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CEW Contents CHEMICAL ENGINEERING WORLD RNI REGISTRATION NO. 11403/66 Chairman Publisher & Printer Chief Executive Officer

Jasu Shah Maulik Jasubhai Shah Hemant Shetty

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Place of Publication: Jasubhai Media Pvt Ltd

Vol. 48 | No.10| OCTOBER 2013 | Mumbai | ` 150 NEWS ► Industry News / 08 Technology News / 20

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How will Gujarat Continue to Lead the Chemicals & Petrochemicals Industry in India? / 32 – Jaimin Vasa, Gujarat Chemical Association Supply Chain Cost Management: A Necessity for the Future? / 38 – Siddharth Paradkar, Manish Panchal & Sangeeta Mishra, TSMG Gas Sensor Technology to Control Plant Emissions / 48 – John Warburton, City Technology Significance of Turbine Oil Testing / 52 – ExxonMobil Corporation Better Separation with Combined Materials / 56 – Jörg Koch and Daniel Egger, Sulzer Chemtech Ltd Remote Colloboration for Operational Excellence / 62 – Andrew Stuart & Chris Morse, HPS

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Printed and published by Mr Maulik Jasubhai Shah on behalf of Jasubhai Media Private Limited, 26, Maker Chamber VI, Nariman Point, Mumbai 400 021 and printed at Anitha Art Printers, 29-30, Oasis Ind. Estate, Next to Vakola Market, Santacruz (E), Mumbai-400055 and rd published from 3 Floor, Taj Building, 210, Dr. D N Road, Fort, Mumbai 400 001. Editor: Ms Mittravinda Ranjan, 26, Maker Chamber VI, Nariman Point, Mumbai 400 021.

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CEW Industry News India to Slap Safeguard Duty New Delhi, India: To protect domestic producers from critical injuries caused by the rising inward shipments, India may implement safeguard duty on imports of sodium nitrate, chemicals utilised by the Pharma and Textile industries. The Directorate General of Safeguards (DGS) in the Finance Ministry, carried out search investigation on the complaint of domestic chemical producers and concluded that there have been considerable raise in imports and recommended levy the of the safeguard duty. The DGS mentioned that the increased imports of sodium nitrite into India have caused and threaten to cause serious injury to the domestic producers and it will be in the public interest to impose safeguard duty on imports of Sodium Nitrite for a period of one year and three months. It has been suggested the duty at the rate of 30 per cent ad valorem for the first year and 28 per cent ad valorem for last three months, which is measured to be the minimum required to guard the interest of domestic industry. Sodium nitrite is imported from several countries, whereas primarily from Germany and China. China constitutes 81 per cent of total imports in India in 2012-13. Safeguard duty is a WTO-compatible provisional measure that will bring in for a definite time-frame to prevent any destruction to domestic industry from cheap imports. The final findings and the recommendations of DGS is considered by the Standing Board on Safeguards headed by Commerce Secretary. Then the views of the Board were placed before the Finance Minister for approval in esteem of safeguard duties and to the Commerce Minister for imposition of quantitative restrictions. The imports rose from 14,290 MT in 2009-10 to 22,162 MT in 2012-13. The domestic producers had a market share of 55 per cent in 2010-11 which has been declined to 41 per cent in 201213. On the other hand, the market share of import increased from 35 per cent in 2010-11 to 45 per cent in 2012-13. The domestic producers of the chemical include Deepak Nitrite Ltd (Pune), Punjab Chemicals & Pharmaceuticals Ltd (Chandigarh), National Fertilizers Ltd (Noida), and Rashtriya Chemicals and Fertilisers (Sion, Mumbai). Deepak Nitrite Ltd is the last producers of the chemical in the country.

A Successful Star t for Water tech Expo and Conference 2013 Gandhinagar, Gujarat: Organised for the first time by Messe Frankfurt, Watertech Expo and Conference 2013, a trade and networking event dedicated to the water and wastewater treatment industry, enjoyed a successful first day. Exhibitors from across India displayed a wide range of products, services and technologies suited to the Indian market. Under new organisation, Watertech 2013 received much support from the government and several key industry associations. This was notably reflected in the amount of association support and the number of dignitaries and professionals attending the event. Watertech 2013 also featured a Ministry of Drinking Water and Sanitation Pavilion, representing water supply and sanitation programmes of 18 participating states and union territories in India. Opening the Inauguration Ceremony, Raj Manek, Managing Director, Messe Frankfur t Trade Fairs India stated, „There has been a global realisation of the importance of treating wastewater and its contributions to environment, health and economic development. I am glad that through Watertech Expo and Conference 2013, we can invigorate and encourage the development that IndiaÊs water and wastewater treatment sector requires.‰ Bharatsinh Solanki, Minister of State (I/C), Ministry of Drinking Water and Sanitation, Government of India, in his inaugural speech warned that IndiaÊs water scarcity is only expected to worsen as the countryÊs overall population grows. He said, „I congratulate Messe Frankfurt for organising Watertech 2013 as a national level exhibition and conference on water and wastewater treatment and management. I sincerely hope that all deliberations and ideas exchanged here helps in a movement towards ensuring efficient, sustainable water supply for all.‰ The highlight of Watertech 2013 was the launch of the ÂSolar Energy Based Dual Pump Piped Water Supply SchemeÊ by the Ministry of Drinking Water and Sanitation, as the way towards sustainable water supply for 10,000 naxal affected habitations.

Chem industries Need Revised Green Norms Chem Industry Seeks Clarity in TN Molasses Sales Chennai, India: The Chemical Industr ies Association has r e q u e s t e d t h e Ta m i l N a d u G o v e r n m e n t t o a p p r a i s e t h e policy of molasses allotment to ensure clarity in making more transparency. Downstream chemical units have been hit by extended delays in the Sugar Directorate calling for molasses tenders. The Tamil Nadu Cooperative Sugar Federation had few days back called for bids at an upset price of ` 4,500 a tonnes but cancelled the tender. The Association has conveyed that in order to protect the industries and employment in this sector, it is important to have transparency in molasses allocation. 8 • October 2013

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Chennai, India: The Chemical Industr ies Association has u r g e d t h e U n i o n M i n i s t r y o f E nv i r o n m e n t a n d Fo r e s t s t o review its policy of banning new industrial activity in areas wherein the inclusive environmental pollution index surpasses predetermined levels. The Association officials mentioned that even if one or two industrial units do not meet the set standards, the index can exceed permitted levels in an area. If the Ministry follows its policy of banning establishment of new units or allowing existing players to expand, it results in even those units following norms being penalised. The association has urged the Ministry to lift the ban on setting up new industrial projects in Ranipet, Tamil Nadu whereas they are welcoming the MinistryÊs decision to lift a similar ban in the industrial area of Manali. According to the association, Ranipet in Vellore District was an important industrial hub. Chemical Engineering World

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CEW Industry News Akzo Nobel India MD to Head Europe Kolkata, India: A new operating model for their decorative paints business has been introduced by Akzo Nobel Dutch International along with streamlining their management structure. As a part of the reshuffling plan, Amit Jain, Managing Director, Akzo Nobel India, will be Akzo Nobel NV Director, Decorative Amit Jain, Managing Director, Paints - North & Central Europe, based in Akzo Nobel India Amsterdam, from January 1 next year. The planned changes effective from January 1, 2014 will involve reducing the number of senior management teams and introducing a new management structure for decorative paints business. Amit Jain confirmed that these changes will have no implication for the Indian business whereas according to the company officials, the intended developments will involve numerous potential relocations. The company said that there would be centralisation of numerous key global functions including research and development, finance, human resources, information management, sourcing and supply chain. It is said that the execution of such changes are due to recent divestment of the decorative paints business in North America and thus such changes will eventually result in efficiency benefits and significant cost savings.

Haldia Petrochem on Greasy Track Kolkata, India: Ambiguity continues to dodge Haldia Petrochemicals and the attempts to sell its shares by the WestBengal Government was no exception. Even after huge publicity, the state government could lure only one bid from Indian Oil Corporation Limited. According to sources, government feels that lack of competition will definitely not help the state to attract maximum value for its investment in HPL. Even after keeping aside the financial implications, it is uncertain to invest in HPL due to legal battles. Dr Pur nendu Chatterjee, Founder, The Chatterjee Group

Approximately, 9 per cent of the government stakes are disputed wherein the private promoter Dr Purnendu Chatterjee, Chairman & Founder, The Chatterjee group holds close to 41 per cent. If TCG gets control of the disputed stakes, then the company will own majority of stakes. Indian Oil has bid for the project in spite of these risk, since they are the shareholder in the company with about 9 per cent stake and apar t from that they enjoys the backing of financial institutions that hold over seven per cent interest in the company. 10 • October 2013

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BPCL Signs Pact with Prodair Air Products Kochi, India: A long term agreement between Prodair Air Products India Pvt Ltd and Bharat Petroleum Corporation Ltd for the supply of hydrogen, nitrogen and steam to BPCLÊs integrated refinery expansion project in Kochi, has been signed. As per the agreement, Prodair would start supply of gas from November 2015.Prodair is a 100 per cent subsidiary of Air Products, one of the leading global industrial gas suppliers. The company will build, own, and operate new industrial gas production facilities in Kochi whereas, BPCL is an Indian state-controlled oil and gas company headquartered in Mumbai, Maharashtra. BPCL has been ranked 225 th in the Fortune Global 500 rankings of the worldÊs biggest corporations for the year 2012.

Pe nna r Indus tr ie s Buy s As s e ts Hyderabad, India: Hyderabad-based, Pennar Industries has engaged themselves in the production & marketing of specialised and engineered steel solutions. They have also entered in hydraulic business with the acquisition of assets of Wayne-Burt Petro Chemicals Private Limited (formerly Bailey Hydropower), a hydraulics cylinder manufacturing company in Chennai, for approximately `15 crore. According to Suhas Baxi, President & CEO, Pennar, this acquisition is part of the organisationÊs strategy to move up the value chain in present businesses. They will be investing another ` 15 crore in these assets, including in technology and manufacturing. Thus, it will double the plant capacity in the next one year. Pennar has acquired the production, engineering, product development programme and the existing customer relations of Wayne Burt, which has two client relationships. This includes the USD 2 billion asset-based conglomerate Wayne-Burt Group.

Odisha Upset with IOCL Odisha, India: The state government has shown its disappointment over the lack of commitment by Indian Oil Corporation Limited (IOCL) in regards to set up the downstream petrochemical complex planned by the oil major at Paradip. Due to delay in establishment of this petrochemical complex, it has postponed the developments of the PCPIR to the back foot. IOCL is the anchor occupant for the PCPIR centre to be set up on 70,214 acres of land straddling Jagatsinghpur and Kendrapara districts. The government officials have confirmed that IOCL have shown negligence towards their commitment to meet the deadlines for developing petrochemical complex. They have requested the IOCL officials to take the issue as the first priority and appraise the concerns of the state. The mega project is set to create employment for 648,000 people which includes direct employment for 227,000 people and indirect employment for 441,000 others. The turnover of this PCPIR hub is estimated at ` 4.23 lakhs crore with an export potential of ` 43,000 crore. The PCPIR hub is expected to generate taxes to the tune of ` 42,000 crore and contribute six per cent to Odisha Gross Domestic Product (GDP). Chemical Engineering World

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CEW Industry News New Urea Policy for Chemical Industry

Policy on Underground Coal Gasification Soon

Mumbai, India: The Department of Petrochemicals and Chemicals has suggested plans for procurement of technical grade urea which will eventually ease the availability of cheap urea for the chemical industries.

New Delhi, India: According to top officials from Coal Ministry, the government will bring on new policy on underground coal gasification. They mentioned that due to some barriers in the past, this policy was unable to move forward but now they definitely need to work on the underground coal gasification area. This needs to be addressed especially when the open cast S r i p r a k a s h J a i sw a l , C o a l Minister, Government of India. mining process becomes complicated. Underground coal gasification is a method of converting coal still in the ground to combustible gas that can be used for various things, including power generation.

According to the proposal, the fertiliser department have asked the Ministry of Fertilisers to allocate some definite area of urea manufacturing by the domestic fertiliser companies for the utilisation of chemical industry. Since the industries conveyed that imported technical grade urea costs around ` 32 per kg, many of the suggestions were accepted in regards to this were involved in the proposal. The domestic manufacturers sell urea at ` 5.36 per kg to the farmers and thus the difference between selling cost to the farmers and the imported price is subsidised by the government. Since, fertiliser is a controlled commodity and movement of urea in domestic market is regulated by the government but monitoring the consumption of urea from the domestic industrial players is worrisome matter. As per the industrialists, the difficulty in monitoring leads to duty diversion and smuggling out of the country. On the issue, department of chemical said that it will be equally convenient situation for both, if the particular portion of the urea manufactured by the domestic fertilisers companies is allocated exclusively for the chemical companies. The shor tfall can be imported and sold to the farmers through its canalising agent MMTC where monitoring will not be a problem. The technical grade urea consumption of the Indian Chemical Industry is currently on the edge of 1.5 lakh metric tonnes per annum.

Shriram Group to Invest ` 700 Crore

T Shivaraman, Vice-Chairman, OGPL

C h e n n a i , I n d i a : S h r i r a m G r o u p ĂŠs renewable energy arm, Orient Green Power has planned to invest approximately ` 600- 700 in order to set up a new wind energy projects. The organisation is already in the process o f e s t a bl i s h i n g n ew p r o j e c t s wo r t h ` 250 crore which indicates the growth of the organisation.

According to T Shivaraman, Vice Chairman, OGPL, the organisation focuses to grow as countryÊs largest energy and biomass with a capacity of approximately 1,000 MW over the next few years. The company will fund the projects through structured equity and debts. The US based venture capital Bessemer Ventures Partners along with private equity fund Olympus Capital Holdings Asia have invested in the company. Since Orient Green has tied up exterior commercial borrowing of USD 50 million, it has reduce the cost of borrowing and thus has pursued refinancing of receivables for the whole amount of loan ` 300 crore. 12 • October 2013

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In this structured process, once the policy is finalised, the blocks for coal gasification would indentified and eventually companies interested for blocks would be invited. The companies have net profit above ` 200 crore would be only able to apply for these blocks. Sriprakash Jaiswal, Coal Minister, had initially looked for cooperation from countries such as South African for underground coal gasification technology. The gap in demand and supply of coal had widened to 135 million tonnes in the last fiscal and will reach 140 million tonnes in 2013-2014.

Oil Spill Near Navi Mumbai Mumbai, India: An oil spill has been reported by the Oil and Natural Gas Cor poration (ONGC) off the coast of Uran near Navi Mumbai. Due to puncture in trunks pipeline, 5000 litres of oil spilled that was being carried to Uran processing complex from Mumbai High Fields. The officials from company mentioned that the leak prompted due to shutting down of power in a section of the processing complex which eventually led to develop up pressure in the pipeline and thus causing crack. As soon as the spill was detected, the crisis management team was deployed late Sunday evening to prevent further spreading of the oil. The officials confirmed the appointment of agency for clearing up operation and also mentioned that no production loss is identified at Uran and Mumbai High Fields. In the meanwhile, ONGC recently received show-cause notice from The Ministry of Environment & Forests in regards to the oil spill in the west coast near Mumbai. The Ministry has formed a team headed by Member Secretary, Central Pollution Control Board, J S Kamyotra and have ordered immediate closure of faulty pipeline/installations. The officials maintain the record of spilling 1000 litres of oil although it is considered that 5000 litres of oil has been spilled. ONGC official have mentioned that spill had not affected the local fisherman and there were no ecological concerns either. Chemical Engineering World

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CEW Industry News Chemplast Sanmar to Sell Marginal Stakes

Essar Secures Project in Gujarat

Mumbai, India: Chemplast Sanmar, Chennai based chemical maker, has planned to sell marginal stakes to strategic investors or private equity funds to raise approximately `1200 crore. The chemical maker of various chemicals such as caustic soda, chloro ă chemicals, industrial salts, polyvinyl chloride (PVC) resins and refrigerant gas has decided to trim their debt of ` 700 crore. Thus, they have delisted themselves from stock exchange a year ago. According to one of the investment banker, aware of the deal said, „There is a lot of scope in the chemicals and speciality chemicals business. Though the group has had liquidity problems, the outlook for the sector remains positive. The company has approached a couple of distressed asset funds operating in India.‰ The ex- NSE and Madras Stock Exchange listed companyÊs officials had mentioned their shareholders that Chemplast needs capital infusion to correct the gearing and liquidity issues, which the promoters are willing to support. The four facilities of Chemplast in Southern India can generate around 292,000 tonnes of PVC( used of creating plastic products) per annum. The company competes with Aditya Birla Chemicals, Sree Rayalaseema Alkalies & Chemicals, Gujarat Alkalies & Chemicals and Tata Chemicals. According to the India Brand Equity Foundation, Indian chemical industry is anticipated to grow more than two-and-ahalf times to USD 290 billion by 2017, from USD 110 billion in 2011.

Alwyn Bowden, President & CEO, Essar Projects

Gujarat, India: Headquartered in Dubai, Essar projects, an engineering procurement and construction contractor has through its Indian subsidiary Essar Projects (India) Ltd. secured a project from Jamnagar Municipal Corporation in Gujarat, involving construction of a 70 MLD sewage treatment plant (STP) and its allied infrastructure as well as the operation of the plant for 15 years.

Officials from Essar projects, part of the Essar Group, said this is a path-breaking project since it incentivises sale of treated water to industries. To facilitate these sales, Essar Projects will invest an additional ` 80 crore to create the necessary pipeline infrastructure for sale of water to industries in and around Jamnagar. Both projects shall be completed in two years, they added further. Alwyn Bowden, President & CEO, Essar Projects said, „This project provides a platform for launch of our water, sewage and solid waste business. While the sector is at a nascent stage in India today, this win shall open up a huge oppor tunity for these businesses, owing to rapidly growing urbanisation of the country. These sectors are well suppor ted by government initiatives such as JNNURM and have a great future in India,‰ he added.

