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Chemical & Process World 

July 2013


Editorial

Policy imperative for propelling growth

Editorial Advisory Board Dr Kishore Shah

Chairman and Managing Director, Sauradip Chemical Industries Pvt Ltd

Dr P D Samudra

Executive Director - Sales and Member of the Board, Uhde India Pvt Ltd

Pratik Kadakia

Principal, Roland Berger Strategy Consultants Pvt Ltd

Ravi Kapoor

Indian chemicals and petrochemicals industry head into clear horizons of profitable prospects. has been one of the prime contributors to While the answer would entail successfully the national economy since decades. With an leveraging the high-growth domestic market annual turnover exceeding $ 100 billion and in an increasingly competitive scenario, nearly 70,000 units in the country, this sector the time has come for Indian chemical is estimated to account for nearly one-eighth companies to put in practice indigenous of India’s industrial production and one-sixth strategies befitting their growth objectives and areas of operation(s). of the country’s manufactured goods export. In these circumstances, the government’s Of late, some of the megatrends visible plan to introduce a new chemical policy soon in this industry include the following. While is a welcome step. According to top official the domestic market still has several highgrowth opportunities in store, there has been sources in the Department of Chemicals and Petrochemicals, the policy is a surge in the intensity of The time has come for intended to provide a push competitive headwinds both Indian chemical companies to the chemical sector. It is from imports as well as global to put in practice indigenous reported to cover all aspects majors foraying into India by of the industry including strategies befitting their having their manufacturing imports, exports, patents, footprint here. These are growth objectives and R&D, innovations as well as accompanied by an incessant areas of operation(s) basic and specialty chemicals, focus on lowering costs and knowledge-intensive technologies, etc. increasing throughput by deploying various Hopefully, this new policy will act as means & measures. Amid this fast-emerging global paradigm, a catalyst to drive the growth of Indian the Indian chemical sector seems to be losing chemical industry at 11 per cent pa as against steam and descending from its earlier peaks the current rate of about 5 per cent. In this process, one can be optimistic of seeing the as far as growth is concerned. The present level of growth witnessed over the recent times country’s production levels return to the order of above ` 3 lakh crore. is nowhere close to the earlier highs of 15 Suffice to say, this should give rise to new per cent per annum (pa). Not surprisingly, the entrepreneurs in this space as well as formulate sector’s contribution to GDP has come down a comprehensive roadmap for the country to 1.9 per cent from 2-3 per cent earlier. The big question facing the industry today with short-term and long-term strategic is how it can steer clear of this rising storm and perspectives in tow.

Managing Director, Heubach Colour Pvt Ltd, and Chairman – Gujarat Chapter, Indian Chemical Council

Sunil Chaudhari

Country Manager - South Asia, AspenTech India

Manas R Bastia manas@network18publishing.com

July 2013 | Chemical & Process World | 7


Contents Cover Story........................................................................................................

R&D in specialty chemicals: Evaluating the promising prospects

22

Recent investments in applications and research labs by both domestic and overseas specialty chemicals companies in India clearly indicate the enormous potential the Indian market offers to this sector. It is time to take the plunge to make the most out of the emerging opportunities.

In Conversation With

20

“We need to prove that we are responsible stakeholders” Shrikant Kulkarni

Cover photo: Joshua Navalkar; Location courtesy: MicroChem Silliker Pvt Ltd, Mahape (Navi Mumbai)

Country Manager - Specialty Chemicals, Akzo Nobel India

Editorial....................................................... 7

Policy imperative for propelling growth

News, Views & Analysis................................ 12

User-industry Monitor................................... 50 Textile industry: Adding new colours to dyes and pigments sector

Technology Transfer............................... 18

Automation Trends....................................... 52 IT in logistics: Facilitating smooth and seamless transportation

Tenders..................................................... 65

Sustainability Mantras.................................. 54 Bio-refining: Combining profitability with environmental benefits

Technology & Innovation................................ 16 Projects.................................................... 64 Event List.................................................. 66

Policies & Regulations.................................. 56 Chemical clusters: Yet to make a difference!

Products............................................. 72

Strategy.................................................... 58 Management degree: Is it a necessity in chemical sector?

Book Review............................................... 71

List of Products..................................... 82 List of Advertisers.................................. 83

Tips & Tricks.............................................. 60 Personal protective equipment: Practical guidelines for right selection

Event Report l l

Engineering Expo Hyderabad 2013: Invoking the ‘Andhrapreneurial spirit’ for Industrial Leap............... 68 Engineering Expo Hyderabad 2013 - Panel Discussion: Is Hyderabad ready for the industrial leap?............... 70

8 | Chemical & Process World | July 2013


Contents Facility Visit.......................................................................................................

