate layer can be formed depending

Internal Corrosion taken care by inhibitor dosing

Figure 4: Schematic of a pipeline corrosion issues

Chemical Engineering World

p


Paints & Coatings CEW amides, imidazolines, fatty acids, and their salts [12].

p

Figure 5: Nomogram to predict sweet corrosion [ 8]

upon the pH and temperature. However, when pCO 2 / pH 2S is less than 200, an iron sulfide layer is formed preferentially. Moisture Content: Moisture is a serious problem for steel pipelines. It is noticed that natural gas, obtained while drilling wells, typically remains very moist. Cold ambient temperature can make the moisture available in the gas condensed, and the corrosion can start when the relative humidity reaches above 60 percent. Hydrate formation is a combination of high moisture and high hydrocarbon concentration, which together form a solid aggregation that can slowly decrease the diameter of the pipeline, thereby reducing the gas supply capacity and blocking the valves. The icing problem is also a result of excessively high gas moisture content. Icing can occur in cold climates as well as at higher temperatures due to a fast-changing pressure such as in valves, where the pressure drop causes the natural gas to cool down. Cooling can make the moisture to condense and even to freeze, resulting in disruptions to the natural gas supply. The most common way to dry the natural gas is – to use glycol to separate the gas from the water. The gas will then either be compressed for delivery via the pipeline, or be liquefied in a tank for Chemical Engineering World

delivery by other transporta-tion methods. In pipeline transmission, the gas must be in a dry state to avoid pipeline corrosion, forma¬tion of hydrates, as well as icing of valves [10]. Methods of combating Internal Corrosion: Usually internal corrosion problem arises when crude or gas is sour in nature. Usually a corrosion resistant coating is required for sour-gas environment. These internal coatings are usually epoxybased coatings, and are being applied by internal spray of epoxy coatings. However, crude or gas when transported to refineries and storage tanks, sulphur and moisture are removed to make the fluid sweet and after that using various inhibitors helps in combating internal corrosion. The basic purpose of these inhibitors is to create a thin film of organic material on to the inner wall which prevents its direct reaction with the moisture or corrosive gases. Most of the inhibitors, being used for oil and gas applications, are usually organic in nature – for example, acetylene, alcohols, quaternary ammonium salts, aldehydes, amines, etc. [11]. The effectiveness of inhibitors varies in static as well as in flowing conditions. Active inhibitors recommended for various flow conditions are long-chain amines, fatty

External Corrosion Problem: This is due to remaining in a continuously varying environment of different kinds of soils, sand, marshy land, brackish water, river-beds, and sea organisms & microorganisms, espe¬cially SRB. In addition, the corrosive environment of soils may also be due to moisture, minerals, oxygen, chloride, etc, which further enhances corrosion. Coatings are the natural choice to create a barrier for the corrosive environment in soils. Over the years, there have been different coating materials and formulations used to protect pipelines. For example, in the 1940s and 1950s, coal tar, wax, and vinyl tape were used; in the 1960s, asphalts were used; and since 1970s, several polymer based insulating coatings are being used. Polyethylene (PE) tape and extruded PE jacket material also have been used since early 1950s. Fusion-bond epoxy (FBE) has been one of the most successful measure being used since 1970’s and is equally popular even today. It is the most important to note that the coatings alone are not a permanent solution for the pipeline’s corrosion protec¬tion as it deteriorates with time while interacting with environment. Hence, to take care of this underground pipeline degradation, an additional cathodic protection is being given. A total pipeline protection system, thus includes the consideration of steel quality, coating applica¬tion, surface condition and treatments, design of coating, and cathodic protection system. Although there are many types of coatings that have been applied on buried pipelines, the three main coatings commonly used are – coal tar, FBE coating, and three-layer PE (3LPE) coat¬ings. The coal tar coatings are now banned for causing carcinogenic vapor release thus affecting the workers. The most acceptable coating today is plastic coatings, especially 3LPE, which consists of a primer fusion bond epoxy layer, followed by a thick Polyethylene layer. An intermediate tie layer is required to join the primer FBE (polar) and external PE (nonpolar). FBE Coatings: Out of various organic coatings, epoxies have the strongest resistance to oxygen, moisture, and chlorides, which are important soil constituents. Further, they are highly November 2019 • 47


CEW Paints & Coatings Unloading of Pipes, followed by shot blasting up to Sa2 ½

Heating of pipelines to a temperature of 180-200oC

PQT Holiday Detection, Impact Test, Peel strength

Electrostatic Powder Coating using FBE Powder

Quenching

Figure 6: Schematic of Single layer Fusion Bond Epoxy coating on the Pipeline.

insulating with very low conductivity and high dielectric resistance. That is why epoxies are the preferred choice for strong corrosion resistance. There are many ways by which the epoxy coat¬ings can be applied: brush, spray, using liquid epoxies, or electrostatically spraying the fine epoxy powder on a heated pipe, which immediately melts it and fuses instantly. The coating has good cathodic disbondment resistance, hot water resistance, and good flexibility (5° of pipe diameter) at −50oC. FBE coatings are thermosetting compounds, which once set, cannot be re-melted. The most important requirements of the coating are the surface, once set, cannot be remelted. The most important requirements of the coating are surface cleanliness, proper heat¬ing, and sufficient cure. The first step is the blast cleaning of the pipe to Sa21/2, followed by heating the pipe uniformly using an induction furnace [13, 36]. This is followed by electrostatic spraying of FBE powder, which immediately melts and fuses. The hot coated pipe is quenched immediately. The temperature at the pipe surface usually ranges from 180oC to 210oC. The coating thickness depends upon the pressure of the FBE powder, electrostatic voltage, and conveyor belt speed. A 350–500 μm coating is required from a pipe diameter of 8 to 36 inch. A schematic of FBE production is shown in Fig.6 Three Layer PE Coatings: One of the drawbacks of such a thin-coated pipe is its damage during transportation and handling. In the mid-1980s and in the beginning of the 1990s, two additional coating systems were discovered. The first was the 3LPE system and the other was the dual-layer FBE system. The purpose for both the cases was to enhance the damage resistance of the single-layered FBE coating (described above). In 3LPE, it was achieved by the application of an extruded PE coating of 48 • November 2019

1500 to 3000 μm over the FBE primer layer of 100–150 μm. Since it is not possible to directly coat a PE layer over an already-coated FBE layer, an intermediate adhesive coat of polyolefin is made, which adheres primer to the FBE layer through its polar functional groups and to PE by its hydrocarbon groups [37]. The temperatures required to coat an adhesive layer and PE layers are, 220°C and 238°C respectively, and the two coatings must be applied within a small time interval of 13–25 s (depending upon the pipe surface temperature). A schematic of 3 LPE system is shown in Fig. 7, and different coating layers on pipe in Fig. 8 Dual FBE Coating: Another way of strengthening Single FBE coating is to make a dual FBE coating. In dual-layer FBE coating, an outer layer of FBE powder of different composition is applied over the primer layer [14, 15]. The purpose of the inner layer is to have a strong adhesion to the pipe, while the outer layer is expected to be very tough to have a high impact resistance. 3M made a coating system where the outer layer achieves the maximum toughness because of the cellular structure of the coating. The method of application is very similar to that of a single FBE coating,

and coating can be carried out in a single booth, with some guns carrying inner-layer powders and others carrying outer-layer powders, placed in such a way that the outer powder sprays after the inner powder is sprayed and is still not being able to gel well [16]. The coating of the inner layer is generally fixed at 250 μm, while the thickness of the outer layer varies with the diameter of the pipe, 250 μm for 8–22 inch pipe diameter and 350 μm for a pipe with a diameter of above 22 inch. Amongst all the coatings discussed above, technically it can be said that dual FBE is perhaps the best. Because, dual coating gives two-fold benefits – The inner primer layer having good adherence properties and is responsible to provide long life, and high cathodic disbandment resistance. The outer layer has a cellulose type structure, which gives it strong resistance against impact, scratch, and abrasion, and thus providing additional protection. This is nicely shown in the schematic (Fig.9), where these two layers are shown along with their structure. The third important point about dual FBE is that it has the best response to cathodic protection as it has small but limited permeability to moisture, making dual FBE very active to cathodic disbondment. Thus dual FBE which has adequate thickness as well as has strong durable properties along with resistance to external damage has also one of the best coating for cathodic protection. Three layered PE, though has much larger thickness, has two very serious limitations.

Figure 7: Schematic of three layer PE coating

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Paints & Coatings CEW

Figure 8: Showing three layers (1) FBE layer, ~ 100-150 microns, (2) adhesive layer ~ 200 microns and (3) polyethylene layer ranging from 500 microns to 2500 microns

Firstly, its poor response to cathodic disbondment as PE is totally impermeable to moisture. That’s why cathodic protection in 3PLE works only when external PE is damaged. Secondly, it has shielding corrosion problem. Once the corrosion starts under the coating, it grows continuously with time till it becomes a catastrophe. In addition to these three main coating systems, several other coatings are also applied on pipe¬lines. For example, for high-temperature fluids, polypropylene coating is used instead of PE. Tape coatings or wrappers are another types which are being used for protecting pipelines. However, these are used only for rehabilitation [17,18]. The application involves cleaning of the surface with wire brush, followed by the application of a primer, and then inner wrap, and finally the outer wrap as shown in the schematic Fig. 10. In Germany, there are a few examples where cold-applied tapes are used for short-distance new pipelines. Visco-elastic coatings is a very recent coating introduced a few years ago by trade name STOPAQUE [19]. This coating also, though good for rehabilitation work,