Reliance to Produce More Gas New Delhi, India: Global oil giant BP Plc and its partner Reliance Industries declared to invest USD 8-10 billion in generating more gas, but conveyed worries over a double penalty being sought to be imposed on them for KG-D6 fields output for not matching the targets. Bob Dudley, Chief Executive, BP and Mukesh Ambani, Chairman, Reliance Industries met Oil Minister M Veerappa Moily and then followed it up with a meeting with Finance Minister P Chidambaram. The meeting was conducted due to the decision of Oil Ministry at the insistence of the Finance Ministry to deny RIL-BP a gas price revision for producing less than projected gas from their eastern offshore KG-D6 fields. This punishment is on top of USD 1.8 billion penalty that is already being imposed on them for the same reason. While Moily said issues surrounding KG-D6 were discussed in the meeting that lasted more than one hour, Dudley said BP was „committed to working with the Government of India in their quest for energy security‰. Dudley demanded to conduct a fair trial since according to him, they did not intentionally produce less than the targets alloted. Whereas, Ambani, said if the government is citing the production sharing contract to say that no international expert can be appointed to verify reasons for fall in KG-D6 output, then how was one-man reservoir expert P Gopalkrishnan appointed by DGH and on whose recommendations RIL and BP were being penalised. 14 • October 2013

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Floods Disturb Grasim IndustryÊs Operation Gujarat, India: The operations of Grasim Industries Ltd’s Greenfield Viscose Staple Fibre Project was hampered last week, due to unexpected floods at Vilayat in Gujarat. The flood badly affected the projectÊs commissioning schedule. The operations of Grasim Industries LtdÊs Chemical plant are suspended due to floods affecting the plant/ power supply. This, however, is not likely to have any significant impact on the companyÊs profitability, considering the present contribution of this plant to overall profitability. Shares of Grasim Industries Ltd was last trading in Bombay Stock Exchange at 2675.25, down by 27.50 or 1.02 per cent. The stock hit an intraday high of 2704.20 and low of 2649. The total traded quantity was 3355 as compared to last two week average of 5113. The company have informed BSE about the current situation and have assured that BSE will be informed once the work is resumed. G ra s i m I n d u s t r i e s L i m i t e d i s a n I n d i a n bu i l d i n g m a t e r i a l s manufacturing company based in Mumbai, Maharashtra. It was started in 1948 as a textile manufacture and now is a a flagship company of the Aditya Birla Group, ranks among IndiaÊs largest private sector companies. Chemical Engineering World

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29-10-2013 10:59:10


CEW Industry News Karplus, Levit, Warshel Receive Nobel Prize

Dow Adds Polyether Polyols Facility at Thailand Site Midland Texas, USA: A business unit of The Dow Chemical Company, Dow Polyurethanes will add a polyether polyols facility at the CompanyÊs Map Ta Phut, Thailand which will further address regional consumersÊ needs.

L to R - Michael Levit, Martin Karplus, Arieh Warshel

Sweden, Stockholm: The Royal Swedish Academy of Sciences has conferred Martin Karplus, Michael Levitt and Arieh Warshel with the Nobel Prize in Chemistry for 2013, for the development of multi-scale models for complex chemical systems. Martin Karplus is from Université de Strasbourg of France and Harvard University of US, and Michael Levitt is from Stanford University School of Medicine of US whereas, Arieh Warshel represents University of Southern California of US. The scientists have managed to make NewtonÊs classical physics work alongside with fundamentally different quantum physics.Earlier, chemists used to select classical physics to model large molecules and simple calculations, but it failed to offer a way to simulate chemical reactions. Thus, the Nobel-winning scientists have taken the best from both worlds and devised methods which combine both classical and quantum physics. Chemical reactions take place at lightning speed, where electrons jump from one atomic nucleus to the other in a fraction of a millisecond.

Due to the facilityÊs 165 kilotons per annum capacity, the logistical costs and transpor tation r isks will minimize the amount of transportation across various assets in the regions. The facility will transport reliable supply of polyether polyols utilising state-ofătheart DMC for the flex slab applications which presents a variety of unique opportunities and particularly address consumer demand in adhesives, coatings, elastomer, sealants applications. Mark Bassett, Global Business Director for Dow Polyurethanes, said that „This expansion is directly aligned to our long-term strategy for DowÊs Thailand Growth Project. We are committed to listening and responding to market dynamics with technologies that benefit our customers and contribute to their growth plans.‰ Announced in 2006, the project began with cracker and polyethylene chain developments and has expanded to include the CompanyÊs most recent advancements ă further positioning Dow as a committed business partner for market dynamics.

Genomatica Wins 2013 Kirkpatrick Award San Diego, USA: Genomatica has been named the 2013 winner of the prestigious Kirkpatrick Chemical Engineering Achievement Award for its successful commercialisation of its bio-based process for the production of 1, 4-butanediol (BDO), a widely-used chemical.

Sabo SpA Announces Pacts with BASF Bergamo, Italy: Sabo SpA declared that they have signed agreement with BASF for licence of the Chimassorb 2020 technology. Chimassorb 2020, an extremely creative innovation of BASF, which combines significant high UV and long thermal stability in applications such as tapes and polypropylene fibres. In the current scenario, there has been steady increase in the demand for solution based on Chimassorb 2020, eventually developing the technology as the product of choice for several applications. The acquisition of the license for Chimassorb 2020 will further expand the product range of Sabo SpA and complements the offer of high molecular weight monomeric light stabilizers already produced by Sabo SpA in Bergamo. BASF SE is the largest chemical company in the world and is headquartered in Ludwigshafen, Germany. Originally, stood for Badische Anillin- und Soda ă Fabrik, BASF in India manufactures polymers, tanning agents, leather chemicals and auxiliaries, crop protection chemicals, textile chemicals, dispersions and specialty chemicals, performance plastics, automotive and coil coatings, construction chemicals, polystyrene and polyurethane system along with wide range of intermediates, catalysts and other chemicals for life sciences, chemical and allied industries in the country. Whereas, the Sabo SpA is a world leader in the development and manufacturing of specialty chemicals and ingredients used in a wide range of markets, including additives for plastics & coatings, cosmetic ingredients, and specialty chemicals for industrial applications. 16 • October 2013

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The Kirkpatrick Award recognises the most remarkable chemical engineering technology commercialised anywhere in the world during the prior two years, and involves over 100 senior professors that head accredited university chemical engineering departments around the world. Genomatica has garner spotlight after Kirkpatrick AwardÊs recognition of process maturity, commercial readiness and industry significance as a technology-focused enabler for the mainstream chemical industry with new, advantaged process technologies and the core engineering strengths to apply its advanced science to real production plants. Christophe Schilling, CEO of Genomatica.

Christophe Schilling, CEO of Genomatica, „Winning the Kirkpatrick Award confirms that our process technology works; our economics w o r k ; a n d o u r ove r a l l p r o c e s s e n g i n e e r i n g , s c a l e - u p a n d technology transfer work. Our first process, for BDO, is ready for widespread deployment and use. We are championing the product value chains that will benefit from the BDO made by licensees using our process. We are looking forward to applying the same disciplined development and industrial-scale engineering to deliver processes for multiple widely-used chemicals.‰ Chemical Engineering World

30-10-2013 11:02:44


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October 2013 • 17

29-10-2013 11:08:50


CEW Industry News ALTANA Completes RockwoodÊs Goal

IC Potash to Finish Study on SOP Project

Wesel, Germany: Atlanta, GermanyÊs specialty chemical group has achieved the rheology business of RockwoodÊs Performance additives segment for USD 635m. Altana has acquired four new manufacturing facilities in Gonzales, Texas, Louisville, Kentucky, US; Widnes, UK, and Moosburg, in Germany.

Toronto, Canada: IC Potash is suppose to finish the feasibility study on its Ochoa Sulphate of Potash Project in south eastern region of New Mexico by December, 2013. The organisationÊs technical professionals have been working with a team of 100 industrial consultants on the study that will be completed by SNC- Lavalin, Novopro Projects and Agapito Associates. The plant and pilot studies have been carried out by HPD systems and Hazen Research, a par t of Veolia Water and Technology Solutions. Sidney Himmel, President and CEO, IC Potash, said the company is focused on mining polyhalite, a potash mineral, and its processing into sulphate of potash (SOP), which used in the agr iculture of fr uits, vegetables and in salt-sensitive soils.

Thus, due to this acquisition, AltanaÊs sales are expected to reach about EUR 1.9bn per annum and the groupÊs employees increased by 350, to 5,700. Dr. Matthias Wolfgruber, CEO, Atlanta, said „The acquisition not only opens up new growth opportunities, it also emphasises our strategy focusing on profitable growth and is fully in line with all our acquisition criteria.‰ The acquired rheology business will be integrated into AltanaÊs BYK Additives & Instruments division. Dr. Christoph, President, Altana BYK Division said that BYK is part of one of the most innovative and high-growth specialty chemicals companies worldwide. „We are a leading supplier of wetting and dispersing additives, of air-release, defoaming, and surfaceimproving additives, of wax additives - and now also of rheological additives,‰ Schlünken further added. Rheology additives are used in coatings, construction materials and personal care products.

Chevron Philips Chemical to Construct USGC Petrochemical Projects Texas, USA: Chevron Philips Chemical has successfully secured approval to build a US gulf coast petrochemicals project (USGC) This project comprises of building an ethane cracker at Chevrons Cedar Bayou plant in Baytown along with the two polyethylene units at a site in Old Ocean, near the organisationÊs Sweeny plant.Chevron has bestowed an engineering procurement Pe t e C a l l a , P r e s i d e n t a n d and construction contract to a joint venture CEO, Chevron Philips between JGC (USA) and Fluor Enterprises, Chemical to execute 1.5 million metric tonnes per year ethane cracker portion of the project whereas, Gulf Coast Partners, a partnership between Technip USA and Zachry Industrial, has secured the EPC contract to construct the polyethylene facilities for Chevron. Each polyethylene facilities is estimated to have a generate capacity of 500,000 metric tonnes per year. Construction is anticipated to commence in early 2014, with startup scheduled for 2017. Pete Calla, President and CEO, Chevron Philips Chemical, said that the project will benefit the companyÊs consumers, suppliers, local communities as well as existing and future employees. „We are able to realise this important milestone thanks to continued strong growth in demand for our products, shale resource development in the United States, and the tremendous support of our owners,‰ Cella further added. 18 • October 2013

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„The completion of the study will mark the most significant milestone achieved by ICP. Upon completion, with the final economic data and definitive cost assessments, we will continue negotiations with various domestic and international institutions and strategic industry partners to fund the New Mexico Ochoa SOP project,‰ Himmel further added. IC PotashÊs well known output will be incor porated into the study with respect to final equipment selection and sizing the computation of projected capital costs and operating costs. Pilot testing comprises the crushing, grinding, washing and dewatering of mined ore; calcination, which is the controlled heating to remove entrapped water, thereby increases ore solubility; leaching of the calcined ore and the crystallisation of SOP.

Arkema-Watan JV to Build Organic Facility Lorraine, France: Arkema,France-based chemicals producer A r ke m a a n d S a u d i i nve s t m e n t c o m p a ny Wa t a n I n d u s t r i a l Investment have planned to build an organic peroxide production plant on the Al Jubail platform, Saudi Arabia, as part of a joint venture (JV) agreement. The project to build the organic production plant forms part of ArkemaÊs plans to expand its high performance materials segment and bolster its footprint in fast-growing countries, where the Group aims to achieve 30 per cent of its sales by 2016. Being the first organic peroxide facility in the Middle East region, the plant will require an investment of approximately USD 30m The organic peroxide production plant will supply all Middle East petrochemical customers and support their strong growth anticipated by 2020. The plant will focus on manufacturing organic peroxides, which are stored at low temperature and are widely used as polymerisation initiators in the thermoplastic industry. Pierre Chanoine, Vice President, Arkema, said that the plant will enable company to offer Âgenuine serviceÊ to local petrochemical companies.The plant is scheduled to begin operations in the first months of 2015. Arkema currently runs eleven organic peroxide facilities Chemical Engineering World

30-10-2013 11:02:44


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29-10-2013 11:15:06


CEW Technology News AkzoNobelÊs German Design Centre H o n ey w e l l W i n s a t A s i a n M a n u f a c t u r i n g Awards 2013 Bangalore, India: Honeywell was declared as the Best Control Service Provider at the Asian Manufacturing Awards 2013(AMA).

Ian Verhappen, Director and Principal Engineer, Industrial Automation Networks

The winner, HoneywellÊs Experion Process Knowledge System (PKS) was nominated against major distributers of control systems.

The award was present on the g r o u n d s o f H o n e y w e l l Ês s o l u t i o n innovation, client engagement, customer impact and regional market penetration. Ian Verhappen, Director & Principal Engineer at Industrial Automation Networks in Canada, also one of the judges stated „Experion PKS is the mind share market leader for DCS systems in the Asia Pacific region. The new Universal I/O and virtual environment technology has changed the approach to control system design and life cycle maintenance.‰

Merck Launches Meoxal Taklamakan Gold in India

Siddhartha Sengupta, Regional Sales Director Asia (Decoratives), Merck Group

New Delhi, India: Meoxal Taklamakan Gold follows with Meoxal Wahiba Orange as the second effect pigment in the new Meoxal range to be launched in India. Meoxal Taklamakan Gold was developed with unique effects and superb performance for automotive coatings, thus satisfying the needs of plastic coatings as well as other demanding applications.

A s a p i o n e e r i n t h e e f fe c t p i g m e n t s, Merck has always been at the forefront of advanced technology and the latest in global trends. Merck created Meoxal that gives consumers an opportunity to witness and experience the latest innovations in the world of design. This special CWT („Carbitol and Weather Treatment‰) surface treatment is highly suitable for innumerable high performance applications and it can be straightly utilised in waterborne coating system as it requires no additional passivation Speaking about the new launch, Siddhartha Sengupta, Regional Sales Director Asia (Decoratives) said, „With the tremendous response received for the Meoxal Wahiba Orange, we continue to support our customers in the development of new and innovative coatings. With the launch Meoxal Taklamakan in India, we are setting yet another milestone in pigment technology and are confident that it will be well received by the auto and plastic industry‰.

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Amsterdam, Netherlands: A new design centre has been launched by AkzoNobel Specialty Finishes in Offenbach, Germany which has added to their existing business design centres located in Seoul, Beijing, and South Carolina. The German facility shares its premises with one of the specialty FinishesÊ Solution labs, allowing technicians to quickly change colour and coatings concepts into samples so that the consumer can have exact view of the products. Peter Brenner, Business Director, AkzoNobel Specialty Finishes, said, in todayÊs market the ability to deliver made-to-order innovative coatings solutions represents an important competitive advantage. One of our goals with the new design centre is to help our customers to be the first in market with new colours and effects.

New Technology by Agilent Technologies Santa Cara, California: New Agilent J&W gas chromatography columns designed for energy and Chemical exploration, processing and distribution applications has been launched by Agilent Technologies Inc. The designed columns include extensions to the plot PT, product line with aluminium oxide and molecular sieve stationary phases along with DB sulphur SCD (sulphur chemiluminesence detection) columns eventually increasing system reliability and detection stability. On the launch occasion, Michael Feeney, Vice President and General Manager of AgilentÊs Supplies Division, Chemical Analysis Group, said that we continually converse with our consumers to understand their needs and provide customised solutions. Ruggedness and productivity, for example, are key drivers in the energy and chemistry industries. Our new columns evolved from conversation with one of our client who wanted to run more samples with low maintenance of their GC systems. Agilent PLOT columns are the optimal choice for analysis of permanent gases and light hydrocarbons. s Apar t from that AgilentÊs new PLOTPT GC columns are also available in 36 configuration consisting of new porous polymer(Q and U), aluminium oxide and molecular sieve stationary phases.

Unipetrol Licenses Ineos for HPDE Prague, Czech Republic: Unipetrol RPA in the Czech Republic has licensed Ineos TechnologiesÊ Innovene S Process for its cracker complex in Litvinov to manufacture medium density and high density polyethylene (HDPE). The Innovene S HDPE facility will manufacture a range of polyethylene grades to meet the increasing demand for high performance products for European and Commonwealth of Independent States (CIS) markets. Peter Williams, CEO, Ineos Technologies, said, thatINEOS Technologies is proud to have been selected by Unipetrol as its technology partner for the development of its polyethylene business. UnipetrolÊs predecessor Chemopetrol had opted for the Innovene PP Process in 2002 to produce homopolymer, random copolymer and impact copolymer at its Litvinov facility. Switzerland-based Ineos is a developer and licensor of technologies for the petrochemicals industry and also supplies catalysts, additives and coatings. Chemical Engineering World

29-10-2013 18:07:18


CEW Technology News HRS Exhibits Energy Efficient Range of Heat Transfer Solutions at Chemtech South, 2013 Pune, India: HRS Process Systems Ltd (HRS), part of HRS Group, UK, one of IndiaÊs leading heat transfer specialists has effectively supplied more than 8000 heat exchangers and has left a footprint in the chemical industry in less than a decade. HRS exhibited a wide range of energy and well-organised innovations at this event that will enable the chemical process industry to estimate better heat transfer solutions. A collection of world class solutions were showcased In CHEMTECH SOUTH EXPO by HRS like the HRS Hot Water Generation Systems based on ECOFLUX Corrugated Tube Heat Exchangers (CTHE) and Plate Heat Exchangers (PHE) which have a prime application in chemical, Pharma, HVAC, hotel, textile, food and brewery industries. This heat transfer innovations are the preferred choice of major chemical process companies in key applications such as condensers, vent condensers, re-boilers, water coolers, heaters, oil coolers and heat recovery units. The organisation is expert in exotic materials like Alloy 20, Haste alloy, Titanium and Nickel alloy based on special applications in chemical and pharmaceutical processing. Chemical majors such as India Glycols Ltd, Bayer Crop Science, Haldia Chemicals, Atul Ltd, Deepak Fertilizers Ltd, Reliance Industries Ltd., Goodlass Nerolac, Nocil Ltd. and Gujarat Flourochemicals rely on HRSÊs energy efficient heat transfer solutions. During the event, V Gokuldas, Managing Director, HRS Process Systems Limited said,„HRS has over a decade of experience in supplying state-of-the-art solutions for the chemical industry. Chemtech being one of the largest events in the chemical sector in India, it was a great platform to showcase our products and this Expo has opened up wider business opportunities.‰ Chemtech South 2013 was pioneered by Chemtech Foundation. The Expo brought together the entire cross-section of IndiaÊs Chemical and Process Industries.

G e r m a n C o m p a ny D ev e l o p s N ew H y d ro g e n Transport Technology Berlin, Germany: Linde Company for Industrial gases and engineering company has developed a new storage solution, which will optimise the hydrogen value chain. The new technology, which works at a higher pressure of 500 bar (7,250 psi), will use new, lighter storage materials of compressed gaseous hydrogen (CGH2) that can be transported in a single truck load. According to Dr Andreas Opfermann, Head of Linde Clean Energy and Innovation, the 500-bar technology is another significant landmark for hydrogen mobility. It cuts the cost of transporting hydrogen to fuelling stations and reduces the amount of space required on site to store the gas. Linde has opened a 500-bar fuelling station at itÊs gases centre in Leuna, Saxony-Anhalt, Germany. The project is supported by the Federal Ministry of Transport, Building and Urban Development, whereas GmbH National Organisation Hydrogen and Fuel Cell Technology is in charge of the programme coordination 24 • October 2013

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BASF Expands Ohio Technology Centre Berlin, Germany: Ger man chemical company BASF is renovating and expanding its research and development (R&D) centre in Beachwood, Ohio, US. The USD 25m investment is likely to toughen companyÊs North American R&D platform. On completion of the renovation, the site will offer space for a new cathode materials research team and a team of researchers focused on chemical and process engineering, as well as existing catalyst and battery materials research. The Research and Development centre, which has been a hub of catalysis research for more than 35 years, currently employs approximately 50 personnel and will nearly double to more than 90 employees by 2015. Peter Pfab, Vice President, BASF Catalysis Research said, „Expansion of the Beachwood facility will allow us to optimise our research activities by bringing together a high degree of expertise in chemical catalysis, battery materials and process engineering in a greatly enhanced and highly collaborative operating environment.‰ The construction work, which is underway, is scheduled to be completed in early 2014. Andreas Fischer, Vice President, BASF Battery Research and Electrochemistry said that the investment in Beachwood will allow the company to focus on developing new battery materials that can provide higher energy density, greater power, increased safety and reduced cost. „These are the key areas in which the chemical industry can play a significant role in determining the future performance of batteries for electromobility, helping drive higher adoption rates for hybrid and full electric vehicles in North America and around the world,‰ Fischer further added. Established in 2009 and in advance of the opening in 2012 of a new materials production facility in nearby Elyria, Ohio, the existing battery materials research team focuses on advanced materials for lithium-ion batteries.