Kirloskar Brothers Ltd: Pumping in process efficiency for high productivity

27

36

39

Special Focus

Supply Chain Management for Chemicals Chemical SCM ....................................28 Global megatrends bolstering logistics strategies

Reducing carbon footprint .....................30 Leaving a green mark on supply chain

Insight & Outlook Petrochemicals

Petrochemicals...................................40 Plastics fuelling high demand

Chemical manufacturers........................32 Strategic moves to attain supply chain efficiency

Supply chain dynamics..........................33 On the transformation mode

Petrochemical processing......................42 Inherent safety approach for a safer tomorrow

P Vijayaraghavan, former Site President in the Dahej (Bharuch) and Baroda units, Reliance Industries Ltd

Detergent market.................................44

Roundtable........................................34

Surfactants adding to the bubbly prospects

How important is logistics efficiency to the Indian chemical industry?

Gas analysers.....................................46

Piyush Agrawal, former VP (Corporate Affairs), Advance Surfactant India Ltd

Effective tool to monitor air quality

61

R&D.................................................48 Triggering innovation for better returns

Dr Mosongo Moukwa, Vice President - Technology, Asian Paints Ltd

Highlights of Next Edition

Trade exposition on chemical & process industry

Special Focus: Safety, Health & Environment Insight & Outlook: Bulk/Base Chemicals

Details on : page no. 62-63, 66

Note: ` stands for Indian rupee, $ stands for US dollar and ÂŁ stands for UK pound, unless mentioned otherwise

July 2013 | Chemical & Process World | 9


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July 2013 | Chemical & Process World | 11


News, Views & Analysis

Process Equipment

Uhde India certified BS OHSAS 18001 and ISO 14001

Uhde India has been certified under BS OHSAS 18001:2007 and ISO 14001:2004. The certifications – which were carried out by TUV India, the certification agency functioning aegis of TUV Nord of Germany – are valid up to June 2016. The BS OHSAS 18001 certification certifies that Uhde India has in place an Occupational Health & Safety System. The ISO 14001 certification certifies Uhde India‘s Environmental Management S y stem.

Technip awarded services contract for a new petrochemical plant in China Technip was awarded a services contract by BP Zhuhai Chemical Company Ltd, a joint venture between BP and Zhuhai Port Co Ltd, for the execution of a new world-scale Purified Terephthalic Acid (PTA) plant at their Zhuhai site in the Guangdong Province, China.

Lux Research predicts key semiconductors for solar inverters Lux Research has predicted that wide bandgap semiconductors – specifically, silicon carbide (SiC) and gallium nitride (GaN) – will lead the charge as the market for solar inverter discrete devices grows to $1.4 billion in 2020, driven by the downstream demand for solar modules.

Sachin Industries inaugurates manufacturing unit for glass-lined reactors

Sachin Industries inaugurates its second unit

The Ahmedabad-based Sachin Industries Ltd, manufacturer of filtration equipment, has inaugurated its second unit in Mehsana district of Gujarat. The new plant will manufacture glass-lined reactors under the brand name SILGLAS. The facility is spread over one lakh square metre and the production capacity, at present, is 60 reactors per month.

Speaking about the new venture, Sachin K Patel, Managing Director, Sachin Industries Ltd, said, “After rigorous R&D, we decided to enter into the field of glass-lined reactors. The main reason for entering into this segment was to fulfil the demand-supply gap as there are only few companies manufacturing this product.

This had been leading to other problems such as late deliveries. Thus, through this initiative, we would be able to help our customers in terms of timely deliveries. The facility was inaugurated by Shankerbhai R Patel, Senior VicePresident, Gujarat Chamber of Commerce & Industries, who was the Chief Guest for the event. The Guests of Honour included Satish Wagh, Chairman, CHEMEXIL and Umakant Bijapur, General ManagerNorth Gujarat Zone, Bank of Baroda. Avani Jain