Figure 9: Schematic of dual layer FBE Coating

Chemical Engineering World

has been recommended for use of fresh pipelines in Netherlands. Field Joint Coatings: The field joint coatings are the coatings that are used to join individual pipes, coated in the field, just before laying them in the ditch. Such coatings are also called girth weld coatings as these are applied on the weld joint between the two coatings [20, 44]. Since welds are vulnerable areas, prone to be attacked by corrosive species, they need to be coated with special care to enhance their resistance to corrosion while at the same time maintaining their compatibility with the main pipeline coating. Though, there are many coatings that can be applied at field joints, such as liquid epoxy, elastomeric polyurethane, cold-applied tapes, and viscoelastic coatings [19], the most common and acceptable field joint coating is the heat shrink sleeve coating. These are basically the rubberized coatings that, on application and after heating shrink, hold the pipe. The first step is the full cleaning of the girth weld area, followed by application of a primer epoxy coat. This is followed by the application of heat sleeve which requires uniform heating to make an excellent uniform coating on the welded area [20]. Protection of Pipelines by Cathodic Protection: As discussed, above pipelines are coated from external side by various kinds of coatings – CTE, FBE, 3LPE etc. It is well known that coatings are not permanent. They deteriorate with time. Hence for UCCP, which is designed for 30 year design life, there must be an additional fool proof method to check the coating deterioration. This is usually

done by cathodic protection. The basic idea of a cathodic protection system is to protect the pipe through the use of an electrical current. This basically means that the entire pipe becomes a cathode, and the sacrificial anode corrodes. There is no outside power source necessary for this type of protection because the anode material, itself makes the current to flow naturally. The sacrificial anode will eventually become totally corroded and will need replacement as the pipeline structure ages. Because of this reason of frequent periodic anode replacement and also because of the requirement of a large number of costly anodes, this method is not being used for UCCP. Instead, impressed current cathodic protection (ICCP) method is used for UCCP lines. Impressed current pipeline cathodic protection (ICCP) systems are generally being used in larger structures, because the galvanic anodes are not capable of producing enough current to provide sufficient cathodic protection. The impressed current requires a DC power source. Usually, other power sources are used and converted to the necessary DC. A variety of materials may be used as anodes for the impressed current, such as ferro-silica, platinum, or other noble metals or alloys. In this case, the electron flow is due to application of current and not because of dissolution of anodes. Thus, the anodes get a long life and there is no need for further replacement. Pipeline cathodic protection can be applied to new pipelines, the systems that have been around for a while & need additional protection, and even in hot spots where corrosion is becoming a problem. This means that the life of existing pipeline systems can be extended and problems can be avoided with the use of this technology. A thinner-walled pipe may be used if it has been sufficiently protected, which can save quite a bit of money in the production of the pipeline itself. Cathodic protection also acts as a monitoring system for the pipeline. Pipe-to-soil potential is one of the criteria for assuring the protection of a pipeline. If the psp is – 850 mV w.r.t Cu/CuSO4 reference electrode, then it is considered as protected. If however, the psp is lower than -740 mV, the pipe is being considered to have some damage due to coating failure [21]. November 2019 • 49


CEW Paints & Coatings

Figure 10: Schematic of a tape wrap coating for protecting external surface of a pipeline

There are very simple thumb-rules of total protection of pipeline by coating and cathodic protection. For a low cost coating, the current required is rather high; so cost of latter is more. For a costly coating, the current required is less and hence CP cost is less. This is shown schematically in Fig.11 and also current required by three main coatings are tabulated in Table. Conclusion: Transportation of crude and gas is an important activity of oil and gas industry. Because of the flammability of transporting fluid, the best method is the transportation through underground pipelines. However, both internal and external corrosion threats are there, which need to be properly taken care of by the appropriate corrosion protection methods. While the use of inhibitors is the most acceptable method of controlling internal corrosion of pipelines, use of coating and cathodic protection are required for external corrosion protection. The most acceptable external coating across the globe today is three layered PE coating for new pipelines. The cathodic protection does not only augment the corrosion protection by coatings, but also helps in monitoring its health constantly with psp potential values.

References 1.

Major Pipelines of the world, 4th edition, Petroleum Economist Magazine, Sep. 2012.

50 • November 2019

2. 3. 4.

5. 6. 7.

8. 9. 10. 11.

12. 13.

The Use of Coatings for Corrosion Control on Offshore Oil Structures, J. Peter Ault, P.E.ConsultantOcean City, NJ Oil and Gas Pipeline Infra Summit 2014, The waterstones hotel & club, April, 17, 2014, Mumbai A.S.Khanna, Selection of Materials for Oil and Gas Applications, ‘Corrosion and Materials in the Oil and Gas Industries, Reza Javaherdashti, Chikezie Nwaoha, and Henry Tan, Edts., CRC Press, 2013, Chapter 9 Corrintec, USA, Presentation at KFUPM Dhahra, Saudi Arabia, March 5, 1982 http://projects.propublica.org/pipelines/ Corrosion resistant alloys for oil and gas production- guidelines on general requirements and testmethods for H2S service ( EFC-17, 2nd edition). Maney Publication, 2002, ISBN: 978-1-902653-556, Knovel (editor). De Waard, C.; Milliams, D. E. Corrosion 1975, 31, 177. Srinivasan, S., Kane, R. D.; Corrosion/96, Paper no. 11, NACE, Houston, TX, 1996 J.Gronblad, The Challenges of moisture measurement in natural gas, Vaisala Finland. Rajeev P, Surendranathan AO, Murthy CSN (2012) Corrosion mitigation of the oil well steels using organic inhibitors – a review. J Mater Environ Sci 3(5):856–86951. Muller S, Syed QA, Yokose K, Yang W, Jackel M (2009) Corrosion inhibitors. SCUP Home Performance of FBE on Pipelines – at operating temperatures above 120oF, prepared for joint industry project(JIP) committee alternate design with life cycle management, May 16, 2008, www. regulations.gov/search/

14. Alan Kehr, Matt Dabiri and Ray Hislop, Dual layer FBE coating for pipeline, alankehranti-corrosion.com. 15. A.S.Khanna, Audit report for Gas Authority of India, on the performance evaluation of FBE and 3 LPE coatings, March 2000, Delhi, India. 16. A.S. Khanna. Dual fusion bond epoxy coatings—versatile solution for underground pipelines. Chemical World, 2010, 52–54. 17. Abboud L. Mamish, Tape coating system for pipeline corrosion protection, Berry Plastics Corp., Lexington, MA, http://www. pstc.org/files/public/Mamish09.pdf 18. ANSI/AWWA C-214-07 standard,” Tape Coating System for the Exterior of Steel Water Pipelines.” 19. J.F. Doddema. Self healing visco-elastic anticorrosion system for critical infrastructural objects such as oil and gas pipelines. Paint Coating News, 2011, 7, 74–78. 20. J. Duncan and G. Friberg. The definitive field joint coating—is there or can there be such a thing. Proceedings of the 14th International Conference on Pipeline Protection, Oct. 29– 31, 2001, Barcelona, Spain, pp. 129–138. 21. 21. M.E.Parker and E.G. Peattie, Pipeline Corrosion and cathodic protection, 3rd ed. Houston, Texas Co. 1984

Author Details Prof A S Khanna IIT Bombay (Retd), Chairman – SSPC India Chemical Engineering World


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ATEX Certification: Operate Roots Pump Safely in EX Zones

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any vacuum applications in the chemical, pharmaceutical and technical gas industries take place in explosive atmospheres. In the EU, the ATEX directives were put into place in order to minimize the risks that these applications may represent for personnel and plants. The word ATEX is an acronym of the French title of Directive 2014/34/EU: AT mosphères EX plosibles.

Since 2003, there are two ATEX directives, Directive 2014/34/EU (also known as ATEX 95) and Directive 1999/92/EC (or ATEX 137). ATEX 95 defines the general health and safety requirements for equipment used in potentially explosive atmospheres. ATEX 137 specifies the "Minimum requirements for improving the health and safety protection of workers potentially at risk from explosive atmospheres" (Directive 1999/92/EC, p. 1). The connections between these two directives are shown in Figure 1. Accordingly, ATEX 95 is relevant for manufacturers of vacuum pumps, whereas ATEX 137 applies to operators who use the equipment in their systems or processes.

an explosive atmosphere can be avoided. Such atmospheres occur when a critical amount of combustible material, in the form of gas, mist, steam or dust, and sufficient oxygen are present at the same time. If this cannot be avoided, the ignition of the atmosphere must be prevented. The European Standard EN 1127-1 names the following possible ignition sources, which are analyzed within the framework of the ignition hazard assessment for products according to ATEX 95:

Functional Principle of Roots Pump Figure 2 illustrates the design of a Roots pump. Inside the pump, two Roots pistons (4) rotate in opposite directions. With them, the gas in the housing is conveyed from the intake connection (3) to the pressure connection (11). A motor (1) drives the main piston. The pair of gear wheels (6) in the gear chamber synchronizes the auxiliary piston. Lubricants are used only in the bearing and gear chambers. These chambers are separated from the suction chamber (5) by a labyrinth seal (8). A narrow gap between the pistons and the casing ensures contact-free running. This enables high speed operation (1,500 to 3,600 rpm).

■Hot surfaces

■Flames and hot gases

■Mechanically generated sparks

■Electrically generated sparks

■Electrical compensating currents

Pump Characteristics and Heating

■Static electricity

■Electromagnetic waves

■Ionizing radiation

■Ultrasound

■Adiabatic compression

■Exothermic chemical reactions

The pumped medium is neither compressed inside the Roots nor does an outlet valve at the pressure port prevent the emergence of a flow against the conveying direction. This means that the gas flows back from the outlet into the suction chamber as soon as the position of the pistons allows for it. As a consequence,

Vacuum pumps for use in potentially explosive atmospheres must be certified according to 2014/34/EU. To achieve this, the measures outlined in Figure 1 must be taken. The first step is to analyze potential ignition sources. In accordance with the CE label category, potential ignition sources relating to the conditions of normal operation (category 3), expected failures (category 2) and rare failures (category 1) must be considered. The next step is to prevent these ignition sources from taking effect. The operator is, according to directive 1999/92/EG, obliged to check whether Chemical Engineering World

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Figure 1 : Responsibilities in accordance with Directives 2014/34/EU and 1999/92/EG.

this reverse flow must also be pumped against the outlet pressure. This effect results in high energy consumption, which causes the pump to heat up significantly. This is especially the case if the difference in pressure between the inlet and outlet is large. A built-in overflow valve prevents such an un-allowed heating by limiting the maximum differential pressure. This overflow valve opens and closes a bypass which connects the suction and pressure sides of the housing. If the maximum differential pressure is exceeded, the valve body rises. Depending on the counter pressure level, some of the gas throughput then flows back to the inlet. Standard Roots pump cannot operate against atmospheric pressure, as their differential pressure is limited for the reasons given above. With the aid of backing pumps, the pressure at the outlet is kept sufficiently low. Thanks to the overflow valve, the Roots pump can be switched 52 • November 2019

on at the same time as the backing pump even at atmospheric pressure. This enables faster evacuation and makes the pump much easier to use. Roots Pumps with ATEX Certification ATEX vs Standard Pump With ATEX-certified pumps, the overflow valve described above is blocked. This is necessary since the valve hits the housing with high acceleration when the Roots pump are operated. Both parts are made of metal, which means that mechanically generated sparks can occur. This makes the overflow valve a potential source of ignition which must be prevented from taking effect. With the valve blocked, the gas is prevented from flowing back. In this case, the Roots pump must be operated with a frequency converter. This ensures that the pump is started up slowly. Alternatively, the pressure at the outlet can also be monitored

so that the pump is only switched On when the counter-pressure is sufficiently low. Prior to the market launch of the ATEX pumps, the use of a frequency converter was considered to be an adequate replacement for the overflow valve. However, through close contact with customers and continuous exchange with them, Pfeiffer Vacuum’s experts quickly realized that retrofitting a frequency converter was not possible in some cases – especially in all applications where the ATEX Roots pump was to replace a previously used standard version. And if there are no additional pressure gauges, then starting the pump at a defined counter-pressure is not possible either. Based on these cases, the development experts identified the need of some customers for ATEX-Certified Roots pump with an unblocked overflow valve to make pump replacement and operation as easy as possible. Chemical Engineering World


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Figure 2 : Illustration of a Roots Pump design.