Sibur Inducts New Rubber Technology Moscow, Russia: Sibur, Russian Petrochemical company mentioned that thier Voronezhsintezkauchuk operating plant has modified its rubbermaking technology to generate new and more durable types of rubber. According to the company Officials,the operating plant has finalised the investment project to transfer part of its polybutadiene rubber production to neodymium catalysts system technology (SKD-ND) as well as starting the production of soluble butadiene-styrene rubber (DSSK). The new technology will allow production of new types of rubbers that offer better wear resistance and durability apart from meeting global standards on environmental impact. Production units will be made fully operational based on the test results of the rubber samples Chemical Engineering World

29-10-2013 18:09:42


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CEW News Features

Industry Welcomes ‘Chemtech’ to South

D

r K Rosaiah, His Excellency, Governor of Tamil Nadu, inaugurated ChemTECH South 2013 on 10th October 2013 at Chennai Trade Centre which was attended by over 300 industry professionals from the chemicals, petrochemicals, EPC, industry automation, water, process equipment manufacturing & fabrication and allied sectors. Dr Rosaiah congratulated Jasu Shah, Founder & Chairman Chemtech Foundation and applauded ChemtechÊs initiative to organise the international exhibition & conferences in South at a time when the region is witnessing a surge in investments in chemicals & petrochemicals sectors. He added that during the mid-90s the Southern region of the country was projected as the 2nd fastest growing region in India and attracted lot of international attention. After a brief hiatus, this region is once again gearing up for promising growth with the announcement of a PCPIR in Cuddalore, existing refineries like CPCL in Chennai, MRPL in Mangalore, HPCLÊs refinery in Vizag and BPCLÊs Kochi refinery, which is currently undergoing a major expansion that will offer ample opportunities to the allied service sectors and open multitude of avenues for the downstream manufacturing segments. P Thangamani, Honorable Minister for Industries, State Government of Tamil Nadu, Dr Shailesh Nayak, Secretary, Ministry of Earth Sciences, Govt of India, A B Pandya, Member Central Water Commission, Govt of India, B Narayan, Group President (Procurement & Projects), Reliance Industries & P D Samudra, Executive Director ă Sales

Highlights • Dr K Rosaiah inaugurates ChemTECH South 2013 & concurrent EPC, WaterEX and IAC South exhibitions & conferences • Over 300 industry professionals mark their presence during the inaugural • Over 50 globally renowned speakers deliberate on topical issues in three conferences • 160 exhibitors from India & overseas showcase technologies & services during the three-day meet 26 • October 2013

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(L to R)- P D Samudra, Executive Director – Sales & Member of Board, Uhde India, A B Pandya, Member Central Water Commission, Govt of India, P Thangamani, Honorable Minister for Industries, State Government of Tamil Nadu, Dr K Rosaiah, His Excellency, Governor of Tamil Nadu, Jasu Shah, Founder & Chairman , Jasubhai Group & Chemtech Foundation, Dr Shailesh Nayak, Secretary, Ministry of Earth Sciences, Govt of India, B Narayan, Group President (Procurement & Projects), Reliance Industries

& Member of Board, Uhde India attended the inauguration of the event. Maulik Jasubhai, Group CEO, Jasubhai Group & Chemtech Foundation said, „We are glad to organise the South edition of ChemtechÊs series of international exhibitions & conferences once again as this region is getting ready to enter a new phase of growth with multiple projects and huge investments lined up across the key industrial sectors of refining, petrochemicals, infrastructure, power, food processing, which will provide immense opportunities across the manufacturing industries and allied sectors.‰ He added, „ChemTECH South 2013 will bring entire ecosystem for the chemicals downstream processing industry and the allied service sectors for exchange of ideas in the realms of technology management and quality of life facilitating proximate interactions between academia, research bodies, industrial and end users, and will continue doing so as we march into the fifth decade.‰ B Narayan delved upon ample opportunities that the growing manufacturing industry would open for the engineering contracting service providers and the allied sectors. He admired ChemtechÊs initiative to organise the exhibition & conference in Chennai. A B Pandya further emphasised on the need of implementation of innovative

ways and technologies to meet the growing demand of water in the country through Reduce, Recycle, Reuse, Recharge, and Rehabilitate & Regulate to meet the water challenge. Dr Shailesh Nayak advocated the need of sustainable management of water resources including providing adequate supply of potable water, irrigation, industrial use, ecosystem and flood protection is a major challenge. In his concluding remarks, P D Samudra shared that though the outlook for the economy continued to be gloomy, he emphasised this as the right time to invest. Elaborating on the proposed PCPIR complex in Cuddalore, he added that Tamil Nadu should think of setting up cracker unit to produce ethylene from naphtha from the refinery in the PCPIR that would further create avenues for the downstream units and value additions and open many avenues for entrepreneurs to enter the petrochemicals sector. Over the three days, 4280 visitors came to see the display of latest technologies and services by 160 exhibitors during the three-day meet in Chennai. More than 50 speakers & 200 delegates engaged in discussions on topical issues during focused conferences viz. EPC, WaterEX & Industry Automation & Control. Over 60 students from various colleges attended the conferences. Chemical Engineering World

28-10-2013 21:11:25


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October 2013 • 27

29-10-2013 11:23:02


CEW Features

FOCUS:GUJARAT

Investor-friendly Policies Drive Gujarat’s Growth If there had been no ‘focus’ on the development of the industrial sector in the state, Gujarat wouldn’t have established itself as one of the most preferred locations for industrial investment in India. Apart from sound infrastructure facilities, skilled manpower, excellent domestic and international connectivity and availability of raw materials, the ‘strong will’ of the state is the major factor for the overall growth of this western region, states a recent report by Tata Strategic Management Group released at India Chem Gujarat 2013.

T

oday, at a domestic market size of ~USD 108 billion the chemical industry in India accounts for only 3.3 per cent of the global chemical market. It is highly diversified with more than 80,000 chemicals and currently accounts for ~11 per cent of India’s industrial output which makes it very crucial for the economic development of the country. The report outlines the demand-supply scenario over the next 5 years and also the key growth drivers. Gujarat as a state contributes a major share of the country’s chemicals output: 62 per cent of petrochemicals, 51 per cent of chemicals and 35 per cent of pharmaceuticals. The report by Tata Strategic Management Group also highlights the advantage that Gujarat as a state offers with its business friendly policies. The state government has taken care to set up industrial estates on non-agricultural land after assessment of industrial 28 • October 2013

Narendra Modi, Chief Minister, Gujarat, releases ‘India Chemical Report’ at IndiaChem Gujarat 2013

viability. Such availability of product clusters ensures opportunities across the value chain and facilitates investment in the state. According to ‘India Chemical Report’ that provides an analysis of key sub-segments of chemical industry such as agrochemicals, fine chemicals, dyes & pigments and other specialty chemicals, Gujarat has achieved an annual growth rate of over 10 per cent p a over the past five years and is one of the most industrialised states of India. It accounts for 17 per cent of the nation’s industrial production and 25 per cent of its exports. The report mentions several advantages highlighting ‘investor-friendly policy’ as the major one.

The chemical industry is today the largest and fastest growing component of Gujarat’s manufacturing sector. The report focuses on speciality chemical industry in the county and states that specialty chemical industry is a knowledge driven industry and it has been growing rapidly at 2x of GDP growth rate (~12%) over the last five years. It currently stands at ~USD 23 billion. “Domestic demand of specialty chemicals is expected to follow an accelerated growth path. This demand is mostly driven by the strong growth outlook for end use industries. This along with increased adoption of specialty chemicals and newer applications can propel the growth further,” it states further.

Gujarat has achieved an annual growth rate of over 10 per cent p a over the past five years and is one of the most industrialised states of India. It accounts for 17 per cent of the nation’s industrial production and 25 per cent of its exports. Chemical Engineering World


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CEW Features Indian Chemical Industry According to report, chemical industry is a knowledge as well as capital intensive industry. This industry plays a significant role in the global economic and social development. It is also a human resource intensive industry and hence generates huge employment opportunity. Globally, more than 20 million people are expected to employ in this industry. it further states that the diversification within the chemical industry is huge and covers more than eighty thousand commercial products. Global chemical market size was estimated at USD 3.7 trillion in 2012 and is expected to grow at 4-5 per cent per annum over the next decade to reach ~ USD 5.8 trillion by 2021. Gujarat State Advantage This section in the report states the growth story of the state highlighting Gujarat’s contribution to India in the year 2012. In 2011-12, Gujarat contributed 25 per cent to India’s total exports of goods. Exports include products from sectors such as textiles, petroleum, chemicals, pharmaceuticals, automobile, engineering, gems and jewellery, naphtha, petrol, clinker, cement, oil cakes, bauxite, paraxylene, salt, soda ash, food grains, cement clinker, ethylene, Pet-cock etc. The total cargo handled by the Kandla Port (Only Major port of Gujarat) was 82.5 million tonnes during 2011-12. Gujarat is also the largest exporter of cotton (60%) in the country, it states.

Contribution of Gujarat to India

Figure 2: Industry-wise contribution, 2012; Source: Industry Reports, Analysis by Tata Strategic

The report lists all the names of the companies working in Gujarat. “The production facilities for some of the largest global and Indian chemical and petrochemicals manufacturers” in the state has driving the growth of the industry for the state. The advantages explained in the report include: Infrastructure and Strategic Location: Gujarat is well connected by the Indian Railways network and has built one of the best road networks in India. Further, power sufficiency, highest number of airports and second highest number of ports, integrated statewide gas grid, the longest coastline in the country, etc are the other advantages. Raw Material Availability: Rich availability of natural resources and basic feedstock facilitate production of a large number of downstream chemical products. Availability of Talent: Gujarat has always been well known for its entrepreneurial talent who have spread their footprint nationally and across the globe. I mpe tus for G row th: Integrated development and PCPIR, Upcoming external infrastructure and Support for micro, small and medium enterprises, etc are the other features illustrated in the report.

Figure1: India’s chemical industry, F12 (% of total); Source: Industry Reports, Analysis by Tata Strategic

30 • October 2013

The 107-page report further classifies the crucial segments of the industry

and analyses different markets for Agrochemicals, Fine Chemicals, Dyes and Pigments, and other speciality chemicals such as paints & coatings, construction chemicals, water treatment chemicals, polymer additives, and personal care chemicals. An analysis on Chemical Technology containing Science & Technology Setup in India, Research & Development expenditure in the year 2012, Recent Investment in India, Research & Technology in Petrochemical sector, role of academia, etc have also been expounded in the report. It further details inadequate Level of R&D and Quality of Education and Training Infrastructure as the k ey c onc erns the in d u s tr y faces today. The report includes chapters on ‘M&A Opportunities in Indian Specialty Chemicals Industry’, ‘Specialty chemicals in personal care products: Opportunity for unique positioning’, ‘Legacy to Lean - Taking on Challenges Plaguing the Agrochemical Supply Chain’, ‘Opportunities in India in the evolving Global Petrochemical Industry’ and ‘Oleochemicals gaining prominence in speciality chemicals’ Manish Panchal, Practice Head - Chemical & Energy and Charu Kapoor, Engagement Manager – Chemicals, Tata Strategic Management Group authored the ‘India Chemical Report.’ - Harshal Y Desai Chemical Engineering World


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CEW Features

FOCUS:GUJARAT

“How will Gujarat Continue to Lead the Chemicals & Petrochemicals Industry in India?”

Gujarat’s chemicals and petrochemicals industry is one of the fastest growing sectors in the state’s economy, and is the leader in the production of chemical and allied products in India. The state has become one of the most preferred locations for industrial investment in the country. Jaimin Vasa, President, Gujarat Chemical Association, Managing Director, Vasa Pharmachem Pvt Limited and Chairman, MSME-Committee, Gujarat Chamber of Commerce and Industry, writes.

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hemical industry is one of the oldest industries in India. It not only plays a crucial role in meeting the daily needs of the common man, but also contributes significantly towards industrial and economic growth of the nation The chemical industry covers agrochemicals, paints & coatings, specialty polymers, home care surfactants, plastic additives, textile chemicals, construction chemicals, water chemicals, personal care ingredients, flavours & fragrances, paper chemicals, printing inks, industrial & institutional cleaners, rubber chemicals etc. This segmentation does not highlight the colorants separately (dyes & pigments) as the colorants, which are mostly used in many of the listed categories of specialty chemicals like paints & coatings, inks, plastic additives, textile chemicals

etc, are the most diversified of all industrial sectors. Contribution of Chemical Industry in India The Indian chemical industry is an integral component of the Indian economy. Indian chemical industry currently accounts for more than 3 per cent of the global chemicals industry (~USD 3.4 Trillion) but is expected to account for~6 per cent of the same (Expected to be ~USD 5 trillion) by 2022. India has a robust base for chemicals and petrochemicals-driven businesses. Though the industry has undergone drastic changes, Indian chemicals and petrochemicals share has been continuously increasing on a constant basis. India also produces a large number of fine and specialty chemicals, which have very specific uses and are essential for increasing industrial production.

The Indian chemical industry is an integral component of the Indian economy. Indian chemical industry currently accounts for more than 3 per cent of the global chemicals industry (~USD 3.4 Trillion) but is expected to account for~6 per cent of the same (Expected to be ~USD 5 trillion) by 2022. 32 • October 2013

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CEW Features Major Initiatives in Gujarat

Contribution of Chemicals Industry in Gujarat GujaratÊs chemicals and petrochemicals industry is one of the fastest growing sectors in the stateÊs economy and is the leader in the production of chemical and allied products in India. Gujarat is also known as the ÂPetro CapitalÊ of India. According to the Ministry of Chemicals and Fertilizers, Government of India, the state accounts for 51 per cent share of the production of major chemicals, including organic chemicals, inorganic chemicals, alkali, pesticides and dyes & dyestuffs. According to the Industries Commissionerate, Government of Gujarat, Gujarat produces around 94 per cent soda ash, 80 per cent salt and 42 per cent caustic soda of the total production in India. Also, Gujarat contributes significantly to the countryÊs petrochemicals production (62%), chemicals production (51%) and pharmaceuticals production (35%). The chemical industry is today the largest and fastest growing component of GujaratÊs manufacturing sector. Export Gujarat contributes around 15 per cent of the countryÊs chemical exports, bulk of which is to USA, Europe and other developed nations. Investment There has been a considerable increase in the number of MoUs signed and investment proposals made for projects executed and established in the chemical and petrochemical sector during various ÂVibrant GujaratÊ summits. 34 • October 2013

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Environmental Concerns Manufacturing standards of developed economies are aimed to improve the protection of human health and the environment through the better and earlier identification of the intrinsic properties of chemical substances. Globally, the awareness towards concept of environmental safety and management is rising with a rapid pace. Therefore, Government of Gujarat is promoting green technologies and Ecofriendly solution by way of incentives. Raw Material Availability Gujarat has witnessed growth in chemical industries because of availability of mineral oil and port facilities of Kandla through which raw materials can be imported easily. Blessed with natural resources such as limestone, salt, Gujarat is one of leading manufacturer of basic chemicals, including caustic soda, caustic potash, which facilitates production of a large number of downstream chemical products. Beside these, minerals, natural gas, limestone, dolomite, gypsum etc are also available here in large quantity. Gujarat also has reserves of limestone and clay deposits in Saurashtra region. Manufacturers are leading the course in the domestic and international market with new products, technological advancement and thorough research and development (R&D). Foreign Investments in Gujarat Gujarat has been the leading state in terms of attracting investment for chemicals industry. FDI inflows into the chemical industry have increased over the last few

years, owing to several incentives by the Government of India and Government of Gujarat. GujaratÊs business friendly policies have made it the first choice for investors. Gujarat is the only state to emerge as ÂInvestor friendlyÊ. Gujarat has achieved the distinction of being the top most industrially developed state in India in respect of investment in industrial sector and second among states in respect of value of production and value addition in industrial sector in India. O v er the y ears , Gu ja r a t has become one of the most preferred loc ations for industr ia l in v e s tme n t in India. Industries AssociationsÊ Role Industry bodies - like Gujarat Chemical Association and Gujarat Chamber of Commerce & Industry - are acting as a helping hand to its members, right from inception to the promotion of its products, and also to performing as a bridge between manufacturers and the government. The government agencies are building and providing the necessary infrastructure and ease trade barriers for the economic development of the chemical industry. Government Initiatives The Gujarat government policy provided enough support for development of micro, small and medium sized chemical & petrochemical industries in the state. Some of the key policy features include interest subsidy on loans for modernisation Chemical Engineering World

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CEW Features programmes, interest subsidy on eligible parameters, like sector, size, etc., venture capital and patent monetisation assistance, technology acquisition fund, support for vendor development, support for auxiliary industries for value-addition, cluster development in PPP mode, rehabilitation of sick units, etc. (See the illustration) Since Gujarat state has following advantages, it will continue to lead the Chemicals and Petrochemicals industry in India:Ć Gujarat is well-connected to major trade routes to Europe, Middle-East, East Asia and Australia. Ć Gujarat has nearly 38 per cent (564 km) of the dedicated freight corridor passes through. Gujarat state, having one-fifth of countryÊs coastline (1,600 km) with 41 ports, second highest in the country. Ć The state also targets to handle 40 per cent of the traffic through Indian ports by 2020. Ć Gujarat is the only state in India organising the ÂVibrant GujaratÊ Summit a biennial summit organised to attract foreign investment for development of Gujarat aimed at bringing together business leaders, investors, corporations, thought leaders, policy and opinion makers. This summit served as a perfect platform to understand and explore business opportunities with the State of Gujarat. During these Summit large-scale investments flow from the partner countries. Ć Japan has a cooperation pact with the Union Government for 19 projects, of which seven are proposed in Gujarat. In fast-industrialising zones of Dahej and Sanand in the state, two ÂSmart CityÊ projects by Japan are proposed. Ć Gujarat is the only state in India having concentration of petroleum, chemical and petrochemical estates around PCPIR. Out of the all the PCPIRs in India, Gujarat PCPIR has the benefit of rich natural resources and feedstock, chemical port and storage facility and PCPIR-specific infrastructure - effluent disposal pipelines, solid waste disposal sites. Ć Gujarat is the only state have better infrastructure like road, rail, port, power, gas, water with planned up-gradation. Ć Gujarat is the only state in India with Integrated State Wide Gas Grid and having 24 hours uninterrupted electricity. Gujarat is the only state in the country to have LNG terminals (at Dahej & Hazira) Ć Over and above it is clearly evident that Gujarat is definitely poised to become the global business hub of India, under the dynamic and visionary leadership of Chief Minister (Shri) Narendrabhai Modi. To progress continually, the Government of Gujarat is constantly in the process of identifying new avenues of investment opportunities not only in the industrial sector, but in the chemical sector as well. Due to all these innovative, constructive and result oriented progressive policies of the State Government for the promotion of Chemical and Petrochemical Industries, Gujarat seems to be lead chemical and petrochemicals industries in India for long. 36 • October 2013

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CEW Features

Supply Chain Cost Management: A Necessity for Future? The chemical industry has been on a fast growth trajectory in the past decade, resulting in increasing revenues and growing profits. However, due to changing business environment, increasing competitive intensity and need for increased focus on QSHE are raising costs and putting pressure on product margins and overall profitability. Adding to these woes is increasing logistics and supply chain cost. Going forward supply chain cost management will play a crucial role in addressing these challenges for chemical companies, say Manish Panchal, Siddharth Paradkar and Sangeeta Misra of Tata Strategic Management Group.