LEATHER CENTRE

Clariant opens new Leather Excellence Centre in Chennai Clariant, a world leader in specialty chemicals, has opened a Leather Excellence Centre in Ranipet, Chennai. It is a major investment by the company in its leather business, and a strong indication that the company’s Leather Business Unit sees huge opportunities for continued growth in the Indian leather manufacturing sector. “We are committed to the long-term development of our products and services for India’s leather sector. We see the country’s leather-related businesses growing, and we expect an above average growth for our products and services. We are looking for double-digit growth of the business in India,” stated Oliver Kinkel, Head-Global Leather Business Unit, Clariant. Clariant already has major production sites at Kanchipuram, Tamil Nadu, and at Roha, Maharashtra. Ranipet was chosen for the development of the new Leather Excellence Centre as it is perfectly positioned to enable Clariant to provide the central application laboratory and technical services for the whole country and especially across southern India. Dr Deepak Parikh, Vice Chairman & Managing Director, Clariant Chemicals (India) Ltd, said, “As one of India’s leading specialty chemicals business, we are committed to sustainable and innovative growth in India.” Mergers & Acquisitions

Oil India Ltd to acquire 49 per cent equity in Assam Petrochemicals Ltd In a strategic move, Oil India Ltd (OIL) is set to acquire 49 per cent equity in Assam Petrochemicals Ltd (APL), credited to be the first company in India to manufacture petrochemicals using natural gas as feedstock. A deal with the Assam Government, which holds majority stake in the company through Assam Industrial Development Corporation Ltd (AIDC), is likely by October 2013. The Assam Government currently holds 88.2 per cent stake in the AIDC, while

12 | Chemical & Process World | July 2013

domestic institutions and others hold the remaining stake. The Union Governmentcontrolled OIL would bring in the much-needed equity infusion of about ` 230 crore in the company. It will also partly fund ` 1,030-crore investment in building a new petrochemical plant at Namrup in Assam. OIL already has stakes in Brahmaputra Cracker and Petrochemicals Ltd (BCPL), a joint venture with GAIL India, the Assam Government, and Numaligarh Refinery Ltd.


News, Views & Analysis

Recognition

Tata Chemicals bags Unilever’s sustainability award

Tata Chemicals team felicitated with Unilever’s ‘Partner to Win’ Award for Winning Sustainability

Recognising Tata Chemicals’ effort in aiding Unilever to significantly reduce the environmental impact of laundry powders and their business association to create traceability for mined chemicals, the company was conferred with the prestigious Unilever’s ‘Partner to Win’ Award for Winning Sustainability.

The award is a testimony to the synergistic relationship between Tata Chemicals and Unilever, which drives consistent sustainable growth and responsible care. R Mukundan, Managing Director, Tata Chemicals, stated, “At Tata Chemicals, our corporate philosophy is deeply rooted in the principles of sustainability, which implies a commitment to environmental stewardship while adding economic value. Our partnership with Unilever further endorses this and to get an award for the same is gratifying and enabling. We thank the team at Unilever for encouraging best practice initiatives across various fields of business and look forward to our continued association.”

REFRIGERANTS

Honeywell develops solutions to aid modern retail industry

Invensys acquires SmartGlance software

Invensys, a focussed supplier of industrial software, systems and control equipment to the world’s major industries, has acquired the SmartGlance mobile reporting product of Sarla Analytics, LLC, a part of the Sarla Group of software companies, headquartered in Barrington. Sarla Analytics’ mission is to leverage the power of enterprise mobility to increase productivity, reduce costs and streamline operations.

Clariant invests in India

Honeywell recently released its new range of refrigerants in air-conditioning applications. The Indian modern retail industry will hugely benefit from this launch. “For modern retail industry, Honeywell has commercialised and successfully launched Performax LT, which can replace R404A and R22 in modern supermarkets for commercial refrigeration applications. Honeywell has worked with leading supermarkets in Europe and USA to replace R404 and R22 with Honeywell Performax LT and these supermarkets have benefitted from lower carbon footprint (in terms of lower Global Warming Potential of the refrigerant) and also increased energy savings, as Honeywell Performax LT has demonstrated lower energy consumption Vs R404A that is currently used,” said Paul Sanders, Managing Director, Honeywell Fluorine Products in Europe, Middle East, Africa and India.

Clariant Chemicals (India) Ltd (CCIL) recently announced an investment of ` 38 crore in its pigments business at its Roha site, Maharashtra. The investments also include the construction of a new pigment plant at Roha that will double the plant’s capacity.