Development of the ATEX-Certified Overflow Valve Against this backdrop, developers at Pfeiffer Vacuum were clear that a new version of the relief valve would have to be developed. The greatest challenge here was to find a combination of materials that would not produce any sparks and thus any ignition sources during normal operation or in the event of expected valve failures. The solution is an ATEX valve made of PTFE and stainless steel, where no sparks can occur in contact with the housing (material GGG-40). In addition to the material pairing, the kinetic energy during opening and closing also influences spark formation. Tests have shown that the kinetic energy of standard Roots pump during opening of the valve is sufficiently high to ignite a combustible mixture. For the ATEX version, therefore, a way had to be found to dampen the impact of the valve. The effectiveness of the measures was checked in various tests. Therefore, the developers at Pfeiffer Vacuum carried out the opening and closing process more than 20,000 times. This made it possible to simulate longer-term loading of the valve. The test results showed that, thanks to the changes in the valve design, no sparks are Chemical Engineering World

formed when the valve is opened or closed. The ATEX overflow valve thus enables safe operation in areas with explosive atmospheres and no longer constitutes an effective ignition source.

Vacuum Solutions from a Single Source

Standard pumps can easily be replaced by the new ATEX pump with its unblocked overflow valve. Neither frequency converters nor pressure monitoring devices need to be installed. Once again, the Roots pump can be started at the same time as the backing pump, so that the new overflow valve ensures not only safe operation but also shorter evacuation times. If the ATEX overflow valve is used in addition to a frequency converter, it ensures faultless operation even if a failure in the frequency converter occurs.

Complete Range of Products

Even though it is now easier to simply replace older units, Pfeiffer Vacuum recommends that the previous design and dimensioning of the vacuum system should always be checked. Experience shows that already small process flow changes conducted over time can make a new examination necessary. One option is here to optimize the gradation of the Roots pump and the backing pump, which allows for a better distribution of the loads and temperatures.

Pfeiffer Vacuum stands for innovative and custom vacuum solutions worldwide, technological perfection, competent advice and reliable service. From a single component to complex systems: Pfeiffer Vacuum are the only supplier of vacuum technology that provides a complete product portfolio.

Competence in Theory and Practice Benefit from our know-how and our portfolio of training opportunities! We support you with your plant layout and provide on-site service worldwide.

For details contact: Pfeiffer Vacuum (India) Pvt Ltd Tel: 040-27750014 Fax: +91-40-27757774 E-mail: pvin@pfeiffer-vacuum.in Web: pfeiffer-vacuum.com November 2019 • 53


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Nitrogen Generator

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e might have seen those people who struggle to transport heavy long cylinders filled with nitrogen in industries for various applications. Now-a-days those cylinders were slowly replaced with onsite nitrogen generators. Summits Hygronics manufactures nitrogen generators which can provide

uninterrupted high purity nitrogen gas based on the demand. It can also save a lot of energy spent in the cryogenic plants and transportation of cylinders. Summits Hygronics is successful in the process of air separation made by two technologies. They are Pressure Swing Adsorption (PSA) process and Membrane Technology. The former is most efficient process, and gives higher purity of nitrogen, latter is suitable for producing nitrogen with minimum pressure drop. In both the process air separation is accomplished by removal of O 2 and other effluent gases from air. Nitrogen generators can supply nitrogen based on the demand for 24/7 with a consistent purity and reduce nitrogen costs up to 90 per cent. There will be no supply delay, escalating costs, or inventory of N 2 cylinder. It can give a fast payback with ROI average 12-14 months over bulk liquid. The PSA and Membrane type nitrogen generators have a system life of 20 years.

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Pressure Swing Adsorption (PSA) Process The original PSA system was the Heatless Air Dryer developed by Skarstorm for air drying, but in recent years processes of this kind have been developed for a wide range of industrially important gas separations. The PSA system in its basic form consists of two beds which are alternately pressurized and depressurized according to the preprogrammed sequence. Regeneration of adsorbent during the desorption cycle is achieved simply by reducing the total pressure and purging the bed at low pressure with a small fraction of the product stream. The adsorptive separation is achieved by one of the three mechanisms: steric, kinetic and equilibrium effect. Air separation is made by kinetic separation, particularly for nitrogen production from air. Kinetic separation is achieved by virtue of the differences in diffusion rates of different molecules. Oxygen diffuses about 30 times faster than nitrogen in carbon molecular sieve. So, carbon molecular sieve is used for nitrogen generators. Summits PSA nitrogen generator plants can generate nitrogen of purity up to 99.9995 per cent while the membrane technology nitrogen systems can provide 90 to 99.9 per cent of purity. We can also produce PSA nitrogen generator with Deoxo unit which can give a purity of 99.9997 per cent. Membrane Technology Summits Membrane type nitrogen systems has many membrane modules through which the air pass through and N 2 got separated. Each module is made up of thousands of hollow tubular fibres with tiny holes on their walls. The oxygen molecules are smaller in size Chemical Engineering World


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whereas nitrogen molecules are larger in size. The tiny holes in the membrane are sized to allow oxygen molecule through the walls of tubular fibres and nitrogen molecules will reach the other end and separated. The separation is assisted by providing a pressure difference between inner and outer side of the membrane. Outer side is kept in lower pressure so

that the O 2 molecules permeate through the wall to other side. This is how the N 2 gas separation is accomplished in the membrane type gas generators.

of operating over a wide temperature range of –40oC to +60oC with appropriate maintenance, membrane unit useful life ranges between 130,000 and 180,000 hours.

Nitrogen gas separation systems produced by Summits with membrane technology have no moving component parts, thus ensuring exceptional reliability. They are capable

Applications Summits nitrogen generators work efficiently in various industries including food and beverages, heat treatment, laser cutting and pharma industries. Other Products of Summits Hygronics Summits Hygronics manufacture other compressed air products such as refrigerated air dryer, heatless air dryer, HOC air dryer, blower re-activated dryer etc. It is also best solution provider for compressed air purification products.

For details contact: Summits Hygronics Pvt Ltd SF# 192, Eari Thottam Kannampalayam Coimbatore Tamil Nadu 641 402 E-mail: mis@airdryer.in Chemical Engineering World

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CEW Products Agitated Thin Film Dryer

Agitated Thin Film Evaporator

KEP Engg Services Pvt Ltd offers agitated thin film dryer (ATFD) for evaporation of water/solvents to make concentrated liquid to dry powder up to 5 per cent moisture or flakes. Based on application, either recovered solvent or dry product is important. Agitated thin film dryer design is the ideal apparatus for continuous processing of concentrated material for drying. Agitated thin film dryer design is the ideal apparatus for continuous processing of concentrated material for drying. Agitated thin film dryer consist of cylindrical, vertical body with heating jacket and a rotor inside of the shell which is equipped with rows of pendulum blades all over the length of the dryer. The vapours produced rise upwards, countercurrent to the liquid and pass through a cyclone separator mounted at the vapour outlet of agitated thin film dryer. Further, these vapours will be condensed in a condenser and recovered as condensate. The system will be operated under vacuum for temperature sensitive products and atmospheric conditions for normal drying. For details contact: KEP Engg Services Pvt Ltd 6-A-52, Opp: Park, Nr Vedant Intnl School Apurupa Colony, Jeedimetla Hyderabad, Telangana 500 055 Tel: 040-23096275 E-mail: info@kepengg.com

KEPs agitated thin film evaporator is an alternative and economical solution for heat sensitive products. KEP has developed agitated thin film evaporation technology with innovation at an optimised capital and operating cost. Agitated thin film evaporators are used for the purification of liquid compounds that are heat sensitive, viscous and have high boiling points. Features continuous operation; low maintenance; easy to start, operate and shut-down; heat transfer coefficient is high; one shot concentration no recirculation is required; can operate with flexible operating parameters; higher operating vacuums; efficiently processes viscous solutions; and low residence time eliminates thermal degradation. For details contact: KEP Engg Services Pvt Ltd 6-A-52, Opp: Park, Nr Vedant International School Apurupa Colony, Jeedimetla Hyderabad, Telangana 500 055 Tel: 040-23096275 E-mail: info@kepengg.com

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Flaker Flakers which are also known as cooling drums are used for solidifying molten material. After processing on flakers, such materials can be obtained in the form of films or easily handled flakes which are suitable to further processing or packing into containers for transport. A great advantage of flaker is that they offer a continuous process. The hot material is applied to the cooling drum by direct immersion into a trough, indirectly using doctor/ applicator rolls, etc. The molten liquid is cooled after application on the cooling drum and after a partial revolution the cooled and solidified product is removed by a scraper in the form of flakes or film. The cooling drum of the flaker is specially designed to provide an even cooling effect by having uniform and effective internal distribution. As a result, both high output and homogeneity of the product are possible. A variable speed drive arrangement enables adjustment of the drum speed for optimum performance. Material of construction of wetted/contact parts can be SS, carbon steel hard chrome-plated or special metals such as Monel, Inconel, Hastealloy, etc. Optional include hood, rear scraper, flake breaker, flake conveyor, etc. Hood can be of SS, aluminium, FRP, etc. For details contact: Tech-Mech Engineers A-227, 16th A Road, Wagle Indl Estate Thane, Maharashtra 400 604 Tel: 022-25828749 Telefax: 91-022-25827883 E-mail: info@techmecheng.com / techmecheng@gmail.com or Circle Readers’ Service Card 03