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he Indian chemical industry is estimated to be the fifth largest in the world and second largest in Asia after China. The fact that the industry contributes about 10 per cent of the output of the Indian manufacturing sector, 13 per cent of IndiaĂŠs total exports and 9 per cent of the countryĂŠs total imports underlines its criticality for the national economy.

Siddharth Paradkar Principal - Logistics Tata Strategic Management Group

Manish Panchal Practice Head (Chemical, Life Science & Energy industry) Tata Strategic Management Group

Sangeeta Mishra Associate Consultant Tata Strategic Management Group

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The chemical industry is very diverse with close to one lakh products across a range of categories. The end-use customer segments are also diverse and have varied requirements. Industry structure ranges from highly fragmented in some segments to highly consolidated in others. Products exist in solid, liquid or gaseous forms, with some being inflammable and hazardous, and hence each product comes with different handling, storage and transportation needs. The western coast of India has been the key hub for chemicals and petrochemicals industry accounting for 60 per cent of trade. Gujarat and Maharashtra alone account for ~65 per cent of chemical and ~80 per cent of petrochemical production in India. Since production clusters are concentrated in one particular region, better infrastructure and logistics are required

to supply chemical products across the country. The lengthening of supply lines makes the distribution of chemicals more transport intensive. The involvement of a large number of stakeholders (shipping lines, transport agencies, environmental agencies, etc.) in the transportation of chemical products further increases the logistics and supply chain complexity of the chemicals industry. Given the complexity of the industry and nature of chemical products, the challenges in chemical logistics are myriad. It has been observed that the logistics burden of all chemical product segments in India has been growing at a faster rate than the sales. As seen in the chart (see figure 1 on next page), logistics cost as a percentage of sales has increased by 8 per cent in the past 4 years. The inventory levels as a percentage of sales have also increased by 7.5 per cent in the same period, which will further add to the supply chain costs for chemical companies. Apart from the direct elements of transportation, warehousing and handling, many other indirect elements contribute towards the overall cost burden including packaging, inventory, inventory holding costs and spend on QHSE.

The western coast of India has been the key hub for chemicals and petrochemicals industry accounting for 60% of trade. Gujarat and Maharashtra alone account for ~65 per cent of chemical and ~80 per cent of petrochemical production in India. Chemical Engineering World

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CEW Features

Figure 1: Logistics cost as a percentage of sales of select chemicals companies. Source: Capitaline

Figure 2: Feright rate and Diesel Prices (Rs/Tonne Kilometer, Rs/Litre)

Respite for the chemical industry from rising logistics cost burden is not expected in the near future.

laws and regulations, and infrastructure, further compounding the logistics cost burden on chemical companies.

Factors Expected to Inflate Future Supply Chain Costs for Chemical Industry in India Logistics spend in India is around 13 per cent of its GDP, which is high as compared to developed countries (7-8%) due to inadequate infrastructure and inefficiency. In the future, there is high probability for the cost to further escalate, driven by the following factors:

Increased Focus on QHSE: There is increasing political and public pressure to reduce industrial risks and accidents. End consumers are also becoming more and more quality conscious. Environmental and sustainability concerns will gradually push chemical companies to increase spend on QSHE to meet customer demands. Shift to greener transport modes, adoption of safety standards/ culture and putting security procedures in place will incur additional expenses for companies. Adoption of green logistics without incurring incremental costs will be challenging.

Challenges in Inventory Planning: Due to uncertain transit times and volatile markets, companies carry excess safety stock in order to avoid losing sales due to stock-outs. Also, in the chemical and petrochemical industry, co- and by-products are common, which often lead to a complex and sometimes cyclic flow of materials. The diversity of product segments and Stock Keeping Units (SKUs) makes inventory management very challenging. Most chemical manufacturing processes involve continuous production, requiring assets to be run at steady levels of production, which makes it difficult to implement lean solutions. Expansion of Chemical Industry: As the chemical industry is expanding across the country, complexity of supply chain and logistics will increase. New routes and locations for transportation will be added to the existing network. Each new link will bring its own local complexities regarding the availability of logistics assets, local 40 • October 2013

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Rising Fuel Prices: Diesel price has increased by 26 per cent in the last year which directly affects the cost of transportation. The trend of rising crude oil and natural gas prices will have a two-fold impact on the chemical industry with respect to fuel cost and feedstock cost. (See figure 2 above) Though rail freight rates have increased by just 1 per cent in the last 3 years, with the adoption of the dynamic Fuel Adjustment Component (FAC), rail freight rates will no longer remain insulated from hikes in fuel and energy prices. Railway, which

has been the preferred mode of transport for bulk commodities accounting for ~50 per cent share in bulk transportation, will get costlier. The upward trend is expected to continue in the coming years, which will only add to the logistics cost for the chemical industry. Process Inefficiencies and Lack of Infrastructure: Apart from rising fuel prices, the transportation cost burden on chemical companies in India is heightened due to higher transit time and lower turnaround of vehicles because of multiple check-points. Bad road conditions, oversaturated railway network, unsuitability of rail wagons to carry different types of cargo, port congestion, shortage of CFSs and insufficient draft at ports to handle large vessels are the major infrastructural issues that Indian companies face in logistics. Moreover, there is a shortage of 3PLs specialized in transportation of bulk liquids and gases, especially hazardous materials. Key Levers for Managing Supply Chain Given the above factors, the logistics cost burden in the Indian chemical industry is here to stay. The chemical industry in India needs to focus on supply chain as a key lever to manage their business and develop solutions towards

handling, many other indirect elements contribute towards the overall cost burden including packaging, inventory, inventory holding costs and spend on QHSE. Chemical Engineering World

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CEW Features Indicators

India

Global

Average truck speed (in km/hr)

30-40

60-80

Four lane road length (in kms)

7,000

34,000 (China)

National highways length (in kms)

66,590

1,900,000

Average distance travelled by a 200 truck per day (in kms)

400

Avg Inventory (in days)

24 (China)

33

Table 1: Logistics Efficiency Indicators

optimization of logistics costs to remain competitive in the global marketplace. A thorough analysis of global best practices in chemical logistics and comparison with India suggests that the following levers need to be managed for reducing logistics cost. Replenishment Models: Differentiated Replenishment models along with increased visibility and reverse/re-transfer logistics is an imperative for the future. Traditional demand planning and forecasting methods are not conducive to today’s volatile environment. A small error in the process results in magnifying the problem and saddling the distribution network with high volume of inventory for some items and stock outs for others. Route Planning: Network and Route planning has to take into account real time events like traffic and availability of equipment and personnel for loading/ unloading, materials handling and flexibility to switch between modes. The traditional view of lowest cost model for transportation is long outdated. The actual cost of the service is fairly insignificant in comparison to the product values, cost of carrying the inventory and more so loss of sales or opportunity. There is a need for a more dynamic approach and having options to enable you to select the most appropriate solution. QHSE Norms: Adopting and complying with QHSE norms and related asset development is going to become a necessity for the industry as customer and consumer become more aware. While it could involve a complete overhaul of operations, the benefits far outweigh the cost. While today the number of incidents is far and few, this is not by design. The collateral damage on account of a mishap can be significant and far greater than the lifetime cost of adopting good practices.

GST Readiness: Implementation of GST would standardize tax rates on a pan-India basis and lead to consolidation of logistics and warehousing units at central locations. A gradual changeover to a hub and spoke supply chain model is expected. Chemical companies will then have to determine their supply chain network on the basis of logistical considerations rather than taxation. This could imply changes like a shift towards larger vehicles for transportation. For example, there could be a transition from road to rail as rail is better suited and more economical for bulk volumes and longer distances. Recent Experiences in Supply Chain Management Many companies in the sector have already recognized the importance of supply chain and have initiated steps in addressing the issues in the right earnest. Tata Strategic has helped multiple clients across sectors facing supply chain challenges. It has been instrumental in transforming their supply chain operations spanning procurement optimization, logistics network planning, order fulfillment optimization and managing organization readiness for change. Case Study – Tata Strategic recently helped a leading agrochemicals company in transformation of their supply chain by redesigning their order fulfilment process through a pull based replenishment model. The organisation was facing challenges on account of increasing logistics cost and inventory in the system coupled with frequent cases of stock outs and non-availability of products leading to lost sales. The existing warehouse network was redesigned to introduce hubs and regional warehouse. The order and product flow was modified to support the new system. This intervention identified inventory reduction of ~10% of the total sales across the supply chain. References • • •

Tata Strategic Database Primary interaction and Industry Experts Industry Reports

Technology and Skill Development: The logistics workforce in India, predominantly operational front-line staff (drivers, goods handlers and workers for loading/unloading) who are minimally educated, lack knowledge of the hazards of the products and the necessary skills for handling. There is a need to undertake skill development initiatives at the lowest levels and adopting latest technologies and IT systems. Improper handling of chemical products will lead to wastage and add to the handling costs. Training the manpower in these aspects will lead to significant reduction in damages, delay and cost. 46 • October 2013

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CEW Features

Gas Sensor Technology to Control Plant Emissions Control and monitoring of the gaseous emissions produced by chemical facilities is a critical part of plant management. Gas sensing, which provides important input for plant controls, is a key technology in ensuring safe operation and reducing potentially harmful emissions. John Warburton, City Technology, reviews the main technologies used in chemical plants.

Stack emission from chemical plants is obviously the largest source of the gases produced during the process.

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he chemical industry is a major player in the global economy, with 2011 sales reported as being worth some 2800 billion with a growth rate approaching 12 per cent as the developed and developing economies recovered from recession. Manufacturing the materials that are indispensible to todayĂŠs world, the chemical industry is, quite literally, one of the foundations of modern society. Producing the raw materials that are used throughout industrial sectors, it is one of the powerhouses underpinning improvements in the living standards for millions, if not billions of people. Unfortunately, by their very nature, many chemicals are toxic, poisonous, flammable or explosive. As well as the intrinsically unattractive properties of the target material, the manufacturing process can also produce a wide variety of by-products, some of which have equally unpleasant attributes. Even if the chemicals are not directly harmful, some can be environmentally damaging, potentially contributing to climate change.

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So, how to square the circle? On the one hand, the chemical industryĂŠs products are essential; on the other, some can be unpleasant and dangerous. The answer, well established in the developed world and becoming increasing prevalent in the emerging economies, is legislation and monitoring. Typically, strict limits and quotas are set for the emission levels of different substances, and record keeping and monitoring by the appropriate regulatory authority is put in place to ensure that the limits are observed. The gas sensing industry plays the key role in enabling the industry to meet its obligations, with many different technologies used to monitor the emissions from the different parts of a typical chemical plant. Gaseous Emissions Analysis Stack emission from chemical plants is obviously the largest source of the gases produced during the process. Recognising that some gaseous emissions cannot be avoided, the quota system to manage emissions has been developed. To comply

with the requirements of the emissions control quota system, Continuous Emission Monitoring Systems (CEMS), provide real-time monitoring and recording of a range of gases emitted from stacks. Typically, CEMS systems will monitor for sulphur dioxide, nitrogen monoxide, nitrogen dioxide, carbon monoxide, carbon dioxide, oxygen, hydrogen sulphide, total hydrocarbons and opacity. Additional gases are added to the core list depending on the specific process. In addition to the main processing equipment, a chemical facility will normally contain a number of small power plants, used for a variety of purposes from space heating for on-site buildings through to pre-heating various chemicals before they are injected into the main processing plant. Depending on the availability of the different materials, the fuel source will usually be natural gas, LPG, light and heavy oils, biomass, wood pellets, coal, propane or butane. Flue gas emissions are monitored for two main reasons, environmental and economic. Chemical Engineering World

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CEW Features Clearly, for emissions control purposes, these boiler rooms will contribute to the plantÊs overall emission levels. There is also an economic driver. With todayÊs ever-increasing energy costs, keeping the combustion process operating at peak efficiency makes complete sense. Flue gas analysers are portable / transportable instruments that are used to take spot measurements of a range of gases including oxygen, carbon monoxide, carbon dioxide, SOx and NOx in the flue gases, thereby monitoring the efficiency of the burning process and taking a reading for emission control purposes. They will normally be fitted with electrochemical sensors, which are arguably the most versatile sensors available, offering a number of benefits over alternative technologies. The sensors are physically small, enabling the analysers themselves to be correspondingly compact. Internal filtration ensures that the readings for the target gas are immune to cross-c o n t a m i n at io n f ro m o t h e r g a se s commonly present in the flue gases. The latest generation of oxygen sensors use lead-free catalytic technology derived from toxic gas sensors, improving response times, reducing current consumption and offering a quicker start up from cold. Electrochemical sensors characterised to a large number of different gases are available, enabling monitoring in specialised applications to be implemented quickly and easily. Leak Detection Leaks are an ever-present hazard even in the best run chemical plants. Depending on the severity of the leak and the gas involved, the effects can potentially be very serious both within and without the perimeter of the plant. An explosion or fire will damage plant and put workers at risk, while toxic gases can spread rapidly, also putting the public at risk. Even a minor small leak has an economic impact of the plantÊs profitability as material is being wasted and the fault has to be rectified. To monitor for leaks, fixed gas detectors are integrated into the plant at key weak points such as valves, joints and pumps. The sensors used will obviously depend on the nature of the gas to be 50 • October 2013

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after an incident to provide perimeter monitoring around the location of a leak, thereby giving first responders additional protection. Open Area Protection - Storage Tanks Infrared open-path gas detectors send out a beam of infrared light, detecting gas anywhere along the path of the beam, which is typically a few metres up to a few hundred metres in length.

Flue Gas Analyser

detected. For flammable gases, pellistors are widely used. This sensor works by burning the target gas; the heat generated producing a change in the resistance of the detecting element of the sensor proportional to the gas concentration. To detect hydrocarbons, NDIR sensors are widely used. Ultrasonic gas leak detectors measure the ultrasonic sound level, typically between 25 kHz to 10 MHz frequencies. Ultrasonic gas detectors are mainly used for outdoor environments where weather conditions can easily dissipate escaping gas before allowing it to reach gas leak detectors that require contact with the gas in order to detect it. These detectors are most useful in facilities with a lot of outdoor pipeline. Personnel Protection Workers wear small gas detectors, typically a device that will detect four or five potential atmospheric hazards including oxygen, combustible and toxic gases. These units are based on electrochemical sensors, which are extremely sensitive and give fast response times when gas is detected. As well as protecting the workers themselves, personal gas detectors also act as mobile leak detectors, a useful back up to fixed leak detectors. Electrochemical sensors are also used in portable area monitors. Often complete with wireless communications to allow for remote monitoring, local area monitors are frequently deployed

They are increasingly used in the petrochemical industry for example in the detection of leaks from storage tanks, mainly to achieve very rapid gas leak detection for flammable gases at concentrations comparable to the lower flammable limit, typically a few percent by volume. Conclusions As this brief overview shows, the gas sensor industry has developed a number of different technologies, each of which has strengths and weaknesses for use in specific applications. All manufacturers share a common purpose in improving the effectiveness of life and property protection in potentially dangerous environments. Advances in sensor design are generally aimed at producing faster response, greater specificity, better stability, longer life and greater reliability. In capital-intensive industries such as the chemical sector, which produces toxic, corrosive, explosive and flammable gases as a matter of routine, plant protection rightly has a very high priority. Add in the duty of care to the workforce, a reduction in emissions to reduce environmental damage and the need to prevent leaks that could affect the local population, the benefits from using todayÊs gas detection advanced technology have never been more obvious.

AuthorsÊ Details John Warburton Strategic Marketing Manager City Technology Email: john.warburton@citytech.com

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CEW Features

Significance of Turbine Oil Testing More and more builders and users of steam and gas turbines are requiring an increased level of oil analysis testing as part of their preventive maintenance programmes. Oil analysis is used to determine not only the oil’s current condition, but potential existence of system problems.

M

any customers, particularly gas turbines users are requiring some specific oil analysis tests to project the remaining life of the used oil. The main purpose of a monitoring programmes is to protect the equipment and ensure long, trouble-free utilisation of the turbine, bearing and gear oils in service. The life of oil varies with the severity of the operation. The life of steam turbine oil may be as long as 10 to 20 years or even longer. The life may only be 10,000 to 30,000 hours for high-severity gas turbine oil. Used oil analysis is a useful tool, which can give you an indication of whatÊs going on in the turbine and what condition the oil is in. Specific benefits of oil analysis are: Ć You can identify changes in your oil and turbine operation or condition by monitoring trends. Ć Early warning of mechanical problems so you can remedy the condition before it becomes a serious problem resulting in savings in maintenance and downtime. 52 • October 2013

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Ć Validate problems that are indicated by other tools such as vibration analysis, infrared heat detection and visual inspections Ć Determine the effectiveness of filtration, oil conditioning equipment and contaminant removal. Ć Determine the effec tiv enes s of flus hing proc edures . A full range of oil analysis test capabilities to satisfy customer and builder requirements is advised. Additional testing may involve a higher charge because of the high costs and/ or non-routine nature of these tests. A few of these tests would be particle counts, RBOTÊs, and ultracentrifuge tests. These all provide additional insight to the oilÊs suitability for continued service as well as operational conditions that could lead to shortened oil service life or even accelerated component wear.

In well-operated and maintained systems, this additional testing may not be justifiable. Performing monthly or even semiannual extensive oil analysis would be overkill and poor economics. On the other hand, the user of a GE MS 7000 gas turbine might see an advantage to annual or semi-annual RBOT testing because of the severity of operation. Used oil analysis has been proven to be highly effective in many applications, but used oil analysis has some limitations. Ć It will not detect every problem. It was designed to give quick basic info on oil condition. Some problems like circulation system deposits will not always be evident in used oil results. Ć The analytical tests themselves have some limitations. For example, oxidation and total acid number (TAN) tests may be affected by interference from oil additives and contaminants.