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Products CEW PTFE-lined with SS-304 Braiding, Covered with Platinum-cured Silicone Imaflexxie is PTFE tubing covered with SS-304 braid reinforcement having outer layer of platinum grade silicone. Imaflexxie is having capacity to withstand high pressure along with greater chemical resistance. The product is having ultra-smooth bore which enhances superior flow properties and least adhesion to particulates. The outer layer of silicone cover acts as insulation to high temperature and keeps outer surfaces dust-free. Imaflexxie conforms to US FDA 21 CFR 117.2600 Food Grade Standard, USP Class VI and ISO 10993-1. It is certified by ROHS and Animal Origin Certification (free of animal derived material), free of restricted heavy metals. It is free of Phthalate/Bisphenol/Volatile Plasticizer. It has USFDA DMF accreditation #26201. Complete validation package available upon request. Imaflexxie has excellent chemical resistance. It permits easy cleaning. Its smooth silicone cover provides safety to operator while handling high temperature. It prevents operator from injury due to Frayed SS Braids. It is lot traceable. Its temp range is -80oC to 230oC. It is available with SS-316L Tri-clover end. It is sterilizable by autoclave. For details contact: Ami Polymer Pvt Ltd 319 Mahesh Indl Estate, Opp: Silver Park Mira-Bhayander Rd, Mira Road (E) Thane, Maharashtra 401 104 Tel: 022-28555107, 28555631, 28555914 E-mail: mktg@amipolymer.com

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Structured Packing Pyramid Technolplast’s intermediate bulk containers protect and ensure hygiene standards of food grade products. The entire operation usage of the container has been found to be economical and cost-saving. The container design is environment-friendly and highly professional. The IBCs are known for their sturdiness, logistical ease of use, capability to handle pressure during transportation. It is convenient for loading and discharge. It bears overload and prevents goods from unexpected falling down. It combines the advantages of both steel and plastic. Inner container is made of high molecular weight, high density polyethylene resin. It has very high envirornmental stress cracking resistance and ultraviolet light resistance (UV). Valve and interface are chosen according to the properties of liquid medium to be loaded. It is convenient and reliable for drainage with less residual liquid. It is convenient for cleaning, cost-effective and environment-friendly. In order to ensure safety, feeding mouth can be equipped with breathable lid, which avoids over-pressure condition caused decomposition and evaporation of liquid medium. Modular design prolongs service life and reduces cost. Spare part damaged by accident can be replaced. It has good compatibility with the same kind of product. It is convenient for filling and transportation. Inner container and valve conjoined technology 100 per cent ensure no leakage. All containers are manufactured as per International Standard, UN Approved and fully stackable. For details contact: Pyramid Technolplast Pvt Ltd No: 2, Shah Trade Centre, 2nd Floor Rani Sati Marg, Malad (E) Mumbai 400 097 Tel: 022-42761500 E-mail: yashbarrels@gmail.com or Circle Readers’ Service Card 05 00

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CEW Products Structured Packing Vantage Series Structured Packing exceeds the performance of almost all other standard Structured Packings due to its exceptional liquid spreading characteristic. The unique texture provides an excellent liquid spread and lateral distribution. Vantage Series Structured Packings have innumerable fine perforations throughout the surface. This is a distinct advantage over other Structured Packing that have punched holes resulting in loss of valuable surface area that in-turn reduces the potential efficiency of the product. Owing to its fluid dynamic curved shape our Vantage Additional Structured Packing smoothens the gas passage and minimizes localized hold-up thus compounding the advantage further. It reduces premature flooding at the inter-layer transfer zone. This salient feature provides significant margin at higher loads compared to the traditional product. The Vantage Additional series is available in vivid sizes (from surface area 200 m2/m3 to 750 m2/m3 along with optional customization to suit the need. For details contact: Munters India Humidity Control Pvt Ltd Plot # 11, Street # 10, MIDC Andheri (E), Mumbai, 400 093 Tel: 022-61478000 E-mail: sameer.mehta@munters.in or Circle Readers’ Service Card 06

Horizontal Flow Wrapping Machine Hermetic packages protect pharma products from external influences like humidity, oxygen and light. The new Sigpack HML from Bosch Packaging Technology, allows products such as blow-fill-seal vial cards, blisters and various medical technology products including pens and inhalers to be reliably hermetically packaged. The Sigpack HML is suitable for the production of both small and large batches. Depending on the desired output volume, the film reels can either be changed manually during short machine stops or with the help of a splicer. The improved splicer fully automatic connects the old and new film to avoid disturbances, such as at the film former. Products are delivered to the flow wrapping machine via a transport chain. The transverse and longitudinal film sealing uses the proven Longdwell heat sealing technology. The machine achieves an output of up to 350 sealed packages per minute. The sealing rolls used for horizontal wrapping can be opened from both sides. This prevents the film from coming into contact with the heated sealing rolls, and from being damaged during machine downtime. For particularly temperature-sensitive products, the cover plates at the sealing station can be cooled. The Sigpack HML is also available with ultrasonic sealing, allowing customers to gently package heat-sensitive products. The Sigpack HML can be equipped with options for additional product protection, such as the “no gap no seal” function. This is especially used for product piles in blister or BFS packages, which is checked once again shortly before it reaches the cross-sealing. If the pile is not in the correct position, the cross-sealing stops. This avoids product rejection or damaged sealing jaws. The optional MAP module (Modified Atmosphere Packaging) offers optimal product stability by removing residual oxygen from the hermetic packages. Sensors precisely monitor and regulate the gas content of the packages. Based on the Bosch systems competence, the Sigpack HML can be combined with other equipment, like cartoning machines as well as track and trace systems for seamless traceability of the packaged products. For details contact: Commha Consulting GmbH & Co KG Poststraße 48 D-69115 Heidelberg Germany Tel: +49 6221 18779-32 E-mail: bosch@commhaconsulting.com or Circle Readers’ Service Card 07 00

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Products CEW Bursting Strength Tester – Analogue Bursting strength is a reliable index of the strength and performance of materials like paper, paper boards, corrugated boards and boxes, solid fibre boards, filter cloth, industrial fabric, leather, resin, etc.

Mono Flange Valve

PRESTO bursting strength tester is ideal for testing a wide range of materials to determine their quality, strength and performance. It is easy to operate. It is scientifically calibrated for reliability and is widely used by industries and institutions and stands out as proven and reliable equipment.

For connections to the process using connection flanges, the mono flange enables an optimal and compact measuring point assembly. In addition, stress from vibration, potential leak points as well as installation and maintenance costs are reduced. The mono flange is mounted directly on to the axial flange (radial flange on request), allowing the gauge to be kept in an upright position. The mono flange includes a block valve, a bleed valve and a vent hole.

For details contact: Presto Stantest Pvt Ltd I-42 DLF Indl Area, Phase I Delhi Mathura Road Faridabad, Haryana 121 003 Tel: 0129-4272727 E-mail: info@prestogroup.com

For details contact: Chintamani Engg Industries India Pvt Ltd 201 New Rahul CHS, Suyog Nagar Chulne Bhabola Road Vasai (W), Dist: Palghar, Maharashtra 401 202 E-mail: info@chintamaniengineering.com or Circle Readers’ Service Card 08

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Ready-to-Use Electroactive Silicone Laminates WACKER offers a novel silicone laminate with electroactive properties called NEXIPAL for the very first time. It consists of several ultrathin precision films made of silicone rubber. The films are coated with an electrically conductive material prior to lamination. The result is an actuator that creates movement, as soon as electrical voltage is applied. In addition, NEXIPAL can also be used as a sensor by measuring deformations electrically. The silicone laminate is wear-free, compact and energy saving and ideal for use in innovative applications. Tablet displays equipped with NEXIPAL create vibrations and haptic feedback which simulate the shape of keys or control panels that can be operated blindly by touch. Such a feature can be especially useful in automotive applications. The new laminate technology is based on ELASTOSIL Film. WACKER produces the extremely thin silicone film in thicknesses between 20 and 400 μm. The silicone rubber is a key component whose dielectric properties are an important prerequisite for the desired electroactive effects of the laminate. For the film to execute and/or measure deformations, however, it must be coated with an electrically conductive layer, and subsequently laminated to form a multilayer stack. WACKER will produce such prefabricated laminates itself under the trade name NEXIPAL. NEXIPAL laminates are made of several ultrathin precision films coated with conductive material which acts as a flexible electrode. When voltage is applied, the positive and negative charge carriers of the electrodes attract one another, forcing the silicone film in-between to change its shape. As a result, the film flattens and at the same time elongates horizontally. The elongation of the surface is proportionate to the compression force. When discharged, the resilience of the highly elastic silicone film allows the laminate to return to its original shape. This process can be repeated indefinitely. One of the most outstanding advantages of electroactive silicone laminates compared to existing solenoid technology is the fact that electric power is only applied during the short period of switching between ON and OFF status, not for holding it. This results in a significantly reduced consumption of energy as well as in sustainable and cost saving processes. Moreover, silicone laminates do not produce any heat when in use. This avoids investments into expensive thermal management systems. The electroactive component also acts like a sensor, since any movement or deformation alters the charge on the electrodes. This dual function makes NEXIPAL a genuine all-rounder and suitable for applications in medical technology, sensors and robotics. For example, the material is able to control the orientation of headlamps or mirrors in cars. Moreover, since fluid movements are possible with NEXIPAL, the laminate can also be used as an artificial muscle. For details contact: Wacker Chemie AG Hanns-Seidel-Platz 4 81737 München, Germany Tel: +49 89 6279 1588 E-mail: agnes.froeschl@wacker.com

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CEW Products Heating Cooling Systems for Multi-reactors The user can get closed repeatable temperature control in a wide temperature range can achieve -120 to 300oC temperature control. Avoid replacement of traditional equipment and facilities and the maintenance of jacket the small fluid volume also ensure the rapid response of the control loop and the thermal reaction delay is small. Built-in electric heating heat transfer oil auxiliary systems, which can automatically turn on the auxiliary heating system according to the demand to reduce the steam use pressure. It can achieve accurate energy saving by accurately matching the heat demand with fast operation. Control the temperature of the whole reaction process through precise and fast calculation, and perform rapid response for the exothermic and endothermic reactions in the whole reaction process. Reserve the standardised interface which can increase the heat source heat exchanged module according to actual needs. Optionally controlling the reaction process temperature and single fluid heating temperature, and the temperature difference between the reaction process temperature and the thermal single fluid temperature is settable and controllable. It can carry out recipe management and production process records. For details contact: ATR-ASAHI Process Systems (P) Ltd 668 GIDC, Makarpura, Vadodara Gujarat 390 010 E-mail: prosys@atrasahi.com or Circle Readers’ Service Card 11

PROFIsafe-Module At present, NORD DRIVESYSTEMS supplies frequency inverters with integrated STO and SS1. The drive specialist provides failsafe communication and safe movement functions according to IEC 61800-5 with the SK TU4-PNS PROFIsafe module. Functions such as SLS (Safety Limited Speed), SSR (Safe Speed Range), SDI (Safe Direction), SOS (Safe Operation Stop) and SSM (Safe Speed Monitor) can be integrated and expand the drive units’ safe stop functions. With this, the PROFIsafe interface module provides comprehensive safety for the reliable operation of plant and machinery. PROFIsafe is the world’s leading and generally used technology for safety applications for production and process automation. With SIL3 and PLe (Performance Level e) Category 4, the fail-safe communication protocol fulfils the most stringent safety requirements. The PROFIsafe fail-safe protocol extension for PROFINET enables standard and fail-safe information to be transmitted with integrated functional safety between the higher level machine or the plant control system and the NORD drives in a single network cable. The PROFIsafe bus interface SK TU4-PNS monitors safe compliance with the limit values and provides safe inputs and outputs. If a limit value is exceeded or undershot, the bus interface switches to a safe state. The voltage is disconnected from all outputs; input information is reset and transmitted to the higher level fail-safe controller. This is essential for the use of the PROFIsafe module. Integration of safety functions into the drive unit offers many advantages in comparison with a drive solution with discrete safety technology. Another advantage is the global availability of the security-related machine data. For details contact: NORD DRIVESYSTEMS Pvt Ltd 282/2 & 283/2, Plot No: 15, Village Mann Tal: Mulshi, Adj Hinjewadi MIDC Phase II Pune, Maharashtra 411 057 Tel: 020-39801217 Fax: 91-020-39801416 E-mail: monika.mishra@nord.com / pl.muthusekkar@nord.com or Circle Readers’ Service Card 12 00

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Products CEW Heat Sealable Thermoplastic Elastomer Tube

Surge Protectors

Imaweld is thermoplastic elastomer opaque tubing designed for fluid transfer in pharma and biotech applications. Imaweld is specially formulated, which meets the requirement of pharma industries with superiority compared to PVC and silicone.

AMETEK Drexelbrook, a world leader in level measurement technology, offers a new line of surge and transient protectors for installed and new applications to protect instrumentation, personnel and the environment from overvoltage via field cabling. The company partnered with Eaton’s MTL Instruments to distribute the surge protectors, which are intrinsically safe and flameproof approved. What’s more, end users can install the devices on existing or new instrumentation to receive up to 20 kA surge current isolation. The new surge protectors are certified with FM, ATEx, IECEx, and various other global safety certifications, ensuring the security of staff, instrumentation, and the environment. Level transmitters, level switches, and water cut monitors often provide crucial data often as part of processes that may cause danger in case of breakdowns. Drexelbrook surge protector’s screw-in mounting allows users to mount the devices inside the hazardous area without compromising the approvals.

Imaweld complies with FDA 21 CFR 177.2600, USP Class VI and ISO 10993. It is manufactured and packaged under GMP guidelines in dust-free area of ISO 9001 QMS, ISO 14001 and OHSAS 18001 Certified facility. It is heat sealable and weldable. It can be laser etched for traceability. It has excellent flexibility and flex crack resistance. It also has excellent acid and alkali resistance. Its smooth bore surface eliminates particle entrapment. It has superior chemical resistance compared to silicone. It is sterilizable by steam, gamma radiation and ethylene oxide. It has custom dimension and available in length size. It is also available in transparent colour. For details contact: Ami Polymer Pvt Ltd 319 Mahesh Indl Estate, Opp: Silver Park Mira-Bhayander Rd, Mira Road (E) Thane, Maharashtra 401 104 Tel: 022-28555107, 28555631, 28555914 E-mail: mktg@amipolymer.com

For details contact: AMETEK Drexelbrook 205 Keith Valley Road, Horsham, PA 19044, U.S.A. Tel: +1 215-674-1234, +1 215-293-4185 Fax: +1 215-674-2731. E-mail: drexelbrook.info@ametek.com or Circle Readers’ Service Card 13

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Membrane Filter Press Membrane filter plates have a chamber below the drainage surface that may be inflated. The common method used is water pressure, which is generated by pumping into the squeeze cavity to inflate the face of the plate against the filter cake. Air may also be used. Fixed membranes are most commonly 100 per cent polypropylene but thermoplastic is also available. The plate is manufactured by moulding a face membrane and a core plate separately. The face membranes are then joined into the core by heat welding to form a homogeneous plate. Although this type of membrane is suitable for many designs, it has particular advantages in food applications, where the lack of joints will prevent contamination. Membrane plates are used to reduce the cake moisture content or shorten the filtration cycle time. Two types of membrane plate designs are used: fixed membranes and replaceable membranes. Mixed pack membranes are the most common configuration (one recessed plate, then one membrane plate alternate in the press plate pack). The final product produces savings in the overall plate pack cost. Membrane plates usually operate at a feed pressure of up to 7 bar and squeeze pressure up to 15 bar. Special plates can be designed to accept higher feed and squeeze pressures. Replaceable membranes use a polypropylene core, which is machined to accept the connection and seal of a rubber membrane. These facts are easily changed. EPDM Thermoplastic and other compounds are used for specific conditions. Savings in operation can be achieved in difficult environments and the membrane’s superior flexibility makes it the best design for many installations. For details contact: Thorat Filtration Pvt Ltd A-12, A-Building, 3 rd Floor Garni Indl Park Plot No: C-39/A, TTC Indl Area Pawane MIDC, Navi Mumbai 400 709 E-mail: info@thoratfiltration.com / sales@thoratfiltation.com or Circle Readers’ Service Card 15

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CEW Products AODD Pumps with New C 40 and C 50 Models Almatec, part of PSG, a Dover company has extended its line of solid plastic C-Series AirOperated Double-Diaphragm (AODD) Pumps to include new C 40 (1-1/2”) and C 50 (2”) Models. Engineered to be a more cost-effective alternative to similar plastic pumps, Almatec C-Series pumps feature an industry-leading design that increases bolt torque to improve pump safety when compared to competitive pumps. What further separates the C-Series is the incorporation of Almatec’s exclusive Perswing P air control system, which offers superior efficiency to optimize production rates and lower energy costs. Ideally suited for the most difficult pumping applications, C-Series pumps ensure the suction and discharge ports are available as separate housing parts with different footprints. This feature allows the C-Series to be quickly and easily matched to existing installations. C-Series pumps do not have any mechanical seals, drives or rotating parts that cause wear over time, which improves reliability and extends product life. C-Series pumps feature self-priming and dry run capabilities, critical considerations for most pumping applications. The C-Series pump line now consists of five pump sizes – C 10 (3/8”), C 15 (1/2”), C 25 (1”), C 40 (1-1/2”) and C 50 (2”). The wetted housing parts are made of either abrasion-resistant polyethylene or chemically-resistant PTFE. For applications in explosive atmospheres, C-Series pumps are available in versions that conform to ATEX requirements according to the 2014/34/EU directive. For details contact: Dover India Pvt Ltd No: 33, NH-4, Pazhanchur, Mevalurkuppam Chennai 600 123 Tel: 044-67193000 E-mail: rajesh.shankar@psgdover.com / ravi.prasad@psgdover.com

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GNX Series Pumps with 3- and 4-inch Models Blackmer, part of PSG, a Dover company announce that its GNX Series Sliding Vane Pumps are now available in 3- and 4-inch models. The market’s only alignment-free reduced-speed positive displacement pumps, the Blackmer GNX Series have been designed to optimize the transfer of non-corrosive, non-abrasive industrial and petroleum products for both portable and stationary applications. Originally launched in 2- and 2.5-inch models, Blackmer GNX Series heavy-duty sliding vane pumps include the proven features of Blackmer legacy GX Series pumps but take them to the next level with the incorporation of a commercial-grade, singlestage gearbox, motor and baseplate. This innovative new gearbox fits between the motor and pump and is held in place by a permanent dowelled connection that creates a structural link between the high-speed and low-speed sides of the system. This results in a pump that will not need to be realigned either at initial installation or following a maintenance procedure, resulting in improved peace of mind for the operator. The 2- and 2.5-inch models have aluminum gearboxes while the new 3- and 4-inch models feature cast iron gearboxes. GNX Series pumps provide flow capacities ranging from 7 to 500 gpm (25 to 1,893 L/min) at working pressures up to 175 psi (12.1 bar). They are also available with optional steel and composite baseplates. The pre-grouted composite baseplate adds additional value to the pump, gearbox and motor setup by providing unmatched surface flatness, significant vibration damping and reduced installation costs. GNX Series pumps have a 90° porting orientation and GNXH Series pumps have a 180° porting orientation. These pumps are available in a full range of motors from 1 to 50 HP. For details contact: Dover India Pvt Ltd No: 33, NH-4, Pazhanchur Mevalurkuppam Chennai 600 123 Tel: 044-67193000 E-mail: rajesh.shankar@psgdover.com / ravi.prasad@psgdover.com 00 or Circle Readers’ Service Card 17

62 • November 2019

Chemical Engineering World


CEW

NATIONAL

INTERNATIONAL Plastivision India

Dates: 16-20 January 2020 Venue: Bombay Exhibition Centre, Goregaon, Mumbai Event: This event provides the perfect platform for plastic industry players

Corrosion Protection

Dates: 10-11 December 2019 Venue: ACHAT Plaza Karlsruhe, Germany Event: Corrosion Protection benefits for this

like manufacturers, dealers, buyers and end-users. It is well-appreciated for helping participants stay updated with the latest technological trends. Visitors can participate in numerous live product launches, seminars, conferences and consultation sessions. They also get a chance to network with overseas delegates and industry influencers. The event has a glorious history that dates back to 1992. It is only a trading fair exhibition from the plastic industry approved by UFI (the leading Paris-based exhibition authority). For details contact: The All India Plastics Manufacturers’ Assn AIPMA House, A-52, Street No: 1, MIDC Marol Andheri (E), Mumbai 400 093

seminar is they know the mechanical and chemical influences that lead to corrosion and are familiar with the specific properties of various materials. In addition, you will learn about the risks of corrosion and various countermeasures and, in exchange with other solutions, develop practical case studies. For details contact: German Machinery and Plant Manufacturers’ Assn c/o VDMA e.V. Lyoner Street 1860528 Frankfurt/Main Germany