Based on the typical long life of high quality oils in turbine applications, the frequency of oil sampling should be adjusted accordingly. For steam and gas turbines in utility industry applications, it is recommended that samples be analysed at a minimum of 6 month intervals. Chemical Engineering World

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CEW Features Ć Used oil analysis does not hold all the answers by itself, but it compliments data from other equipment analysers. Monitoring of operating conditions vibration and routine equipment inspections will help identify conditions that could shorten oil or equipment life. Where, How and When to Sample Many different opinions exist on where samples should be taken. Some feel that oil samples should be taken before cooling and oil filters while others recommend samples be taken after the oil filters. Some even recommend taking a mid-level sample from the oil reservoir. Tests have shown that it does not make much difference where the sample is taken as long as it is taken at the same location each time. While there are disagreements on where to sample, there is almost universal agreement on how to sample. To get representative oil samples, the unit should be up to normal temperature and operating condition or just following shut-down. The sampling point should be clean and purged of all stagnant or dirty oil that may be in the line and valve. Make sure the sample container is clean. Correctly and completely fill in the sample labels and mail as soon as possible to the appropriate lab. Based on the typical long life of high quality oils in turbine applications, the frequency of oil sampling should be adjusted accordingly. For steam and gas turbines in utility industry applications, it is recommended that samples be analysed at a minimum of 6 month intervals. This interval may have to be adjusted based on the length of service of the oil, the severity of the application or if unexpected conditions indicate a need to sample more frequently. In some instances, the equipment builder may require more frequent evaluations of the turbine oil. Also, there may be requirements based on insurance policies. The first 4,000 hours for a turbine is the most crucial period because it is this time frame in which baselines are established. A sufficiently detailed testing programmes must occur during this period in order to obtain reliable information on turbine oil performance and establish base lines. Suggest samples be taken monthly from bearing return lines if possible with oil circulating. The middle of the turbine lube oil reservoir during agitation. As the oil approaches the end of its service life, increased frequency of testing may be required in order to determine, with some precision, the point at which the oil should be discarded. Recommended Test Slates In the absence of OEM specifications, here are some suggested sample frequencies: A. Ć B. Ć Ć Ć Ć

Daily Visual Examination: Appearance & Color Monthly (or 750 operating hours) Test Slate: Viscosity (cSt at 40ÀC) Total Acid No. Contaminant, Additive and Wear Metals (ICP) Oxidation (FTIR)

54 • October 2013

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Test Hours

First 6-Months of Operations, Normal Schedule, and Hours

UD

744 hrs Monthly ă 744 hrs

RBOT

744 hrs Yearly ă 8,700 hrs

Demulsibility

Upon Receipt of New Oil

Source: ASTM D 4378

Ć Water (Karl Fischer) Ć ISO Particle Count Advanced Testing The following tests are recommended to determine the oil condition at a given time AND help predict remaining oil life. Normally, this type of testing is only required annually. However, special circumstances may require more or less frequency. Consult your ExxonMobil Lubrication engineer for more guidance in this area. Ultracentrifuge (UC) · The UC test is a Mobil proprietary test developed specifically for determining the deposit formation potential in critical close-clearance hydraulic servo valves. This test has the ability to pick up early indication of oxidation and nitration materials that could lead to servo valve spool sticking. In gas turbines, this test might be used to help identify oil contaminants or degradation materials that could cause turbine control problems. Rotary Bomb Oxidation Test (RBOT) · The RBOT of a used turbine oil relative to the RBOT of that same oil when unused, is an indication of the remaining oxidation life of that oil. The „New Oil‰ RBOT level is not the important characteristic when selecting an oil. The important consideration is the rate at which RBOT decreases in service. BOT levels decrease based on length of oil service, temperatures and contamination. it would be advantageous to conduct RBOT testing on at least an annual basis until RBOT results drop to < 50 per cent of new oil results. At that point an increased frequency of testing may be merited. One key point to remember is that a high initial RBOT level on new oil does not necessarily mean you will get more life out of that oil. The important criterion is the rate at which that RBOT decreases over time to the 25 per cent level (GEÊs/MobilÊs condemning level) that determines oil service life. Demulsibility · Demulsibility measures the ability of a new or used oil sample to separate water under specific laboratory test conditions. The laboratory test results generally show some correlation to in-plant service conditions, but since this laboratory test does not duplicate actual plant conditions, this correlation may not always exist. In steam turbine circulation systems, it is important to have the water separate readily while in gas turbine systems, it is not as important because of the higher temperatures generally involved in gas turbine systems.

Courtesy: Exxon Mobil Corporation Chemical Engineering World

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Trace moisture measurement device

HYGROPHIL® F basic Drift-free Maintenance-free

Fiber-optical principle

Compressor stations

CNG petrol stations

Biogas infeed plants

For many years now, the Hygrophil® F product family has proven successful in the area of trace moisture measurement in gas. The fiber-optical principle together with standard functionality and compact design makes the Hygrophil ® F basic to a new alternative in the market. Calibration free and configurated by web interface Hygrophil ® F basic is optimal for system integration.

Bartec India Pvt Ltd B-44, Sector 59 Noida - 201301 Phone: +91-1204523-200 info@bartec.ae www.bartec-group.com

Chemical Engineering World

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æ Maintenance-free The fibreoptic measurement principle dispenses with regular calibration æ Pressure-proof up to 200 bar Measurements are possible in areas with very high levels of pressure æ Measurement in gases Reliable measurement results æ Drift-free and with long-time stable Long-life sensor and robust sensor head æATEX-certified Approved for hazardous areas æ Web interface Configuration by web interface æ Compact dimensions for easy integration

October 2013 • 55

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CEW Features

Better Separation with Combined Materials When extraction columns operate at their limits, fine droplets often may form—the separation of which requires special internals. Sulzer Chemtech improves the performance of extraction columns by using coalescers made of composite materials, and thereby extends the range of application for these columns. Pilot tests confirm the process and cost advantages of this solution.

In coalescers, small droplets accumulate on net-like structures and can thereby merge (coalesce). The special feature of the DC Coalescer™ from Sulzer is the combination of two materials with very different wettabilities, normally metal and plastic, which enhances the droplet coalescence of each phase.

W

hen it comes to removing high boiling components from wastewater streams 1 or purifying pharmaceutical agents 2 , liquid-liquid extraction is frequently used (see factbox on next page). As in distillation units, this separation process often is implemented in the form of a countercurrent column. In liquid-liquid extraction, however, two liquids (two liquid phases) are in contact· not a liquid phase with a vapor phase, as in the case of distillation. Special internals are therefore required for the extraction columns, which differ depending on the column technology and the application. The Right Column for Every Application The packed extraction column ECP is used for applications with a high throughput (See Figure 1 on next page). The construction of these columns is very similar to that of the well-known distillation columns, but the packings used have a smooth surface. The main difference is in the distributors for the two liquid phases, because in 56 • October 2013

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extraction one of these phases broken down (dispersed) into To achieve this, specially distributors are necessary different applications.

has to be droplets. adapted for the

The agitated Kühni column ECR is used for separation tasks that require a higher number of separation stages or a high level of flexibility. In this type of apparatus, mixing turbines create the dispersion of droplets in the individual agitated compartments. The speed is selected so that droplets in the desired range of 2ă4 mm diameter are formed. Depending on the density of the liquids, the droplets either rise or sink in the column (see the factbox on next page). In both types of equipment, the droplets collect at one end of the column after flowing through the surrounding liquid (continuous phase). The individual droplets thereby come so close to one another that they flow together and eventually form a continuous liquid layer. This process is described as coalescence. The resulting

separation layer between the two liquid layers is called interface. The Problem of the Entrained Droplets Under certain conditions, considerably smaller droplets·so-called fine drop lets·are also formed in the columns, in addition to the droplets in the desired diameter range. These are no longer able to move against the flow of the surrounding liquid. The drag force of the surrounding liquid is greater than the buoyancy of the droplets. The droplets are thereby carried along and remain in the continuous phase. This process is referred to as entrainment 3 . This microscopic phenomenon has undesired macroscopic effects. Depending on the application, it can lead to contaminated product flows or a yield loss in the process. In some cases, the entrainment of the external phase interferes with the downstream process steps so strongly that the system can no longer be operated safely. This is, for example, the case when toxic or Chemical Engineering World

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October 2013 â&#x20AC;˘ 57

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CEW Features Liquid-liquid Extraction Liquid-liquid extraction is an important basic operation in separation technology. The principle behind this process is a material transfer between two liquids: The key component transfers from one liquid into another. The prerequisite for this is that these two liquids are immiscible or that they mix only to a small extent. In order to create sufficient surface necessary for the mass transfer, one of the liquids is dispersed into the other in the form of droplets. The mass transfer takes place between the droplets (dispersed phase) and the surrounding liquid (continuous phase). In order to be able to subsequently separate the two liquids, they must have different densities. The droplets thereby accumulate above or below the continuous phase depending on the relative density. The boundary surface between the two liquid layers in the columns is referred to as interface and is located at the top or at the bottom. Figure 1: The ECP extraction column from Sulzer uses similar type of packing as in distillation columns but distinctly differs by the specially adapted distributors.

flammable substances are entrained in an aqueous phase that should be discharged as wastewater.

The picture illustrates the two possible dispersion directions:

Solution: Separators Support the Coalescence The entrained phase can be separated in an additional gravity separator, a so-called decanter. However, this step requires a calm flow and a very long residence time of the dispersion. Depending on the diameter of the fine droplets, this time can be up to several hours or even days. Therefore, the decanter has to be uneconomically large. In these cases, separation vessels with internals that help to coalesce the fine droplets are used. Knitted coalescers have proven especially useful here. On their way through the mesh, the droplets come into contact with the individual filaments, adhere to them, and are thereby removed from the continuous phase. When more droplets follow, these merge with the droplets that are already stuck to the filaments, and these grow into larger droplets. Once the droplets reach a certain size, the force of gravity (because of the difference in density) becomes greater than the drag force of the continuous phase flowing around it and the adhesive force of the droplets to the mesh. The accumulated droplet then separates from the coalescer and moves in the desired direction through the column along with the other large droplets. The continuous phase is thereby freed from the entrainment. Universally Applicable Material Combination For the fine droplets to be captured by the mesh and to grow there, the material of the filaments must be wetted by the droplets. Depending on the surface tension of the liquids involved, different materials are wetted to different extents. For example, if fine water droplets are present in an organic liquid such as oil, metallic surfaces will be well wetted, while the water droplets will literally bounce off when impacting onto plastic surfaces. Droplets of an organic liquid, such as a solvent in an aqueous medium, will behave in exactly the reverse way. For the technical application of knitted coalescers, the dispersion 58 â&#x20AC;˘ October 2013

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Feed continuous (left picture) The liquid with the key components which are to be extracted is fed as a continuous material flow, while the solvent is dispersed as droplets. The droplets extract the transfer components and accumulate at the top as the extract.

Feed dispersed (right picture) The solvent is added as a continuous phase and the material flow is dispersed into this phase as droplets. When the transfer components have been removed from the droplets, the remaining residue (raffinate) accumulates below.

Chemical Engineering World

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WE PROVIDE CLEAR SOLUTIONS

STRUCTURED COLUMN PACKINGS & COLUMN INTERNALS EVERPACK WM & SM

(WIREMESH & SHEETMETAL)

HYFLUX

❏ HIGH EFFICIENCY LOW HETP VALUES ❏ LOW PRESSURE DROP Pressure drops in the region of 0.1 – 1 mm Hg per theoretical stage ❏ IDEALLY SUITED FOR ➢ Separation of close boiling components requiring a large number of theoretical stages ➢ Vacuum distillations Widely used for distillation of aroma & perfumery compounds, solvents, fine chemicals, isomers, etc.

EVERGREEN TECHNOLOGIES PVT LTD. 3-D, MAKER BHAVAN-2, 18 NEW MARINE LINES, MUMBAI 400 020. ● TEL: 22012461 /2201 2706 ● FAX: 22-2201 0024 ● E-mail: info@evergreenindia.com ● Website: www.evergreenindia.com

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CEW Features direction must therefore be known from the very beginning. Because this is not always possible, ideally, both materials should be used at the same time, so that both organic and aqueous droplets can wet the material. Sulzer has developed the DC Coalescer™ for this purpose. DC stands for Dual Composite, because metal and plastic filaments are knitted together, thereby ensuring that the finished mesh can be used universally. Tests confirm that the high gradient in the surface properties at the points of contact of plastic and metal filaments significantly improves the level of separation compared with that of mono-material meshes. Customer Success Thanks to Combined Technology By combining extraction columns with a DC Coalescer, Sulzer can significantly expand the application range of the extraction columns for challenging systems. This effect has been confirmed in a recent customer project. In order to increase the production of an established product, a Sulzer customer built a new, second production line. Among other things, the process includes an extraction stage. With less than 1mN/m, the interfacial tension of the mixture is very low, which promotes the formation of fine droplets. In the first pilot trial, this led to an entrainment at the head of the agitated extraction column and thereby to a loss of product. Sulzer solved this problem by combining the new columns with a DC Coalescer. In the pilot trial, the DC Coalescer, fitted with a special lead through for the mixer shaft, visibly reduced the entrainment (Figure 2). Based on this very good experience, the customer decided to equip the new industrial columns with this coalescence aid. Instead of simply copying the existing production line, the customer is now using an agitated extraction column supplemented with a DC Coalescer. By this, considerably less equipment, fewer ancillaries (such as pumps), and consequently, less space is required. As overall result, Making Large from Small

Figure 2: Pilot trials confirm that the DC Coalescer™ from Sulzer considerably reduces the entrainment (carrying along of fine droplets).

these changes have reduced the customerÊs investment costs by 35 per cent. References: 1 Jörg Koch “(Dis)Solving the high boiling problem” Sulzer Technical Review 3/2011, 20–24. 2 Teh C Lo, Malcolm H I Baird, Carl Hanson, Handbook of Solvent Extraction (New York: John Wiley & Sons, 1983). 3 G A Davies, G V Jeffreys, D V Smith, F A Ali “The Formation of Secondary Droplets in a Dispersion at a Phase Boundary” Canad J Chem Eng, Vol 48 (1970), 328-329.

The Sulzer DC Coalescer™ contains two materials with very different wettabilities· typically metal and plastic·whereby the droplet coalescence of liquids with hydrophilic and hydro - phobic properties is significantly increased.

Good wettability

Low wettability While the droplets pass through the Sulzer DC Coalescer, they collect on the filaments and coalesce with neighboring droplets to form larger droplets. This process is repeated continuously within the DC Coalescer. When the droplets become large enough, they separate towards the phase boundary. 60 • October 2013

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AuthorsÊ Details Jörg Koch Sulzer Chemtech Ltd Email: joerg.koch@sulzer.com

Daniel Egger Sulzer Chemtech Ltd Email: daniel.egger@sulzer.com

Chemical Engineering World

28-10-2013 20:19:08


Man-Made Fiber production

Sustainable Solutions for

Processing of New Generation

Man-Made Fibers

LIST Dry Processing

LIST Dry Processing replaces conventional dissolving technology and enables the dissolving of a wide range of raw materials in different solvents. ‡Homogenized and bubble free spinning solution ‡Accurate product temperature monitoring during the dissolving process ‡Process safeguards against uncontrolled reactions MasterContiTM²WKHPRVWHIÀFLHQWWHFKQRORJ\IRU)LEHUSURGXFWLRQ

www.list.ch | www.list.us | www.list.sg

Chemical Engineering World

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CEW Features

Remote Collaboration for Operational Excellence Collaborations station in a plant premises is a place that allow an employee to monitor the different operations and communicate with colleagues. This is a place that allows teams to come together and solve a problem; thus improving overall operations excellence. Increased specialisation of expertise and the need for a faster pace of decision-making make remote collaboration a crucial factor for success.

Figure 1: A major barrier to human performance improvement in industrial organisations is functional “silos,” where each part of an operation only works vertically within its own narrow space.

W

ith short innovation cycles, changing customer needs and intense competitive pressure, harnessing the power of employees across functions and regions has become extremely important for manufacturers. However, such cross-enterprise knowledge sharing requires a robust, scalable and secure platform for collaboration. Recent developments have taken collaboration to a new level in manufacturing operations. Today, plant personnel have access to new tools providing the ability to display and interact with system or plant-wide data. This enables high-quality collaboration with the field or with experts in other locations, and is particularly useful in facilitating regular plant events like shift changeovers and operations meetings, and also when troubleshooting is needed. With secure collaboration across the enterprise, industrial firms can extract maximum value from the talent in their 62 • October 2013

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organisation and release the trapped value from their asset base. Background When you think about it, collaboration is at the heart of every business. Most people are a part of a team that needs to work together to achieve the best possible results; the team is a part of many teams that must collaborate to help grow an enterprise. One of the major barriers to human performance improvement in industrial organisations has been the development of functional „silos,‰ meaning that each part of an operation only works vertically within its own narrow space·not horizontally across functions. These silos limit the amount of interaction needed to drive maximum value from assets (See Figure 1). In complex environments, such as processing plants, turning information into action often requires specialised knowledge and understanding of what the

information actually reveals. A few select individuals may hold this specialised knowledge across the facility. The goal is to make the information available and obtain talented personnel from the various disciplines to work together toward transforming information into actions. Value of Collaboration Industrial companies with a global reach and presence need a way to get everyone on the same page, and to effectively operate as a single entity instead of as a fragmented organisation. They require improved methods of communication to coordinate multinational activities, meet increasingly stringent regulatory requirements, and better manage changing workforces. TodayÊs typical process plant has multiple repositories of data, and the volume of data is increasing each year and becoming more fragmented. There is a growing need to bring all this information together and make sense of it, and make faster and better decisions. Chemical Engineering World

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CEW Features Large-format touch screen monitors offer display capabilities such as pan and zoom, plus the ability to show multiple windows of related information concurrently. Similarly, the use of video for business and operational purposes is increasingly common. Video streaming and video calling are now common methods of communication. In a business environment, desktop sharing is a routine technique covering voice and visualisation.

Figure 2: Modern collaborative tools enabling personnel to connect and interact virtually have a global economic impact on productivity.

At the same time, fewer personnel are operating plants. Process, maintenance and other support resources backing up these facilities are often located remotely. Business support resources such as production planning are normally situated at remote sites, too, typically at headquarters. There are four major market developments making enterprise collaboration increasingly vital for manufacturers and other industrial entities. They are: Ć Globalisation: Every company in the world is affected by globalisation, and the more globalised the business is (or wants to be), the more important collaboration becomes. Ć Specialisation: In a technology-driven environment, increasing specialisation of knowledge-based work has made collaboration a key initiative. Ć Innovation: As competition increases, the only way to ensure a business advantage is through innovation. Collaboration promotes real-time organisational awareness of opportunities for innovation; shortens the cycle time for conception and design; and helps drive acceptance, adoption, and expansion of ideas. Ć Distributed Expertise: In a global economy, employees often have to coordinate efforts with people all over the world. This makes harnessing the power of people across functional/geographic boundaries a critical success factor. 64 • October 2013

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Enterprise productivity can come from a number of areas, ranging from improved decision-making and reduced re-work, to a more robust innovation pipeline and fewer sub-optimal decisions based on imperfect information. Indeed, the promise of timely collaboration is game-changing transformation, if applied in the right way. Latest Technology Trends Innovative solutions enabling people to connect and interact virtually have a global economic impact on productivity. Significant economic returns annually may be unlocked by this technology in knowledge worker productivity, on a scale critical to performance and growth in the 21 st century (See Figure 2). As industrial firms begin to embrace organisational change, more intently on improving communication and collaboration, there are apt to be specific types of technologies that can increase collaborative behavior across enterprise networks, which will help employees to share objectives and activities in achieving business goals. For example, the use of touch screens in mobile phones and tablet computers is well developed and accepted by users.