Renewable Energy Expo

Corrosion Conference & Expo

Dates: 13-15 February 2020 Venue: Chennai Trade Centre, Nandambakkam, Chennai Event: The 2 nd Edition of this event will be held in Chennai. The scope of this exhibition is to stimulate the growth of renewable in the region through collaboration of technology and product sharing. This event will be bringing together businesses, sustainable energy industry trade associations, government agencies, and energy policy research organizations to showcase the status and potential of the cross-section of renewable energy (biofuels/ biomass, geothermal, solar, wind) and energy efficiency technologies. The expo is proclaimed at the right time when there is a paradigm shift in the global trend towards massive deployment of solar power and other renewables along with investments worth billions of dollars in technology and green energy. For details contact: Water Today Pvt Ltd 3D Bhaghreetha Residency, 125 Marshalls Road Egmore, Chennai 600 008

Chemspec India

Dates: 16-17 April 2020 Venue: Bombay Exhibition Centre, Goregaon, Mumbai Event: The Fine and Specialty Chemicals Exhibition features exhibits of organic and fine chemicals, active pharma ingredients, drug intermediates, dyes and pigments, agrochemicals, contract and toll manufacturing, coatings, cosmetic chemicals or ingredients, pigments and solvents, surfactants, laboratory chemicals and a host of specialty chemicals. For details contact: Chemical Weekly 602, 6th Floor, B-Wing, Godrej Coliseum B/h Everard Nagar, Off Eastern Express Highway K J Somaiya Hospital Road, Sion (E), Mumbai 400 022 Tel: 022-24044477, Fax: 91-022-24044450 E-mail: corporate@chemicalweekly.com Chemical Engineering World

Dates: 15-19 March 2020 Venue: George R Brown Convention Center, Houston, U.S.A. Event: Corrosion Conference & Expo showcase your newest products in front of customers, prospects, partners, and influencers; generate leads efficiently and effectively; build relationships with key players and decision-makers; bolster the global influence and reach of your company’s product or service; and expand your reach and tap into new markets meeting new potential buyers and suppliers. For details contact: Nace International - The Corrosion Society Houston, U.S.A. Tel: +1 281-228-6411 E-mail: tiffany.krevics@nace.org

International Converting Exhibition Europe

Dates: 09-11 March 2021 Venue: Exhibition Munich, Munich, Germany Event: This event will showcase product like chemicals and dyes, office and commercial supplies, packaging materials, plant, machinery and equipment, plastic and plastic products, business services, paper and paper products and much more. For details contact: Mack Brooks Group Romeland House, Romeland Hill St Albans, Herts AL3 4ET, U.K. Tel: +44 (0)1727 814400 Fax: +44 (0)1727 814401 E-mail: info@mackbrooks.co.uk November 2019 • 63


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 NOCIL Ltd has commissioned the Phase 1 of expansion of capacities of rubber chemicals and their intermediates at Navi Mumbai, The aforementioned CAPEX programme had been approved by the Board of Directors at its Meeting held on 16th March 2017. Tata Chemicals has completed the acquisition of the silica business of Allied Silica for `123-crore. The company entered into a business transfer agreement to acquire Allied Silica’s precipitated silica business on a slump sale basis. The deal was part of the ` 295-crore investment approved by the Board in February 2017, towards this specialty business. The acquisition includes a manufacturing facility in Tamil Nadu, which will produce highly dispersible silica. The specialty chemical product represents a downstream value addition to Tata Chemicals soda ash business, where it ranks among the top manufacturers globally. R Mukundan, Managing Director, Tata Chemicals, said the next focus would be to enhance the operational readiness of the plant to maximise throughput of product portfolio, while meeting the requisite safety and quality specifications. Precipitated silica is a versatile product with applications in many industries including rubber, oral care, coatings and agrochemicals. The acquisition also offers the possibility to make value added silica for applications that demand high performance. Insecticides (India) Ltd has announced a ` 200-crore expansion plan to increase its capacity in the next three years. In the first two years, it would spend about `100-crore, followed by an investment of ` 100-crore in 2020. The firm is planning to set up an Export Oriented Unit in Gujarat with an eye on increasing export component of the business. Exports contributed about ` 35-crore in the total turnover of ` 1,109-crore in 2017-18. The firm has a share of about 5 per cent in the ` 18,000-crore crop protection market in the country. Shalimar Paints lays down the foundation of its Nashik manufacturing plant with a planned monthly production capacity of 2,180-kilolitres. Shalimar's state-of-the-art Nashik facility will increase the brand's overall production capacity by 65 per cent. The newest Shalimar plant hints at the brand's aggressive push to capitalise on the growing market demand for its high-quality, high-performance paint and coating products, as well as to further consolidate its position as one of the fastest growing paints companies in the country. Shalimar has also pledged further investment into its Nashik plant and aims to establish it as a key component within its regional distribution network, as well as its pan-India supply chain. The paint industry has been growing at a rapid rate in India and measures between 1.5 to 2 times GDP growths. Rapid urbanization, better transparency and consumer evolvement has been leading the growth of the industry. Songwon Industrial Co Ltd a specialty chemicals company of South Korea has launched its new pilot plant in Panoli (Gujarat), thereby strengthening the organisation’s overall specialty chemicals 64 • November 2019

development capability. Built on Songwon’s Indian site with all the necessary main unit operations, the new plant is equipped with the most up-to-date technologies and materials for producing a wide range of chemicals for a broad spectrum of applications - from one kilo up to several hundred kilo samples. To reinforce the organisation’s position in existing areas of business and enhance its ability to enter new areas, the new pilot plant will be supported by the Songwon’s strong local R&D team in Panoli, as well as its central technology innovation center located in Maeam, Korea.

MINING Coal India Ltd (CIL) had supplied in 2018-19, 491.54-million tonnes (MT) coal to power plants which was 8.2 per cent more than the coal supplied in 2017-18. Singareni Collieries Co Ltd (SCCL) supplied 55.3-MT coal to power plants in 2018-19 which was a growth of 3.6 per cent over the same period of previous year. This has led to creation of a coal stock of 30.95-MT at the power plants as on 31st March 2019 which was sufficient for 18 days requirement. In 2018-19, the power plants of Tangedco have supplied 23.26-MT coal from CIL with a growth of 3.5 per cent over the supply of 22.49-MT in 2017-18. As on 16th June 2019, Tamil Nadu power plants have coal stock of 9.67-lakh tonne which is sufficient for 12 days requirement. At present, no power plant in Tamil Nadu is in critical/super critical category. Hindustan Copper Ltd (HCL), on 2nd February, 2019, held a ground-breaking ceremony at Ghatsila Unit of HCL for construction of concentrator plant at Rakha, initiating Chapri-Sidheswar mine, a new mine development and Rakha mine re-opening projects. CMD informed that considering the opportunity to further increase the resource base of copper mineral in the State has finalized plan to undertake depth exploration up to 1,000-meter from surface in its existing lease area in next two years. HCL, in its Unit located at Ghatsila planned to implement total five mine expansion projects to increase the mine capacity from current 4.0 to 72.0-lakh tonne. Successful implementation of the project will also reduce country's dependence on imported copper concentrate. Singareni Collieries Co Ltd (SCCL) has received a boost for its plans of increasing the coal production to 70-million tonnes in 2019-20 by getting the green nod for Kistaram open cast mine recently after suffering some setbacks in getting environmental clearance for its proposed new mines and expansion of existing ones earlier this year. The coal company has achieved a production of 64.4-million tonnes in 2018-19 and getting the environmental clearance for Kistaram open cast mine, with a capacity of 2-million tonnes per annum (MTPA), in Sathupalli mandal of Khammam district is expected to go a long way in its plans to jack up the production by nearly 6-million tonnes. The green nod to the proposal has come three years after public hearing conducted on it. According to SCCL officials, a committee of experts in the Ministry of Environment and Forests (MoEF) that has gone through the proposal has recommended clearance to

Chemical Engineering World


Project Update the mine earlier and stipulating several conditions to keep impact of the mining activity under check on air, water and local people. Environmental conditions in and around Sathupalli town were also appraised separately by the panel before giving its nod. The committee also asked the coal company to take specific measure to minimise the mining impact on air, water, noise, vibrations, stability of structures, health of people in nearby villages and their socio-economic conditions and relief and rehabilitation operations. MOIL recently said production at its Parsoda manganese mine is expected to begin soon. The mine will be operated by open cast mining method. MOIL has been granted mining lease of Parsoda manganese mine near village Parsoda, 46-km from Nagpur in the year 2016. The lease extends for 50 year period, ie, from April 22, 2016 to April 21, 2066 and the project cost is estimated to be ` 19.54-crore. MOIL, under the Ministry of Steel, operates around 10 mines, including six in Maharashtra and four in Madhya Pradesh. Balaghat mine is its largest, which produces top quality manganese ore. NTPC Ltd hopes its captive coal production will reach 100-million tonne as soon as its five coal blocks commence operations, aided by faster regulatory clearances and the part-privatization model of Mine Development and Operator (MDO). The success of the plan would determine fuel security of the operations of India's largest power producer. Coal India aims to raise output from its troubled Rajmahal mine in Jharkhand to 60,000-tonnes a day by March 2019, having resolved land-acquisition related problems. Coal from the Rajmahal mine helps NTPC run close to 4,200-MW of power generation plants in eastern India, which supply power to Bihar, Jharkhand and West Bengal, and also to northern India including Delhi and Uttar Pradesh. NTPC’s generation capacities were faced with depleting coal stocks and lower power generation as supplies from Rajmahal dwindled. It led to drastic fall in supplies and stocks at the coalfield, as well as at two critical power plants in the region - at Farakka and Kahalgaon. CIL, ONGC to produce coal-bed methane from 10 new mines: support SAIL in one more. The Coal Ministry has identified 11 mines to produce coal bed methane (CBM). Initially, ONGC will harness the gas and then CIL will extract coal from them. In addition to the mines with CIL, the two (ONGC and CIL) will also help develop SAIL’s Parbatpur coal block (Jharkhand). Here too, ONGC will first harness the CBM. SAIL had surrendered the Sitanala and Parbatpur coal mines. SAIL had engaged MECON to prepare a techno commercial viability report, which declared the project unviable. JSW Energy, part of the Sajjan Jindal-led JSW Group, is believed to be in the race for buying out the thermal power assets of Monnet Power and Jindal India Thermal Power Ltd (JITPL) in Odisha. Monnet Power’s 1,050-MW coal-based power plant near Angul was in advanced stage of commissioning. Monnet Power’s parent company, Monnet Ispat & Energy had won the Mandakini coal block in Odisha in competitive bidding, it surrendered the block later on grounds of economic unviability. Besides Monnet Power, JSW Energy is also eyeing takeover of BC Jindal controlled JITPL’s 1,200-MW Chemical Engineering World

coal-based plant at Derang near Angul. The first unit (600-MW) of the 1,200-MW plant had begun commercial operations and started power supplies to the Odisha grid. This project has been completed at a cost of ` 7,537-crore which includes a debt component of ` 5,900-crore. JITPL has power purchase agreements (PPAs) with Odisha’s Gridco Ltd, Kerala State Electricity Board and Tata Power Trading Corpn. Apart from JSW Energy, JITPL also had competing offers from Adani Power and Singapore’s SembCorp. The valuation of the prospective deal is not known. NLC India (formerly Neyveli Lignite Corporation) which is in the hunt for buying out power assets is understood to have shown interest in the 700-MW Odisha plant of Hyderabad-based Ind-Barath Power Infra Ltd (IBPIL). The power plant located at Sahajbahal, near Jharsuguda, has commenced commercial operations. Though the exact size of the potential deal is not known, the valuation could be anywhere in the range of ` 5,000-5,500-crore. In August last year, NLC India had floated an EoI from companies owning coal and lignite-based power projects, for a possible acquisition. NLC India’s installed thermal power capacity is 3,240-MW. It runs a 10-MW solar power unit and wind power assets with a capacity totalling 37.5-MW. Western Coalfields has received the environment clearance for its ` 263-crore expansion project in Nagpur district, Maharashtra. The proposal is to enhance the production capacity of the Gokul open cast mine to 1.875-million tonnes per annum (MTPA) from the existing 1-MTPA. The mine, located in 767.17-hectare, has a mineable reserve of 14.50-million tonnes. The clearance to the project is subject to certain conditions. The company has been asked to get Consent to Operate certificate from the State Pollution Control Board for the existing production capacity of 1-MTPA and also the Consent to Establish for the proposed capacity of 1.875-MTPA prior to enhancing the production capacity.

OIL & GAS Haldia Petrochemicals (HPL), plans to deploy an innovative technology for its project that seeks to convert crude oil into chemicals and petrochemicals directly. As opposed to the customary production of refined petroleum products, HPL’s plant will concentrate on higher output of petrochemicals. HPL, is setting up an integrated refinery with aromatic complex for production of paraxylene and purified terephthalic acid (PTA) units in the first phase. The production capacity of paraxylene unit will be 1.6-million tonne per annum (MTPA) and PTA will have 2.5-MTPA capacity. The first phase of the HPL project approved is expected to be operationalised within five years of allotment of land. HPL has committed an investment of ` 28,700-crore ($4.05-billion) in the first phase on its Odisha project. Recently, the High Level Clearance Authority (HLCA) in Odisha headed by Chief Minister Naveen Patnaik gave its nod to the proposal, which HPL submitted on March 1. Official sources have touted HPL’s proposal as the country’s single-largest domestic investment in the last 12 months. Vedanta Ltd’s has received environment clearance for the expansion of its oil and gas operation in Rajasthan that would entail an investment of ` 12,000-crore. The proposal is to expand onshore oil and gas

November 2019 • 65

CEW


CEW

Project Update production from the existing 3,00,000-BOPD (barrels oil per day) to 4,00,000-BOPD and 165-MMSCFD (million standard cubic feet per day) to 750-MMSCFD from the 'RJ-ON-90/1' block located in Barmer and Jalore districts, Rajasthan. The environment clearance (EC) is, however, subject to compliance to certain conditions. The estimated project cost is `12,000-crore. The company aims to implement the project in a phased manner during seven years. The project involves oil augmentation to produce up to 4,00,000-BOPD and 250-MMSCFD of associated gas from the oil field and natural gas augmentation to produce up to 500-MMSCFD. Total area of the oil and gas block is 3,111-sq km. Out of it; the project presently covers an area of 1,501.7-hectare in Barmer and Jalore districts. Additional 150 hectare of land in Barmer district will be used for the proposed expansion. The 'RJ-ON-90/1 block' comprises of Vedanta Ltd and state-run ONGC for hydrocarbon exploration, development and production activities in the block, while Cairn Oil and Gas division (part of Vedanta Group) is the operator of the block. BPCL-Kochi Refinery is going ahead with its second petrochemical project to produce polyols at an investment of ` 11,300-crore. An import substitute, polyols are used in the production of polyurethanes used in diverse products such as automotive seats, mattresses and shoe soles. The project is expected to go on stream by 2022. BPCL is in talks with various global firms to finalise the technology for six different products. There is a huge demand for polyols and it is growing at 10 per cent per annum providing good scope for MSMEs to set up units in the complex. The first petrochemical project of BPCL-KR constructed at a cost of ` 5,500-crore is all set to commence operations by the middle of the year. It will produce acrylic acid, acrylates and oxo-alcohol that are used in the manufacture of paints, super absorbent polymers, detergents, adhesives, sealants and solvents. The technology has been sourced from Mitsubishi, Air Liquide Global and Johnson Mathey Davy. The two projects will facilitate ` 13,000-crore forex savings per annum for the country. With the completion of the second petrochemical project, BPCL-KR is expecting around 16 per cent increase in its turnover in three years. BPCL-KR is slated to complete its fuel upgradation project to comply with BS-VI norms by February next year. The project cost is around ` 3,300-crore. Vedanta Ltd announced an oil discovery in its Krishna Godavari basin block in the Bay of Bengal. The block previously had a gas discovery in the very first well drilled. Vedanta holds 100 per cent participating interest in the block. "Multiple reservoir zones were encountered in the well H2 within the Mesozoic sequence between the depths of 3,310 to 4,026-metres with hydrocarbon indications during drilling and downhole logging," it said. The zone from 3,403 to 3,431-metres was tested through conventional well testing (Drill Stem Test) and flowed oil to the surface. Further appraisal will be required to establish the size and commerciality of the oil discovery. The first exploration well A3-2 drilled in the block was a gas discovery. Cairn India, the company Vedanta bought and merged with itself, had in June 2010 won the KG-OSN-2009/3 block in the 8th round of New Exploration Licensing Policy (NELP). It had committed to drill six exploratory wells on the block. These were expandable to 10. The KG basin is a proven basin where there have been many hydrocarbon

66 • November 2019

discoveries. The company acquired around 1,000-sq km of 3D seismic data based on which it drilled two wells. KG-OSN-2009/3 offshore block in the Bay of Bengal was originally spread over in an area of about 1,988-sq km which was later reduced to 1,298-sq km due to exclusion of area within firing range. It is located in the shallow waters of the Indian Ocean along the East coast of India, approximately 1.5 km from the Indian coastline. Chennai Petroleum Corpn Ltd (CPCL) the Indian Oil Corpn's (IOC's) group company is planning to set up a greenfield refinery at Nagapattinam in Tamil Nadu, at a cost of ` 27,460-crore. The products, including motor spirit (MS) and high speed diesel (HSD), which will be produced from the refinery will help meet the latest BS-VI specification in the southern States. The new refinery will be part of the Government of India's plan to set up a petroleum, chemicals and petrochemicals investment region (PCPIR) in this region. The boards of CPCL and IOC have accorded in-principle approval for the 9-million metric tonne per annum (MMTPA) refinery at CBR at an estimated investment of ` 27,460-crore, plus or minus 30 per cent. The investment includes ` 2,800-crore for setting up a polypropylene unit of around 500 thousand metric tonne (TMT) per annum capacity. Detailed feasibility report (DFR) preparation is underway. The refinery is expected to be operational by 2023-24. It will produce valuable products, including liquefied petroleum gas, petrol, diesel, aviation turbine fuel, polypropylene, etc, besides petrochemical feed stocks. The petrochemical complex will also feed stocks to downstream industries, including pharma, paint and lacquer, printing inks, adhesives, coatings, chemicals, automobile lubricants, and PVC, among others. CPCL operates two refineries with a total capacity of 11.5-MMTPA (10.5-MMTPA at Chennai and 1-MMTPA near Nagapattinam) in Tamil Nadu. The company's crude throughput increased to 10,789-TMT in 2017-18, from 10,256-TMT in 2016-17. Its profit after tax stood at ` 913 crore in 2017-18, as compared to ` 1,030-crore in 2016-17. Reliance Industries Ltd has secured backing of the key expert appraisal committee (EAC) in the Ministry of Environment, Forest and Climate change to expand the capacity of its export-oriented refinery in the special economic zone (SEZ) at Jamnagar by 5.8-million tonnes (MT). The planned expansion will raise the installed capacity of the SEZ refinery to 41-MT from 35.2-MT and lift the overall capacity of the Jamnagar refinery complex to 74-MT. The additional terms include prior transfer of environment clearance issued on March 30, 2010 to Reliance Jamnagar Infrastructure Ltd to Reliance Industries Ltd (the entity that applied for the environment clearance).The Jamnagar refinery processed 69.8-MT of crude in FY18, exceeding its installed capacity of 68.2-MT. Between April and December 2018, Reliance refined 52.3-MT of crude. Reliance Petroleum Ltd, a unit of Reliance Industries, built its first refinery at Jamnagar with an installed capacity of 18-MT which was later expanded to 27-MT. The capacity of the Jamnagar refinery and petrochemical complex was further expanded by Reliance Industries to 59.7-MT during which the production was split between Reliance Petroleum (26.7-MT) as an only for exports refinery unit and Reliance Industries (33-MT) that sold most of its products in the local market. The capacity of the SEZ refinery was further expanded by Reliance Jamnagar Infrastructure Ltd to 35.2-MT from 26.7-MT.