Technology suppliers are developing powerful solutions that will greatly expand visibility of enterprise information, with a common view for all those collaborating. Through complete visual integration with process control and information systems, these tools can enable plant, business and support personnel to use interactive displays, embedded video and other telecommunication capabilities to communicate, collaborate and make decisions, regardless of whether they are in the control room, conference room, situation room or in remote locations. The new breed of collaborative tools will provide the means for industrial organisations to visualise data across the enterprise in a way never before possible. These tools have the potential to improve collaboration between multiple experts within the organisation, making it easy to integrate all types of overviews, alarm displays and other usersÊ computer screens; display business network data and Distributed Control System (DCS) information; and see the same views simultaneously for enhanced decision-making processes. Intended for large, highly distributed operations, as well as multiple sites with central engineering, an integrated „collaboration station‰ is one way to allow for faster, more efficient evaluation and action on abnormal situations, and support broader communication among employees·no matter where they reside· so they can share the same view of information through intuitive navigation and ease of use (See Figure 3).

The collaboration station approach can be particularly valuable to plant and operations managers who want to track the state of their process for faster response to both routine and emergency situations. Chemical Engineering World

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CEW Features

Figure 3: An integrated “collaboration station” can enable industrial organisations to visualise data across the enterprise.

The collaboration station approach can be particularly valuable to plant and operations managers who want to track the state of their process for faster response to both routine and emergency situations. This includes sites with frequent product grade changes, complex processes and dynamic operations, where addressing problems quickly has significant benefits. It may also be useful in management of emergency situations. A station can be designed to display performance information across distributed assets such as oil & gas fields and pipeline operations, and rapidly establish communication and collaboration between centralised operations, maintenance and specialists without having to bring them to the same location. Putting New Tools to Work Ideally, a collaboration station should employ a large-format monitor with interactive displays and multi-touch gesture control capabilities. This design allows collaboration from the control room, the plant, home, and from experts around the world. The station may be useful during normal operations, as well as for shift handover, troubleshooting, or operations meetings. Specific types of applications that might be opened and displayed on a collaborative screen include: Ć Enterprise historians Ć Maintenance Ć Closed Circuit Television (CCTV) Ć Permit to work Ć Production planning Ć Standard Operating Procedures (SOPs) 66 • October 2013

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Ć Ć

Materials management Reporting

For obvious reasons, a collaboration station should be a read-only station that cannot be used for actual plant operations such as performing set point changes. By locating the station on a network outside the control room environment, users have the ability to display additional applications available on the business network to merge control room and business data. One effective approach could be configuring a collaboration station with enterprise software technology such as an instant messaging client. This provides access to capabilities ranging from instant messaging, voice-over-IP (VOIP) and video conferencing, to real-time multi-client collaboration enabling teams of people to see and simultaneously work on the same documents and communications session. These capabilities may be implemented as follows: Ć Collaboration through PowerPoint® documents, where participants can control and see presentations, as well as add text, drawing and graphical annotations Ć Polling lists, where presenters can organise polls and all participants can vote and see results Ć Desktop sharing, where participants can see and collaborate on their windows screen Ć Windows application sharing, where participants can see and collaborate on a specific application

Benefits for Industrial Organisations The use of modern collaborative technologies promises to heighten situational awareness in a wide range of application scenarios, allowing key organisational stakeholders to display relevant information in a shared environment. This approach can reduce the impact on performance from an abnormal situation through faster analysis and response: Ć Rapidly establish communication and collaboration between centralised operations, maintenance and other specialists supported by relevant information Ć Common view of the situation for both local and remote collaborators, as opposed to collaborators having their own separate view·or no view at all·with more potential for miscommunication Ć Faster navigation between different contexts by accessing displays across the screen with persistent content Ć Exploits all available resources: people, advanced applications and control systems in one collaborative system Conclusion Through implementation of an integrated c ollaboration s tati o n , in d u s tr ia l organisations can employ the latest tools enabling visualisation of multiple streams of process and business information on a large interactive display, around which many people can collaborate for rapid and effective situational awareness and decision making. This approach may be suitable for any organisation that designs, operates and maintains large industrial facilities where co-operation between personnel needs to be catalysed. It can also help address the challenge of skilled labor shortages by leveraging the expertise of remote experts as needed.

AuthorsÊ Details Andrew Stuart Lead Product Marketing Honeywell Process Solutions Email:andrew.stuart@honeywell.com Chris Morse Product Marketing Manager Honeywell Process Solutions Email: chris.morse@honeywell.com

Chemical Engineering World

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CHEM

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High precision gear pump for the chemical industry The CHEM gear pump can be used for a wide range applications from low to high viscosity. It is well suited for high temperature, vacuum inlet conditions and high discharge pressure. Applications can range from liquid metering to basic transfer tasks. Pumps of this type can be supplied electrically heated, jacketed or without heating. The available materials of construction and design options provided by WITTE offers our FXVWRPHUVPD[LPXPĂ&#x20AC;H[LELOLW\

Chemical Engineering World

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October 2013 â&#x20AC;˘ 67

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Marketing Initiative

Unique Trace Moisture Analyzing for Natural Gas and Liquid Hydrocarbons

N

o drift due to fibre optical principle leads to high process safety and low maintenance efforts. For moisture analyzers to gain an international reputation, they have to feature an outstanding reliability and precision, operate without drift and be maintenance-free. As stateof-the-art optical system, a unique fibre-optical principle, the HYGROPHIL ®F 5673 is established in the field of trace moisture measurement for decades. The HYGROPHIL ®F basic, as a new solution for system integrators, completes the range of BARTEC BENKE products for this increasingly important industry. Long-term stable moisture measurement in refinery, petrochemistry or gas application is an essential requirement because moisture can cause extensive damage. This is why companies require to monitor moisture continuously and reliably during the feed, drying or transmission stages in natural gas or during processes of (petro-) chemical application. Too much moisture leads to corrosion, hydrate forming or problems in chemical reactions as the inactivation of catalysts in polyethylene plants Monitoring moisture reduces costs Measuring moisture around driers allows not only monitoring of correct function, but also the optimal control of drying processes. Energy costs involved in excessive drying are reduced and the application of drying agents is kept to a minimum.

Contact Details:

Furthermore the reliable monitoring of moisture prevents a decrease of thermal value. Standards and regulations of the globalise natural gas market also play an important role.

Bartec Benke GmbH Borsigstrasse 10 21465 Reinbek ,Germany Phone : +49 40 72703 215 Fax : +49 40 72703 363 Mobile : 01520 9221 215 Email: Anne-Frauke. Schulz@bartec-benke.de Website : www.bartec-benke.de

A defined dew point has to be guaranteed by the suppliers before the gas is fed into local and international net works. Unsafe and unstable moisture measurement in production plants will increase not only the maintenance effort but also the total costs of these plants in case of shut down. The process safety is not guaranteed.

68 • October 2013

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The drawbacks of conventional sensors In the past, aluminum oxide sensors (Al 2 O 3 ), ceramic sensors or thin-film sensors were usually used for moisture measurement in natural gas. These sensors generally worked by measuring a change in capacitance or dielectric caused by water adsorption. While such sensors may initially be cheaper, the disadvantage of the measuring principle is its lack of long-term stability. In general, depending on the application and gas composition, these sensors start to drift after three to six months. The related costs for maintenance and recalibration very quickly exceed the cost savings of the original purchase within a very short time. Moreover, some sensors are likely to fail if they come into contact with aggressive gas components or liquids such as water, glycol, hydrocarbons or corrosion inhibitors. Additional costs for replacing the sensor will inevitably follow soon. A further and significant cost factor is the acquisition ă mandatory in most cases ă of an analysis (sampling) system with built-in Teflon filters to protect the sensor from liquids. A pressure reducer is also another integral component as many sensors are not suited for high-pressure applications. For some plants it is obligatory to reduce the pressure, as in the case of a downstream gas analysis system using gas chromatography. In case of an emergency, the components installed have to be easily accessible while the process stays online. This also applies to drifting or failed sensors. Conventional analyzing systems can result in large and very costly errors: As soon as the Teflon filter is wetted and contaminated with any liquid, it generates a microclimate in the sample system which deviates from the conditions in the process. Chemical Engineering World

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Marketing Initiative

Hygrophil F 5673 and Hygrophil F basic for system integration

Error is then an inevitable consequence. The moisture sensors for the lowpressure side are installed behind the pressure reducer so that they are not overstrained. However, the decisive variable in the natural gas industry is the pressured dew point which also has to be guaranteed on delivery (e.g. -10ĈDT at 40 bar). In the case of aluminium oxide, ceramic or thin-film sensors, the dew point is measured at 1 ă 3 bar and is then recalculated to match the pipeline pressure in order to determine the pressurized dew point. No physical or chemical processes under pressure are taken into consideration which also results in deviation from the actual pressured dew point. Continuous development with system integration solution The HYGROPHIL ® F 5673 multichannel moisture analyzer is the most established development in the field of trace moisture measurement. It ensures long-term (driftfree) stability, precision and reproducibility by the fiber-optic measuring principle by its high stable L1661 sensor with integrated temperature compensation. The unit can be operated in high-pressure ranges up to 200 bar and is also used for moisture measurement in liquids. The sensor is completely resistant to glycol, hydrates, inhibitors, liquid hydrocarbons and water. 70 • October 2013

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The new device HYGROPHIL ® F basic h a s been dev eloped for s y s tem integration. With less functions and lower dimensions, but with the complete advantages of fibre optical principle, it is perfectly suitable for system integration or uncritical applications. It is equipped with IP65 housing and certified for Class I, Div. II. . Configuration will be done by web interface. Customized Sampling Systems or keep the process on-line Sample conditioning system (SCS) from BARTEC BENKE extracts gas or liquid from a process line and ensures suitable process conditions for a sufficient measurement. BARTEC BENKE sampling systems will be engineered for different customer applications. Whatever is necessary, multiple stream systems with cooling, filter, heating or protection functionality are available. The optimum measuring point for a moisture sensor to determine the exact, pressurized dew point is right in the process. All chemical and physical processes taking place under process pressure have to be taken into account. However, many plant operators avoid in-situ measurements in consideration of sensor protection because failures might cause some problems.

right in the pipeline. The sensor can be taken out of the process at any time and reinstalled within seconds. It can be mounted on lines DN 50 and higher and is certified in Germany (TÜV) for pressures up to 200 bar. No matter whether th e o p e r a to r chooses the sampling system solution, prefers the retractor option or wants to integrate the Hygrophil F into an existing peripheral system, BARTEC BENKE offers advisory support and solutions tailored to the individual application. The scope of delivery consists of accessories such as control cabinets, heated lines, sample probes and enclosures for Ex area (EEx-d, EEx-p) applications. To complete the package, qualified staff mounts and install all parts at the operators´ request. They carry out start-up and train the operating staff, and they are offering single source service from planning up to commissioning. High-quality products, many years of experience, dealing with operators´ problems, developing innovative solutions and providing competent service have made these products to the leading solution in the field of trace moisture measurements for many years!

By using the BARTEC BENKE retraction tool, moisture is measured at the best location Chemical Engineering World

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Marketing Initiative

Shiva Engineering Services

Amresh Mehta Business Development Head Shiva Engineering Services (SES)

S

hiva Engineering Services (SES) is one of the leading engineering services provider offering multi-discipline end-to-end engineering & execution services (EPC/EPCM/ LSTK/PMC) for manufacturing and industrial clients in Chemicals, Specialty Chemicals, Agrochemicals and Pharmaceutical and related sub-sectors. Shiva Engineering Services (SES) provides multitude of services under one roof. Services include Engineering, Procurement & Construction Support as well as Turnkey Executions. It has its head office in Vadodara (Gujarat) and a branch office in Mumbai (Maharashtra).

Contact Details: Shiva Engineering Services 1st Floor, ABS Towers Old Padra Road, Vadodara Gujarat-390007, India Phone +91265 235 7316 Fax +91 265 235 7238 Email: info@shiva-engineering.com Website: www.shiva-engineering.com 72 • October 2013

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SES engages with customerÊs right from concept till start-up phases of a project. CompanyÊs multi-discipline engineering teams consist of professional Project Managers, Domain Experts, Capability Leads, Engineers and Designers with years of collective industrial experience from serving the most reputed and industry leading multi-nationals across the globe. SESÊs primary executions and experience have been from Chemical & Specialty Chemical, Polymer & Plastics, Pigment & Paint, Inks, Agrochemical/ Pesticide and Pharmaceutical Industry Sectors.

SES value each customer and provide specific, time-bound and value driven engineering solutions where customers benefit from reduced capital costs and faster market reach. Some specialized services offered by SES include- Optimization of Plant Performance, Energy Management & Utility Au d its , Speciality Services- Steady & Dynamic State Process Simulation, HAZOP & SIL, Facility Engineering- Mechanical HVAC, Electrical and Plumbing (MEP) Services. The comapny has a joint venture (with Mauritius based Consultec Group) for 3D Laser Scanning & Reverse Engineering services which is the most cost effective and efficient methods to capture as-builds for revamp and re-location of old plants from one location to other The copany has had the opportunity of catering to a vast gamut of clients both nationally as well as globally; these consist of pioneers, industry leaders and new technology start-ups. Our project locations are well spread across the globe where the excellence, experience and expertise of SES are being utilized to provide world class engineering services. Chemical Engineering World

28-10-2013 20:13:52


12th Clean Coal Forum Indonesia 2013 Asia’s Premier Coal Event December 4th-5th, 2013 | Jakarta, Indonesia Sustainable Development Focus: Tapping Into Local Potential, a Myriad of Opportunity in Indonesia

CCFI2013: THE VITAL STATISTICS 200+ distinguished guests comprising senior decision makers from 20+ companies over 12+ countries worldwide. 30+ eminent global powerful speakers in the coal industry 15+ on-track mega demonstration projects in Indonesia. 12+ hours of networking time including cocktail receptions, champagne roundtables, VIP lunches and open Q&A sessions.

6

expert-hosted sessions offering vital industry insights.

Organized by

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Please scan and register for the updated information.

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Contact us: Elva Qiu

Tel: +86 21 6393 1899 Ext:2041

Email: elvaq@cdmc.org.cn

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Fax:+ 86 21 6840 7632

Web: www.cdmc.org.cn/2013/ccfi

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Marketing Initiative

Arvind Pipe & Fittings Industries

A

rvind Pipe & Fittings Industries Pvt Ltd, came into existence in the year 1982, and well known as Arvind Metal Syndicate. The genesis of ARVINDÊs birth and growth is „ACCEPTING CHALLENGES.‰ The planned growth of the company has transformed into two separate manufacturing units one Welded, Seamless Tubes & Pipes, and other Pipe Fittings & Flanges. The company serves its customers for all thier piping requirements under one roof such as Pipe, Tubes, Pipe Fittings and Flanges product. CompanyÊs quality management system confirm to ISO 9001-2008 and PED certificated by TUVNORD. Leveraging on its modern manufacturing process, equipment and inspection tools practiced in producing the products and by putting them through strict Quality Control Procedure, the company has stood the test of close scrutiny with relation to materials and standards laid down for these products. All its products meet the requirements of International and National standards. All the product undergo various stringent inspection & testing stages at the up to date in house facilities, such as Chemical, Mechanical, Hydrostatic, Corrosion test, Non-Destructive test etc before they are dispatched to the customers. This assures high value quality of products.

Contact Details:

Arvind Pipes & Fittings Industries Pvt Ltd Shop No. 2, Ground Floor Nene Building 12 Sadashiv Line, Girgaon Mumbai - 400 004, India Phone:+91 22 2389 5412/ 2389 1702 Email:info@arvindpipe.com arvind@arvindpipe.com Website: www.arvindpipe.com 74 • October 2013

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ArvindÊs clientele base consists of Nuclear Plant, Atomic energy, Chemical, Fertilizer, Petrochemical, Refinery, Power, Dairy, Sugar, Paper and Pharmaceutical Industries, and have founded wide acceptance with reputed Engineering consultants under third party Inspection agencies Like Lloyd, BVQ,SGS, H&G, PDIL, CEIL, DNV, TUV etc.

The human resource base at the comapny is a dedicated and motivated team of employees who are well qualified and trained to ensure quality & timely delivery to meet the requirements of customer. This is epitomized in ArvindÊs corporate philosophy to „EXCEL IN WHATEVER YOU DO‰ and „PROSPERITY THROUGH PERFORMANCE.‰ The talented pool of professionals allow the company to understand clientsÊ requirements, thier urgency, irrespective of size of thier organization. The company is confident of meeting clientsÊ needs whenever they may please. The comapny always looks forward to the occasion when it can offer its clients its humble services. The company is supported by some of the most qualified and technically sound professionals, who are well aware about different techniques required to manufacture products. Its team members hold vast industry experience, which help them in sourcing quality raw material from reputed vendors. They are well versed with the quality testing process of these precision engineered components. ArivindÊs product range includes Pipes & Tubes (Seamless & Welded Pipe, Seamless & Welded Tubes & ÂUÊ Tubes); Fittings (Elbow, Tee, Reducer, SW Fittings); Flanges (Blind Flanges, SORF Flanges, Weldneck Flanges) and Branch Connection (Elbolets Weldolets, Threadolets, Sockolets, Nipolets, Adaptors). Some of comapnyÊs clients are Nuclear Power Corporation of India Ltd. (NPCIL), Bhabha Atomic Research Centre (BARC), Indian Space Research Organisation (ISRO), Larsen & Toubro Limited (L&T), Godrej & Boyce Mfg. Co Limited, Hindustan Door-Oliver Ltd, Mazda Limited, Gujarat Narmada Valley Fertilizers Co. Ltd, Orchid Chemicals & Pharmaceuticals Ltd, Liquid and Propolution Systems Centre, etc. Visit our website to learn more about our company. Chemical Engineering World

28-10-2013 22:09:53


Who’s Who th 14 Edition

Who’s Who is an exhaustive listing & fact book on CHEMICAL PROCESS, PHARMA BIOTECH, HYDROCARBON INDUSTRY & INDUSTRIAL SAFETY

AN ISO 9001:2008 CERTIFIED COMPANY

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Marketing Initiative

Suraj Limited developed and constantly monitored throughout the entire manufacturing process. A quality system to ISO 9001: 2008, AD 2000 ă Merkblatt / W0, and PED ă 97 / 23/ EC as outlined in this manual has been developed and implemented to ensure so that all the customer requirements are met. The quality system is applicable to all departments and all activities undertaken by the company for manufacturing of Stainless Steel Seamless / Welded Pipes, Tubes and ÂUÊ Tubes.

S

URAJ LIMITED is an ISO-9001, 14001, BS OHSAS 18001 Certified Company. The company manufactures and exports Stainless Steel Seamless & Welded Pipes, Tubes & ÂUÊ Tubes and Large Diameter Welded Pipes in various sizes, grades & specifications as per customer requirements. Suraj has strong presence in global market and serving more than 70 countries such as EU, Gulf, South East, US & Latin America. The company was founded by Late Mr Tarachand

The quality policy of Suraj Limited is very simple - to perform work of the highest attainable quality in accordance with applicable codes/standards/ specification and customerÊs specifications. Its products are subjected to various quality testing such as Eddy Current test, Hydrostatic test, Ultra sonic test, Radiography, Hardness test, Air under water test, Dimensional test, visual test etc. Quality Control measures include chemical analysis, measurement of mechanical and metallurgical

Materials

All Austenitic, Ferritic, Duplex & Super Duplex Stainless Steel

Specification

As per ASTM, ASME, DIN, NFA, JIS Standard

Size Range

Welded: 6.0 mm OD ă 1016 mm OD; Seamless: 6.0 mm OD ă 323.9 mm OD

Thickness

Welded: 0.6 mm ă 25 mm; Seamless: 0.8 mm ă 25 mm

Pipe Length

Upto 12 mtr long

Tube Length

Upto 30 mtr long

Exchangers, Heating Elements, Surface Condensers, Specialization Heat Evaporators,Digestors, Instrumentation Tubing and Fluid Piping Application

Contact Details:

Suraj Limited „Suraj House‰, Opp Usmanpura Garden, Ashram Road Ahmedabad ă 380 014, Gujarat India Phone: +91 79 2754 0720/21 Fax: +91 79 2754 0722 Email: suraj@surajgroup.com Website: www.surajgroup.com 76 • October 2013

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Refinery, Petro-chemical, Food, Pharma, Fertilizer, Oil & Gas, Breweries,Sugar, Ship Building.

Bhalaji Shah in 1960. It has been successfully and efficiently lead by Mr Ashok Shah (Chairman & CEO), with the strong support of his teammates Mr Gunvant Shah (Vice Chairman & Wholetime Director) and Mr Kunal Shah (Managing Director). They are supported by a strong professional team with an extensive experience in this industry. Quality Policy All products of Suraj Limited have to meet a very high standard, set by stringent quality specifications and norms. All process parameters and conditions are

properties and close dimensional tolerances as per applicable codes / standards / specification. Suraj also holds certificates for quality in accordance with AD2000 MERKBLATT W0 and Pressure Equipment Directives [PED] 97/23/EC from TUV Nord and offer material under all national & international Third party Inspection. SURAJ also have their own lab to examine various tests such as Hydro test, Eddy Current, PMI, IGC, UT, RT, Spectro analysis, Mechanical properties and many others as per customer requirements. Chemical Engineering World

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CEW Products Triple Screw Pumps UT Pumps and Systems Pvt Ltd offers range of triple screw pumps manufactured as per BORNEMANN Germany design acquired by virtue of previous JV partnership. These pumps are manufactured in different combination of casing materials with replaceable cartridge assemblies. The pumps are available in different designs of mounting arrangements to meet specific requirements of customers for replacement of existing pumps without disturbing already laid out pipelines. These pumps find applications for transfer and pressure boosting in systems handling lubricating oils and light and heavy fuel oils and turbine governing oil systems, boiler feed systems in different industries such as refineries, fertilizers, power plants, paper mills, etc. UTPSL triple screw pumps are available in capacity range of 2,200 LPM and pressure range up to 80 bars. For details contact: UT Pumps & Systems Pvt Ltd 14/7 Mathura Road, Faridabad. Haryana 121 003 Tel: 0129-4045831, 2274861, 2258588, 3299731. Fax: 91-0129-2258584, 2275877. E-mail: sales@utpsl.in or Circle ReadersÊ Service Card 1

VAE Dispersions for Adhesive Applications

Automatic Valve Gate Control for Cold Runners

The WACKER Group offers two new vinyl acetate- and ethylene-based dispersions as binders for sophisticated adhesive solutions.

In hotrunner technology, control systems are used for automatic balancing of multi-cavity moulds because the simultaneous filling of all cavities is a precondition for the optimum part quality. These conditions are achieved by automatically detecting the melt front in single cavities and by controlling the temperature of the hotrunner nozzles in case of deviations. For cold runner moulds in case of liquid silicone rubber applications it is important to achieve an equal filling otherwise the different volumes in the cavities will also cause different compression after cross-linking. The results are unfilled inhomogeneous parts, which sporadically occur in one or the other cavity. The solution is again the automatic detection of the melt front via cavity pressure or cavity temp sensors and the automatic delay of the valve gate opening until an equal filling will be achieved. There is a choice of either balancing the average fill time or control the desired target fill time. This control method can be used for thermoplastics as well as for liquid silicone rubbers or elastomers.

VINNAPAS EP6300 and VINNAPAS EP7000 enable the formulation of high-performance, waterbased adhesives with a broad variety of uses, from bonding paper labels to plastic bottles over vinyl lamination to construction and flooring applications. Moreover, both products are manufactured without the use of alkylphenol ethoxylates (APEOs). Additional highlights are WACKERÊs alpha-silane-based hybrid polymers for solvent- and tin-free sealants and adhesives and vapourpermeable liquid waterproofing membranes, dispersions for high-quality decorative paints as well as its dispersible polymer powders for decorative exter ior plasters and self-leveling flooring compounds. For details contact: Wacker Chemie AG Hanns-Seidel-Platz 4 81737 München Germany Tel.: +49 89 6279-1604 Fax +49 89 6279-2604 E-mail: nadine.baumgartl@wacker.com or Circle ReadersÊ Service Card 2

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For details contact: PRIAMUS System Technologies AG Rheinweg 4, CH-8200 Schaffhausen, Switzerland Tel: +41 (0)52 632 2626 / 2605, Fax: +41 (0)52 632 2627 E-mail: m.trebbe@priamus.com or Circle ReadersÊ Service Card 3

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CEW Products Power Generation Equipment Upgrades Turbine Technology Services Corpn (TTS) is playing a critical role in the upgrade of power generation equipment worldwide by modernizing control systemsÊ hardware and software to improve the operational performance of gas turbines. TTS offers GE gas turbine operators complete HMI upgrade solutions to bring this operator interface systems up to current standards. The TTS solution is based on Industrial Turbine ServiceÊs Turbine Monitoring System (TMOS) software, an established industry product, which has been successfully applied around the world in the replacement of the original GE and product line. These HMI upgrades from TTS provide an improved graphical interface that retains the features of the original operator interface product while adding powerful new capabilities and features including improved unit data acquisition, storage and analysis. These upgrades also provide innovative solutions to the system architecture and communication limitations imposed by the original systems. TTS has performed numerous HMI upgrades for power generation customers, giving the company a unique insight and experience to address the needs of the industry from system design and network architecture to hardware installation. For details contact: Turbine Technology Services Corpn 12661 Challenger Parkway Suite 250, Orlando, FL 32826, U.S.A. Tel: 407.826.1796 E-mail: media@turbinetech.com or Circle ReadersÊ Service Card 4

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Pumps for the Chemicals Industry Wilden offers Pro-Flo SHIFT air distribution system (ADS), which allows Wilden AODD pumps achieve savings in air consumption. It is available in Wilden Advanced Series bolted and Original Series clamped AODD pumps and includes ATEX compliance. Almatec offers its AODD pumps, including its E-Series Plastic AODD pumps to handle and transfer dangerous chemicals. Almatec offers a unique SS containment ring that creates consistent high-torque compression all the way around the ring. Mouvex C-Series Eccentric Disc pumps safely handle dangerous chemicals that requires no magnets, mechanical seals or packing. The seal-less design allows the C-Series to self-compensate for mechanical wear. Blackmer offers System One centrifugal pumps for high-volume, severe-duty applications. It has a stiffer heavy-duty shaft and larger bearings resulting in the widest operational window off the Best Efficiency Point. BlackmerÊs HD Series Reciprocating Gas Compressors, provide efficient transfer, boosting and recovery of wide range of industrial gases. Compressors are equipped with ductile-iron valves with PEEK valve plates, ductileiron head and cylinders, a full-compartment distance piece with two sets of self-adjusting filled Teflon TFE packing on each piston rod for max leakage control, self-lubricating TFE piston rings, precision-ground crankshaft and a pressure-lubricated crankcase. For details contact: Dover India Pvt Ltd ă PSG 40 Poonamallee By-pass, Senneerkuppam, Chennai 600 056 Tel: 044-26271020 E-mail: sales.psgindia@psgdover.com or Circle ReadersÊ Service Card 5

Combustible Dust Hazards Testing Lab Fauske & Associates, LLC (FAI) offers range of services related to characterizing, preventing and mitigating combustible dust explosions and fire hazards. FAIÊs lab capabilities provide testing per ASTM and European (CEN) standards, which include common tests like the Explosion Severity Test - (KSt, Pmax and (dP/dt)max), Minimum Ignition Energy, the Minimum Explosible Concentration and Limiting Oxygen Concentration. These standards are the basis of NFPA codes for combustible dust as well the OSHA Combustible Dust National Emphasis Program. Combustible dust hazards are common in industry and have gained additional exposure due to the OSHA Combustible Dust (NEP) which was re-issued as a result of the fatal accident at Imperial Sugar. FAI also conducts comprehensive plant evaluations. For details contact: Fauske & Associates 16W070 83rd Street, Burr Ridge, IL 60527 , U.S.A. Tel: 630-887-5213 E-mail: afauske@fauske.com or Circle ReadersÊ Service Card 6

Chemical Engineering World

28-10-2013 19:44:01


Frequent Breakdowns

hampering your business?

in Control Rooms ÂŽ

Removes harmful gases Prevents corrosion of electronic components

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RB/BA/1319HVCA2

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CEW Products SmartPlant Fusion Intergraph SmartPlant Fusion rapidly captures, organizes and makes available large volumes of previously unstructured information through a simple web portal interface, in a highly intuitive manner. The types of unstructured information include documents, drawings, lists and sheets, 3D models and even laser scan images or high-resolution photography. SmartPlant Fusion provides the basis for continual, phased improvement in the quality and integrity of information assets. It makes information exposed and immediately accessible to all stakeholders for decision support. —It is the easy, quick starting point of the evolution of unstructured content, enabling owner operators and engineering companies to extract value from legacy documents. The Âas-existsÊ information asset is a vital but often undervalued representation of a plant or a project. With limited engineering, administrative and IT personnel on a brownfield plant site, organizing and keeping track of this information could be a significant challenge, particularly when the plant is subject to continual updates, revamps, turnarounds and maintenance changes. New greenfield construction projects also suffer from handling large volumes of unstructured information that regularly arrives from suppliers, vendors and engineering partners. If this information is not handled properly during the handover process, these valuable records can quickly degrade or be lost forever. SmartPlant Fusion facilitates accurate information capture, reducing the possibility of lost and duplication of data while eliminating errors and time-consuming mistakes. It enables intuitive navigation with an accurate representation of the way things are really connected, making unintelligent information smart. For details contact: Intergraph Consulting Pvt Ltd PPM Division (Subsidiary Intergraph Corporation), 2C, 2nd Floor, 1-8-382, Queens Plaza, S P Road, Secunderabad, Andhra Pradesh 500 003 | Tel: 040-33184000 | Fax: 91-040-33184001 E-mail: Mahesh.Nerurkar@intergraph.com or Circle ReadersÊ Service Card 7

Robust Temperature Sensors for the Injection Moulding Process In order to fulfill the ever-increasing requirements in the injection molding process PRIAMUS offers a new line of heavy-duty cavity temperature sensors, which can also be used at mould temperatures up to 320ĈC. The proved and tested PRIAMUS systems for the monitoring and control of the injection moulding process can therefore also be applied for demanding processes without difficulty.

Side Channel Blowers & Vacuum Pumps In the chambers, set in the periphery of the impeller, air is accelerated due to centrifugal force created as the impeller turns and is thrown into the next chamber and is again similarly accelerated thus increasing compression until it reaches the outlet port.

For details contact: Vacunair Engg Co Pvt Ltd Nr Gujarat Bottling, Rakhial, Ahmedabad, Gujarat 380 023 Tel: 079-22910771, Fax: 91-079-22910770 | E-mail: info@vacunair.com

This involves processes in the field of thermoset, elastomer and liquid silicone processing as well as the moulding of technical plastics in the area of thermoplastics. Heavy-duty sensors dispose of robust connecting cables which were designed for the use in a rough and industrial environment and can be ordered with a hardened sensor front for use with abrasive media. As another new development PRIAMUS introduces a melt temperature sensor for employment in the machine nozzle or in the hotrunner manifold. This sensor has been designed for the temperature measurement of plastic melts under high pressure.

Hot Water Generator

For details contact: PRIAMUS System Technologies AG Rheinweg 4, CH-8200 Schaffhausen, Switzerland Tel: +41 (0)52 632 2626 / 2605, Fax: +41 (0)52 632 2627 E-mail: m.trebbe@priamus.com

For details contact: Aero Therm Systems Pvt Ltd Plot No: 1517, Phase III, GIDC, Vatva, Ahmedabad 382 445 Tel: 079-25890158, Telefax: 91-079-25834987 E-mail: contact@aerothermsystems.com

or Circle ReadersÊ Service Card 8

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or Circle ReadersÊ Service Card 9

Aero Therm offers custom-built units for higher temp and heat output ratings with fully automatic oil/gas burners. Fuel consumption based on NCV of 10,200 kcal per kg for LDO; 9,650 kcal per kg for RO and 8,400 kcal per m3 for natural gas.

or Circle ReadersÊ Service Card 10

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CEW Events

INDIA

INTERNATIONAL

ChemTECH World Expo 2015

World Shale Gas Conference & Exhibition

Dates: 28-31 January 2015 Venue: Bombay Convention and Exhibition Centre, Goregaon, Mumbai Details: World meet of chemicals, petrochemicals, pharmaceuticals and process industry in India Organiser: Jasubhai Media Pvt Ltd Contact: +91 22 4037 3636 Email: sales@jasubhai.com Website: www.chemtech-online.com

Dates: 4-7 November 2013 Venue: Houston, United States of America Details: The World Shale Oil & Gas Summit and Exhibition is the largest international event for the shale oil and gas industry Organiser: The CWC Group Limited Contact: +44 20 7978 0000; +44 20 7978 0080 Email: info@thecwcgroup.com Website: www.world-shale.com

World PetroCoal Congress

SCM Chem USA

Dates: 15-17 February 2014 Venue: Convention Centre-NDCC, New Delhi, Details: World PetroCoal Congress discusses about the sustainable usage of the nonrenewable resources like coal, petroleum and natural gases Organiser: Energy and Environment Foundation Contact: +91 11 24538318; +91 11 22758149 Email: punit.nagi@ee-foundation.org Website: www.worldpetrocoal.com

Dates: 4-6 November 2013 Venue: Wigwam Resort and Spa, Phoenix, Arizona, USA Details: SCM Chem USA gives an insight into the emerging business opportunities of the chemical sector Organiser: Worldwide Business Research Contact: +1 888 482 6012; +1 646 200 7461 Email: info@wbresearch.com Website: www.wbresearch.com

Everything About Water Expo

Clean Coal Forum Indonesia 2013

Dates: 9 - 11 January 2014 Venue: NSIC Exhibition Complex, New Delhi Details: An event for water & wastewater industry Organiser: EA Water Private Limited Contact: +91 11 4310 0568/4310 0500 Email: enquiry@eawater.com Website: www.eawater.com

Dates: 4-5 December 2013 Venue: Jakarta, Indonesia Details: AsiaĂ&#x160;s premier coal event Organiser: China Decision Makers Consultancy (CDMC) Contact: +86 21 6840 7633 Email: ccfi@cdmc.org.cn Website: www.cdmc.org.cn

Industrial Green Chemistry World

Chemexpo Africa

Dates: 6-8 December 2013 Venue: : Renaissance Mumbai Convention Centre Hotel, Mumbai Details: One of the largest Industrial meet on green chemistry & engineering Organiser: Newreka Green Synth Technologies Pvt Ltd Contact: +91 22 2879 1835; +91 22 2879 1275 Email: krishna.dave@newreka.co.in Website: www.newreka.co.in

Dates: 6-7 November 2013 Venue: Sandton Convention Centre, Johannesburg, SA Details: The large scale chemical related product and service sectors will be offered an outstanding international coverage in Chemexpo Africa Organiser: Quartz Chemicals Ltd Contact: +91 99 204 74017; +27 12 640 4600 Email: kerryleemccarthy@quartzltd.com Website: www.chemspecevents.com

Petrotech

WaterChem China + TECH

Dates: 12-15 January 2014 Venue: Greater Noida, India Details: Petrotech features among the most comprehensive oil, petroleum and natural gas sector trade fairs in India Organiser: PETROTECH-2014 Secretariat (ONGC) Contact: +91 11 2331 2607; +91 11 2330 1169/ 1170 Email: exhibition@petrotech.in; secretariat@petrotech.in Website: www.petrotech.in 84 â&#x20AC;˘ October 2013

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Dates: 12-14 November 2013 Venue: Shanghai World Expo Theme Pavilion, Shanghai, China Details: A key event for entering china chemical market Organiser: China National Chemical Information Centre Contact: +86 10 6441 7706; +86 10 6441 6187 Email: likediwmj@163.com Website: www.chinaexhibition.com Chemical Engineering World

28-10-2013 19:39:08


INTERFFA FACE TEECHNO OLOGY

REMOTE R I/O O

FIELDBU S TEECHNOLOG GY Y T

www.turck.com

Point to Point! Point to Bus!

Chemical Engineering World

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Bus to Bus!