Chemical Engineering World


Book Shelf CEW Glycerol: A Versatile Renewable Feedstock for the Chemical Industry Authors: Claudio J A Mota, Bianca Peres Pinto and Ana LĂşcia de Lima Price: $82.00 No of pages: 110 pages (Hardcover) Publisher: Springer (1st Edition) About the book: This book is aimed at providing a concise discussion on the use of glycerol as a renewable raw material for the chemical industry. With the increasing use of biodiesel produced from oils and fats, there is a surplus of glycerol in the world. This abundant and rather cheap raw material can be transformed in commodities and specialty chemicals, as well as in fuels. The book describes the main processes of chemical transformation of glycerol, highlighting those that are currently in commercial use and pointing out potential processes to be used in the future. The first chapter introduces the concept of biofuel and briefly describes the production of biodiesel. It also highlights glycerol as the main by-product of biodiesel synthesis and presents some numbers regarding the world production of glycerol. The second chapter shows the common uses of glycerol and addresses the point whether or not they can drain the large amounts of glycerol produced from biodiesel. The chapter addresses pros and cons of each use. The third chapter covers the main biotechnological processes of glycerol transformation. The fourth chapter thoroughly describes the main thermochemical processes to transform glycerol into commodities, products that will be further used in the chemical industry to produce polymers, for instance. The fifth chapter covers the production of glycerol derivatives of high added-value. The sixth chapter addresses the use of glycerol in the context of a biorefinery. The main idea is to show that many of the processes described in the previous chapters could be entirely green, using exclusively renewable raw materials.

Mastering Digital Transformation Author: Nagy K Hanna Price: $28.22 No of pages: 426 pages (Paperback) Publisher: Emerald Group Publishing Limited About the book: The information and communication technology revolution offers the promise of transforming economies and societies, and the risks of missing on a powerful techno-economic revolution and wasting scarce resources without much developmental impact. Some countries have mastered the process of digital transformation, and continue to realize substantial economic benefits. Others made substantial investments in the ICT infrastructure, with marginal impact. What makes for these differences among countries? The author presents a systematic approach to integrate ICT into development policies and programs across sectors of economy and society. This book bridges the current disconnect between the ICT specialists and their development counterparts in various sectors so as to harness the ongoing ICT revolution to maximize development impact and minimize downside risks. Posing a holistic and strategic framework that draws on lessons learned across all sectors to guide national leaders and development practitioners interested in moving from vision to action, it is an important work for researchers and students of ICT who aim to pursue innovative, inclusive and sustainable development paradigms. Chemical Engineering World

Fundamental Concepts in Heterogeneous Catalysis

Authors: Jens K Nørskov, Felix Studt, Frank Abild- Pedersen and Thomas Bligaard Price: $96.20 No of pages: 208 pages (Hardcover) Publisher: Wiley (1st Edition) About the book: This book is based on a graduate course and suitable as a primer for any newcomer to the field. This book gives a detailed introduction to the experimental and computational methods that are used to study how solid surfaces act as catalysts. The first comprehensive text on the modern theory of heterogeneous catalysis Heterogeneous catalysis is the cornerstone of chemical industry and also holds the key to new processes for sustainable energy conversion and sustainable production of feedstocks for the chemical industry. Heterogeneous catalysis involves chemical transformations taking place at the surface of a solid, and is a very complex phenomenon. There is now a consistent set of concepts that allow an understanding of surface catalysis and they even form a basis for design principles for new catalysts. Based on a graduate/senior-undergraduate course and suitable as a primer for anyone interested in understanding the field, this book presents the fundamentals of surface reaction phenomena including potential energy diagrams, free energy diagrams, and kinetic models; tools to reduce the complexity of heterogeneous catalysis including scaling relations; an understanding of trends in catalysis including activity and selectivity maps; an introduction to electronic structure effects in catalysis and an understanding of structural effects; application to a series of heterogeneously catalyzed reactions including reactions of interest in energy conversion; an integration of the conceptual frameworks of electrocatalysis and thermal heterogeneous catalysis; and an understanding of the effect of promoters and poisons in heterogeneous catalysis. Unlike most textbooks in the field, the aim of this monograph is not to give a complete overview of the types of catalysts or catalytic processes, but to provide interested students and researchers with the atomic-scale concepts for understanding catalytic phenomena. November 2019 • 67


INTERVIEW CEW Interview

The Growth of an Organization is Not Only about the Leadership at Top, But across All Levels. Ranjit Lala

Managing Director Aerzen Machines (India) Pvt Ltd

In an exclusive interaction with Jayati Mukherjee of Chemical Engineering World, Ranjit Lala talked about – Aerzen’s competitive positioning, market expansion & growth strategy, decentralized competence philosophy, water 4.0 performance efficiency and optimization initiatives, integration of company’s quality policy with its products-processes-and-services, customer centric initiatives, and many other important organizational aspects.

You have been with Aerzen since mid2015. What’s your point-of-view about Aerzen’s competitive positioning with respect to its contemporaries? Aerzen is always known for its reliability, quality, energy efficiency, and service support – in addition to 68 • November 2019

the unique features of our products (viz. oil free delivery, reactive silencers, and internal pulsation cancellation). This differentiates Aerzen from our contemporaries, which is very much evident from the fact that Aerzen is a robust brand with a sustainable global presence.

Are you planning for any market expansion? What growth strategy have you depicted for the company? Our growth strategy is focused on market penetration in growing segments like food, cement, waste water, process gas, and petrochemicals. We have the right product mix, which leverages our market position. Chemical Engineering World


Interview CEW How does Aerzen’s philosophy of ‘Decentralized Competence’ confer to its business growth, market positioning, and global invasion? Our ‘Decentralization Competence’ philosophy encourages the localization of blowers and compressors in India, and the local skill development. This is now a continuous process, which translates into upholding the German quality at India centric price levels. Not only is that, this rationale has helped us to bag orders for foreign projects by Indian companies. Rather than going for a global invasion, I see this practice as creating footprints of Made-in-India products in International market – with due modesty. Towards the end of 2018, Aerzen had divested one of its product line – Rotary Piston Gas Meters – to RMA Rheinau GmbH. What objective, strategy, and future orientation worked behind this decision? How did Aerzen benefit out of it? As a part of our product portfolio consolidation, we are focused on air compression solutions and not metering solutions, hence the decision. Being a market leader in wastewater technology, please acquaint our readers with the initiatives your company has taken towards Water 4.0 – Performance Efficiency and Optimization? Aerzen has been a pioneer towards Water 4.0 with its game changing solutions such as Performance 3 ³, AERsmart, and AERaudit. Just to explain in short, Performance 3 ³ allows multiple technologies of equipment to optimize power consumption at the same time, especially in plants having huge variation in oxygen demands as per effluent flow variations. AERsmart allows effective and optimized utilization of equipment, thus resulting in up to 30 percent energy savings. AERaudit allows customers to evaluate the performance of existing blowers and helps in identifying the precise blower Chemical Engineering World

technology to be adopted. This again is a good product for those wanting to switch to energy efficiency with payback period of 2 to 3 years on case to case basis.

Sustainability and circular economy being one of the key focus area, please acquaint our readers with the initiatives Aerzen has been following towards this?

Assuring highest quality standard to customers being the core focus, how does Aerzen integrate its quality policy with its products, services, and processes?

We review our manufacturing and business processes continuously to minimize any excesses in our system. We have implemented LEAN manufacturing at our Vadidara factory. On the customer front, we optimize our solutions with a clear focus on energy efficiency and life cycle costs. We believe in constant change and implement our lessons learnt from field experiences to make our products more reliable. This is a continuous and unending cycle, which drives our sustainability.

Aerzen is always known for its reliability which emanates from its high quality standards. All our products are quality products and we don’t discriminate our quality standards across the group. Being a German subsidiary, the stringent quality standards for products, services, and processes are very much a part of our DNA and company culture, eg • We work on LEAN principles to ensure a reliable product with timely delivery to the customer. • We are certified ISO 9001-2015, ISO 45001-2018, ISO 14001-2015. • We have been rated “Gold” under financial support to MSMEs in ZED Certification scheme by Ministry of MSME and Quality Council of India under the Make-in-India initiatives. Please walk us through Aerzen’s customer centricity initiatives. Customer centricity has always been our prime objective. We work on the philosophy of customer delight and have taken many initiatives to maintain the same, viz. • To support our customers during sales phase with the help of our application specialists. • To offer customized solutions as a differentiation from our competition • A 24x7 customer service approach with dedicated back office support for customer service related queries, and a fully equipped service center at Vadodara.

You being in the leadership role for over 25 years across various functions, what leadership qualities would you like to inculcate into your successors? The growth of an organization is not only about the leadership at top, but across all levels and hence leadership qualities should be inculcated across the genres of teams. The attributes I would look for or inculcate in a leader are: 1. Ethical way of business 2. Customer First approach 3. Team Effort, Unity, and Partnership People-centricity, up-skilling, and reskilling are the talk-of-the-time, which almost all the companies have been following through these days. How does Aerzen live up to this? Apart from providing training to our colleagues at our headquarter in Germany for domain expertise, we work on – enhancing soft skills, customer centric approach, and refresher trainings as deemed fit. Coaching and Mentoring are the key ingredients of our employee development. We have a periodic feedback mechanism through different forums across the organization. November 2019 • 69


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Chemical Engineering World



R.N.I. No. 11403/1966 Date of Publication: 29ththth of every month. Postal Registration No: MCS/095/2018-20 R.N.I. 11403/1966 Date of 29 month. Postal Registration No: R.N.I. No. No. 11403/1966 DateSorting of Publication: Publication: 29 of of every every month. Postal Registration No: MCS/095/2018-20 MCS/095/2018-20 th Office, Mumbai No.:78 Posted at Patrika Channel Office, 400001, on 30 of every month. Total Pages No.:74 Posted at Patrika Channel Sorting Office, Mumbai 400001, on 30thth of of every every month. month. Total Total Pages Pages No.: No.: 96 72

Manufacturer of:

Lined piping systems, Columns, Vessel and Tanks for corrosive media applications

Lining Material: PTFE/PFA/FEP/PVDF/PP/HDPE

Why Resistotech: • Processing capacity of 50+ tonnes per month • Large diameters upto 2000 NB (80”) by paste extrusion • Liners thickness from 2 mm to 14 mm as per application • Seamless lining in Tanks, column and vessel – no weld joints • Liner lengths 6400 mm upto 400 NB and above all 3200 • All sizes 90 Deg Elbows in single piece • Minimizing joints by longer lengths -saves product and installation cost • Full vacuum upto 200 Deg C in any size • Testing as per ASTM F 1545 – 03 for 100% products • FDA certificate and compliance

Techno-commercial solutions provider with pre-engineering and case study of corrosion issues RESISTOTECH INDUSTRIES PRIVATE LIMITED

C-11, MIDC, SINNAR, DIST.: NASHIK, MAHARASHTRA, INDIA, PIN - 421 301. M: 0091 9820429054 | T: 0091 2551 230540 | E: sales@resistotech.com | W: www.resistotech.com