Asset Management Enabled

Turck India Automation Pvt Ltd, A-603/604, ICC Trade Towers, 6th Floor, Senapati Bapat Road, Pune 411 016, Maharashtra – India. Tel : (+91) 20 25630039/40, Fax: (+91) 20 25630040 Email: India@turck.com

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CEW Project Update

New Contracts/Expansions/Revamps The following list is a brief insight into the latest new projects by various companies in India. Ć CHEMICALS Ascent Pharma is planning a synthetic organic chemical manufacturing project in village Veraval, district Rajkot, Gujarat. As of September 2013, the capacity of the proposed unit is yet to be finalized. The project is waiting for environmental clearance. Work on the project is expected to commence in Q1 2014. Vasudha Pharma Chem Limited is planning a 1-(2-Phenylethyl) piperidin-4-one chemical manufacturing project in Parawada, district Visakhapatnam, Andhra Pradesh. As of September 2013, the project is waiting for Government approval. 1-(2-Phenylethyl) piperidin-4-one is used as an intermediate in the manufacture of chemicals and pharmaceutical drugs. This is a new product line in the existing plant. The company also plans to produce Amitriptyline HCl in the same unit in future. Resil Chemicals Private Limited is planning a specialty chemical manufacturing project in Malur, district Kolar, Karnataka. As of July 2013, land has been partially acquired, project is in conceptual stage and other details are yet to be finalized. Macro Polymers Private Limited is planning a 15,000 TPM synthetic resin manufacturing project at a cost of ` 250 million in village Chacharwadi, district Ahmedabad, Gujarat. Land acquisition is in progress. The project is waiting for clearances and is planned for completion on 1 st April, 2014. Hindusthan Chemicals Company, formerly known as Cyanides & Chemicals Company is planning an expansion of its sodium cyanide manufacturing project from 5,400 TPA to 12,000 TPA in Olpad, district Surat, Gujarat. As of May 2013, the project is waiting for environmental clearance. Work on the project will commence in 2014 and is planned for completion in 2016. Ardex Endura (India) Private Limited, belonging to the Ardex Group, is planning a tile-fixing adhesive, flooring, water proofing and allied products manufacturing project at a cost of ` 100 million in Aerotropolis, Asansol, district Bardhaman, West Bengal. As of March 2013, the project is in planning stage and planned for completion in Q4 of 2014. The estimated land area is 3 acres. KPR Fertilisers, belonging to the KPR Group, plans to manufacture dimethyl sulphate (50 TPD), linear alkyl benzene sulphuric acid (40 TPD), alum (ferric/non-ferric) (50 TPD) and chlorosulphonic acid (50 TPD) at a cost of ` 200 million in village Biccavolu, district East Godavari, Andhra Pradesh. As of October 2012, work on the project commenced in January 2013 and is planned for completion in December 2013. The unit currently manufactures 500 TPD single super phosphate, 800 TPD NPK mixtures, 30 TPD di-calcium phosphates and 300 TPD sulphuric acid and has a 3 MW co-generation power project. 86 • October 2013

new Project Update 66-67.indd 86

Ć MINING Sri Venkatesh Granites is planning a colour granite mining project in Kamanpur, district Karimnagar, Andhra Pradesh. As of December 2012, environmental clearance has been received. The project will come up on 4.56 hectares of leased area. Global Enviro Labs is the environmental consultant. Western Coalfields is planning the Pengang (3 MTPA and peak capacity is 4.5 MTPA) open cast coal mining project in village Wirur, district Chandrapur, Maharashtra on 781 hectare land. As of November 2012, the project has been submitted in the 59 th EAC (Thermal & Coal Mining Projects) meeting held on 6 th November, 2012. Central Coal Fields is planning the 0.3 MTPA Ray Bachra underground coal mining project in district Ramgarh, Jharkhand on 1,215.45 hectare land As of September 2012, the project has been submitted in the 57 th EAC (Thermal & Coal Mining Projects) meeting held on 17 th September, 2012. Rajasthan Rajya Vidyut Utpadan Nigam is planning the open cast Parsa East and Kanta Basan (10 MTPA) coal mining project and a (10 MPTA) coal washery in Udaipur, district Surguja, Chhattisgarh. As of August 2012, the project has been submitted in the 55 th meeting of the EAC (Thermal & Coal Mining Projects) held on 28 th August 2012. Odisha Power Generation Corporation is planning the Manoharpur open cast coal mining project in district Sundergarh, Odisha. As of July 2012, the company is waiting for environmental clearance. Chhattisgarh Mineral Development Corporation is planning Sondiha open cast and underground coal mining project in district Surguja, Chhattisgarh. As of July 2012, the company is waiting for environmental and forest clearance. Zain Coke & Energy India is planning 150,000 TPA metallurgical coke manufacturing project at a cost of `450 million to ` 500 million in Chickanthapura, district Bellary, Karnataka. As of May 2012, the project is waiting for revenue and statutory clearance and is planned for completion in 10 months from zero date. Calcom Cement India, belonging to the BK Group, is implementing the New Umrangshu limestone mining project in village New Umrangshu, district Dima Hasao, Assam. As of April 2012, the mining work commenced this year. Jaiprakash Associates is planning limestone mining project in village Kothar, district Satna, Madhya Pradesh. As of March 2012, the project is waiting for environmental clearance and the project completion date is yet to be finalized. Chemical Engineering World

28-10-2013 19:36:09


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CEW Project Update

Ć NON-CONVENTIONAL ENERGY Arunodaya Techsolar Power Projects Private Limited, an SPV of BM Solar Systems LLP, is planning a 5 MW solar independent power project in village Kudluru, district Anantapur, Andhra Pradesh. Work on the project is expected to commence in November 2013. 26 acres of land has been acquired. DPR is yet to be prepared. Approval has been received from the Central Power Distribution Company of Andhra Pradesh. Favorich Sugars, belonging to the Favorich Group is planning a 15 MW bagasse-based co-generation power project in Krishnarajpet, district Mandya, Karnataka. As of January 2013, the company is waiting for land approval from Karnataka Industrial Areas Development Board. The project is waiting for financial closure and is planned for completion in 18 months from zero date. The State Government has allotted 250 acres of land for the sugar project, distillery and mega Food Park. Vishwanath Sugar & Steel Industries is planning to expand from 39 MW to 64 MW its bagasse-based co-generation power project in Bellad Bagewadi, district Belgaum, Karnataka. As of October 2012, environmental clearance has been received and the project is planned for completion in 18 months from zero date. The project is coming up in the existing plant premises. The project is waiting for State Pollution Control Board clearance. Green Planet Energy Private Limited is planning a 11 MW biomass-based IPP in village Bir Pind, district Jalandhar, Punjab. As of July 2012, 30 acres of land for the project has been acquired. The project is awarded by Punjab Energy Development Agency on BOO basis. PPA has been signed with the Punjab State Electricity Board. Work on the project commenced in October 2012 and is planned for completion in the first quarter of 2014. Ć NON-CONVENTIONAL POWER IPL Sugars & Allied Industries, a group company of Indian Potash, is planning a 20 MW bagasse and rice husk-based IPP spread over 250 acres of land in village Motipur, district Muzaffarpur, Bihar. As of March 2012, the existing plant will be demolished and the new plant will be constructed. The project is planned for completion in 1 year from zero date. Ć THERMAL POWER Jayaswal Neco Industries Limited is planning a 50 MW waste heat recovery based independent power project (IPP) in villages Dagori, Ameri Akberi and Udgaon, district Bilaspur, Chhattisgarh. As of February 2013, public hearing for the project is over. MoU is yet to be signed with the State Government. The project is waiting for environmental clearance and is planned for completion in 20 months from zero date. Stork Ferro & Mineral Industries, belonging to the Stork Group, is planning a 100 MW captive power project in India. As of December 2012, the project is in a conceptual stage. 88 • October 2013

new Project Update 66-67.indd 88

Amrut Sugar & Distillery is planning a 18 MW bagasse-based co-generation power project at a cost of ` 2,000 million inclusive of the sugar project in district Jalgaon, Maharashtra. As of October 2012, 120 acres of land has been acquired. Work on the project commenced in January 2013 and is planned for completion in October 2014. Maharashtra State Power Generation Company is planning a 2ï660 MW coal-based thermal power project near Manora, at Tiroda, district Gondia, Maharashtra. As of September 2012, preliminary activity for land acquisition is in progress. SKS Power Generation (Madhya Pradesh), group company of SKS Ispat And Power, is planning a 2ï660 MW super c r i t i c a l c o a l - b a s e d t h e r m a l p ow e r p r o j e c t i n v i l l a g e s Rahiwada and Amarwada, distr ict Chhindwara, Madhya Pradesh. As of August 2012, the project is waiting for environmental clearance and is planned for completion in 1 year from zero date. Rajuri Steels is implementing a 30 MW coal-based captive power project in Mul MIDC, district Chandrapur, Maharashtra. As of June 2012, the civil work was in progress. The project is scheduled for completion in Q1 of 2014. Jharkhand Sales Agencies is planning a waste heat recovery based thermal power project in village Marhand, district Hazaribagh, Jharkhand. As of April 2012, the project is in planning stage. Ć POWER GENERATION Sintex Power, belonging to the Sintex Group, is planning a 1,720 MW (1ï400 MW gas-based and 2ï660 MW coal-based) power project in village Lunsapur, district Amreli, Gujarat. As of June 2013, the project is waiting for the Government approval and is planned for completion in 1 year from zero date. The estimated land area is 600 acres. The main plant will come up on 350 acre land, 175 acres land will be for ash pond and 65 acres land will be for onsite utilities. 10 acres of land will be required for staff colony. Another 50 acres of land will be required for laying 16 km long water pipeline corridor. The coal required for the plant will be 5.6 MTPA and will be imported from Indonesia and South Africa. 1.65 MMSCD natural gas will be supplied by GSPCL. Heidelberg Cement India Limited is planning a 12.15 MW waste heat recovery-based power project at a cost of ` 1,450-` 1,500 million in Narsingarh, district Damoh, Madhya Pradesh. As of February 2013, the project is in planning stage and planned for completion in January 2015. The project has been approved by the Board. The plant will produce approximately 12.15 MW of power from available waste heat of pyro-processing system of all three clinkerisation lines at Narsingarh. Chemical Engineering World

28-10-2013 19:37:51


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Chemical Engineering World

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October 2013 â&#x20AC;˘ 89

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CEW Ad Index Sr No

Client’s Name

Page No

Sr No

Client’s Name

Page No

1

Anzeige Fiber (LIST AG)

61

28

Kevin Enterprises Pvt Ltd

45

2

Arctic Sales (Bry-Dry)

81

29

Khosla Profil Pvt Ltd

79

3

Atomic Vacuum Company (Exports) Inside Cover I

30

Kirloskar Brothers Ltd

4

Bartec India Pvt Ltd

55

31

KSB Pumps

29

5

Bhavya Polymers

85

32

Kwality Process Equipments

47

6

BHS-Sonthofen (India) Pvt Ltd

91

33

Outokumpu India Pvt Ltd

35

7

Boeger Pumps

31

34

PPI Pumps

79

8

Chempro Technovation Pvt Ltd

98

35

R K Dutt Concerns

89

9

Chemtech World Expo 2015

71

36

Raj Process Equipments & Systems Pvt Ltd

19

10

China Decision Makers Consultancy (CDMC)

73

37

RG TexIn Manufacturing Company Pvt Ltd

87

11

D V Polymers

25

38

Sachin Industries

53

12

De Dietrich Process Systems India Pvt Ltd

21

39

Samarth Engineers

89

13

Dip-Flon Engineering & Co

9

40

Seal Excel (India) Pvt Ltd

83

14

Dupont Chemicals

5

41

Shree Ganesh Process Equipments Pvt Ltd

13

15

Emjay Engineers

51

42

Sintex Industries Ltd

83

16

Everest Blowers

69

43

Suraj Ltd

89

17

Evergreen Technolgies Pvt Ltd

59

44

Swagelok

17

18

Faab Industries

57

45

Swam Penumatics Pvt Ltd

65

19

Fenix Process Technologies Pvt Ltd

33

46

Tecnimont ICB

49

20

Forbes Marshall

27

47

Transflow Asia

87

21

Gea Process

Back Cover

48

Tranter India

39

22

Goodie International Pvt Ltd

67

49

Turck India Automation

85

23

Heat Transfer Research Inc

Inside Cover I

50

Ultra Drytech Engineering Projects Pvt Ltd

81

24

Hitech Applicator

11

51

Uni Klinger Ltd

63

25

HRS Process Systems Ltd

7

52

UNP Polyvalves

37

26

IIT Corporation

Front Cover

53

Vacunair Engineering Co Pvt Ltd/Aerotherm

87

27

Integraph Consulting Pvt Ltd

15

54

Warade Automation Solutions Pvt Ltd

41

90 • October 2013

AD Index 68.indd 90

Inside Cover II

Chemical Engineering World

30-10-2013 15:04:27


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28-10-2013 22:07:42


Interview CEW

FOCUS:GUJARAT

GPCB: Zero Tolerance towards Pollution

A home to a number of domestic and international chemical companies, Gujarat has so far been leading the growth of the chemical and petrochemical industry in India. Chemical industry generates a lot of waste and thus causes a great threat to the environment, says Dr K U Mistry, Chairman, Gujarat Pollution Control Board (GPCB). In an exlusive interview with CEW, he further explains how, over the years, the ever-increasing number of chemical units in Gujarat has significantly increased the responsibility of GPCB to check the hazardous wastes coming out of these units, and more.

Chemical Engineering World

October 2013 â&#x20AC;˘ 95


CEW Interview

R

ecently GPCB has issued closure notices to couple of units in the state for not following the environmental norms. When asked why such companies are reluctant to follow these norms, Mistry informs that some of these companies just do not want to spend money required for following the compliances. They give least priority to waste treatment and save the money needed for electricity, fuels, treatment of waste, plant, machinery, chemicals etc. the chairman further adds that difficulty of area or space required for treatment plants in small plots of industrial estates, non-availability of treatment technology or methods for certain type of effluents and weak or poor implementation by industries are some of the major reasons for their unwillingness to follow the environmental norms.

Increased Number of Closure Notices Detail

2009-10 2010-11 2011-12

Closure directions u/s 31-A of the Air Act 1981 126

210

271

547

Closure directions u/s 33-A of the water Act – 1974 293

604

555

1168

Closure directions u/s 5 of the EPA, 1986

29

43

65

65

Notices u/s 31-A of the Air Act-1981

826

475

368

648

Notices u/s 33-A of the water Act-1974

878

600

654

706

Notice of direction u/s 5 of the EPA, 1986

21

30

33

66

production options along with CTE and CCA; we have implemented bar-code system to seal sample containers for the secrecy of result and tamperproof procedure; and we have installed CCTV cameras, on-line continuous monitoring equipment and better and useful online environmental computer system (XGN) to monitor black smoke, certain water and air parameters; and to ensure fast processing of many aspects, respectively” he adds.

“They cannot take the law for granted, even if they find it unaffordable to incorporate proper waste treatment mechanism,” Mistry clarifies. There is a ‘need to protect the environment’ and to ensure this the board makes several efforts to educate the companies by organising different seminars and workshops along with frequent visits of industrial areas. “Further, we have a proper procedure of written inspection, where remarks to comply with suggested control measures are mentioned; we have opened environmental clinic for group compliance or specific pollution problem; we seek suggestions of cleaner

2012-13

The responsibilities of the board have certainly increased over the years. And, to cope up with increasing work, new 12 offices were started at different places in Gujarat during last three years with a view to make it easy to dispose all work within a shorter distance. New regulations and rules under the MSW (Municipal Solid Waste) and BMW (Bio Medical Waste) have established. The state has witnessed an increase in STPs and solid waste collection & treatment sites, health care units

and BMW treatment sites. Mistry says that as there are plenty of chemical units in Gujarat, pollution problem and its control measures are certainly major issues. GPCB has concentrated to solve this problem with high technical skill. More and more engineering controls are suggested to industries, written remarks are given at the time of inspection, environmental clinic and help desk approaches have been started, action plans are devised to solve cluster problems, training for ETP and APCM operators conducted in all industrial estates, issuing of suggestions of cleaner production options started and general implementation is made strict. Edited excerpts from the interview: Over years many small scale chemical companies have emerged in the state. How does the board monitor or/and regulate small scale industries? Because of GIDC infrastructure and promotion of small scale industries, several small and

GPCB’s Initiatives during Last Three Years Year

Industrial Units Plastic STPs* CETPs# Units

TSDF**

C a p t i v e C a p t i v e CBMWTF@ Incinerators MEE

Co-Processable waste MT/A

2010-11 19468

24

51

25

8

39

-

13

22343.83

2011-12 21908

99

72

28

8

78

95

13

41572.78

2012-13 22131

150

76

29

8

83

118

14

108291

Table 1: Workload of Gujarat Pollution Control Board (GPCB) has increased over the years: * Sewage Treatment Plant , # Common Effluent Treatment Plan ,**Common Hazardous Waste Treatment Stabilization & Disposal Facility. ,@Common Bio Medical Waste Treatment Facility

Year

CTE* Granted

CCA** Granted

Plastic Registration

MSW @Authorization

BMW# Authorization Complaints

2010-11

1773

851

24

50

1703

1025

2011-12

2451

899

99

65

1605

1593

2012-13

3171

2301

150

72

4157

1199

Table 2: Similarly, some figures of work disposal have also increased: *Consent to Establish ,**Consolidated Consent and Authorisation application ,#Bio Medical Waste, @ Municipal Solid Waste

96 • October 2013

Chemical Engineering World


Interview CEW Performance of CETPs in the State Parameter

COD

Year

(In mg/L)

2010

Parameter

SPM

Year

(In mg/L)

311.56

2010

135.0

140.60

46.0

66.50

BOD

NH3N

1257.15

317.15

567.12

2011

729.30

178.50

2012

551.30

2013(upto August 2013)

386.50

Table 3: Annual average analysis data of W/W samples collected from the final outlet of FETP Ankleshwar:

medium level chemical companies have come up in Gujarat. Such small units were ignoring guidelines in past but now, due to current strict policy of GPCB, this tendency has decreased and SMEs have also started to comply with the norms. Does the board follow different approach when it comes to deal with chemical companies, which by nature are believed to be generate hazardous wastes? Board`s approach towards chemical industries is stricter than its approach towards non-chemical industries, simply due to more pollution potential and noncompliance status of such industries. GPCB understand this fact and hence devised different mechanism to check on polluting chemical companies. The board ensure to execute compulsory inspection of all such industries at least once in a year; seek written inspection remarks by local officers and further directions by HO officers; and execute frequent sampling and analysis and seek directions based on analysis reports.

SO2

Nox

PM10

180

14.13

18.74

85.49

2011

182.51

12.61

23.99

78

2012

136

11.63

23.48

74.19

Table 4: AAQM Annual Average at Vatva – Odhav S.P. Ring Road, VIA Hall, Ahmedabad:

the board has been able to reduce the toxicity and pollution levels? If CETPs had not been established in the state, it would have been not possible to run thousands of small scale chemical industries. Therefore, concept of CEPTs has been successful in our state. Majority of industries run their plants as per norms. Results of CETP are spoiled only due to a few offenders discharging illegally. We deal with them strictly. CETPs have also made great efforts to improve their performance during last three years and their outlet results are improved as shown in the tables on previous page. The stastatics in tables clearly indicates that major water and air pollutants level is reduced. Now due to insistence of online monitoring equipment and applicability of newly improved technology, CETPs performance will further improve. What should be an ideal way to ensure companies respect the norms – strict actions against the wrongdoer or proper education? Both the ways are necessary to deal with wrongdoer i.e. strict action as well as proper education. All wrongdoers do not change thier habbit by mere education, supervision or training.

increased as shown in table 1. Impact of closer directions shows improvement in performance. Industries now think that non-compliance becomes costlier than compliance and therefore hundreds of such industries have invested huge amount in waste treatment infrastructure in their plants. Will you like to give any message to the chemical companies mushrooming in Gujarat? We cannot afford to harm the environment and it is instructed that chemical companies give top priority to environment protection activities. Quick compliance of all environmental laws and guidelines must be followed without fail and all directions, conditions and instructions from GPCB in the form of EC, CTE, CCA, authorization/registration, inspection etc, must be implemented to the tee.

Will you please share some statistics as to how many companies have received closure notice in this year - 2013 so far? As a part of strict action to control pollution, closure directions have

We advise people to construct and run effectively appropriate ETPs & APCMs; implement action plans and undertaking necessary for them; segregate process streams and to run their plants as per treatability reports; submit all reports as required by law and GPCB regularly; reduce water consumption and to reuse treated waste water as far as possible; adopt and implement principle of 3-R (reduce, reuse and recover) and wasteless processing; and implement principles of green chemistry and cleaner production options as far as possible.

Impact of closer directions shows improvement in performance. Industries now think that non-compliance becomes costlier than compliance and therefore hundreds of such industries have invested huge amount in waste treatment infrastructure in their plants.

GPCB appreciate the efforts of the companies who are concerned about the environment and have already supporting the cause.

We have also set up environmental clinic and help desk (Kiosk) to solve their difficulties during treatment process. GPCB encourage companies to join CETPs and TSDFs, and facilitate meeting with common incinerator facilities and co-processing cement mills for streamlining their treatment of hazardous and non-hazardous wastes. How successful the ‘establishing CETPs’ has been in the state? To what extent

Chemical Engineering World

October 2013 • 97


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Chemical Engineering World

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Chemical Engineering World

Final Ad template.indd 99

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Back Cover.indd 31

+-,3 11 2

  



28-10-2013 17:29:41

CEW October 2013