EPC contract

Atlas Copco introduces 3 ranges of nitrogen and oxygen generators

Mahua Roy

Libra Techcon Ltd receives contracts from India and Saudi Arabia Libra Techcon Ltd (LTL), the Mumbai-based EPC company, announced that it was recently selected by Godavari Biorefineries and Gulf Stabilizers Industries (GSI) as its Detailed Engineering consultants for their upcoming projects. The projects were awarded in June 2013 and are likely to be completed by early next year. GSI, a joint venture company between Zamil Group Holding Company, Middle East’s

leading manufacturing company, and Chemtura Corporation, has entrusted LTL with the task of providing Detailed Engineering for their upcoming chemical expansion project. Besides, LTL has been selected as an EPCM consultant for the project of Godavari Biorefineries Siddharth Wazir, Director, Libra Techcon Ltd, said, “These orders will help us to further establish our footprint in the Indian and global market.”

Market forEcast

Kline publishes its new report ‘Specialty Biocides: Regional Market Analysis’ Considerably reshaped by pending regulations, and despite persistent Eurozone economic uncertainty, the specialty biocides market in Europe is expected to grow by 2.1 per cent over the next five years, according to Kline’s recently published report ‘Specialty Biocides: Regional Market Analysis’. While several segments in the US specialty biocides market are likely to see over 6 per cent volume CAGR, China and India, albeit growing from smaller bases, hold even greater promise. The European specialty biocides market in applications covered by Kline’s report generated an estimated Euro 569 million in revenues through 2012, with market volumes of approximately 1,12,000 tonne.

Recently, Atlas Copco introduced three ranges of nitrogen and oxygen generators for on-site gas generation. With these innovative gas generators, companies can expand their existing compressed air installation to generate their own nitrogen and oxygen. An independent supply of on-site gas can realise significant economies of scale as well as save on operational costs. The new range of on-site gas generators are designed to meet the highest purity standards and run economically for both large and small applications.

July 2013 | Chemical & Process World | 13


News, Views & Analysis

Annual general meeting

ARC releases process automation study

A new ARC global market research study reveals that the market for process InputOutput (I/O) module sales showed growth in 2012, though at slower pace than in the previous two years. In 2013, ARC expects the growth to stay at a low level, but will pick up pace in 2014 and beyond. The market for process I/O modules is mainly driven by two forces: an increasing need for intrinsically safe I/O modules and the increasing demand from the Middle East and the BRIC countries.

Linde to invest $ 200 million for ASU in Texas facility

The Linde Group will invest more than $ 200 million to build a state-of-the-art Air Separation Unit (ASU), a new gasification train and supporting equipment and facilities in La Porte, Texas. The project is scheduled to come onstream in 2015. The ASU will be the largest unit operated by Linde in the US.

WACKER appoints new distributor in Poland WACKER, the Munichbased chemical company, has reorganised its distribution network for its BELSIL brand silicone products for personal care applications in Poland. Effective July 1, 2013, the Dutch IMCD-Groupaffiliated chemical distributor IMCD Polska has replaced the previous distribution partner Brenntag Polska.

63rd AGM for DMAI held in Mumbai The 63rd Annual General Meeting of the Dyestuffs Manufacturers’ Association of India (DMAI) and the awards presentation function were recently held in Mumbai. Dr Anil Kakodkar, ExChairman Atomic Energy Commission of India was the Chief Guest. Indrajit Pal, Secretary, Department of Chemicals & Petrochemicals,

Ministry of Chemicals & Fertilisers, Government of India, was the Guest of Honour. More than 100 members of the Association, special invitees, and other dignitaries attended the meeting. Janak Mehta, President, DMAI, welcomed the members, while presenting the Annual Report for the 2012-

2013. Jitendra Patel, Hon Secretary, DMAI, highlighted the various activities of the association. Mehta, in his address, highlighted the problems faced by the colourant industry. Pal said that the colourant industry is instrumental in adding value to the final products in industries such as textile, leather etc.

NEW MILESTONE

BASF, Cargill and Novozymes achieve milestone in bio-based acrylic acid process BASF, Cargill and Novozymes announced the achievement of an important milestone in their joint development of technologies to produce acrylic acid from renewable raw materials by successfully demonstrating the production of 3-hydroxypropionic acid (3-HP) on pilot scale. The 3-HP is a renewable-based building block and one possible chemical precursor to acrylic acid. The companies also have successfully established several technologies to dehydrate 3-HP to acrylic acid at lab scale. This step in the process is critical since it is the foundation for production of acrylic acid. In August 2012, BASF, Cargill and Novozymes announced their joint agreement to develop a process for the conversion of renewable raw materials into a 100 per cent bio-based acrylic acid. “3-HP is a potential key raw material for the production of bio-based acrylic acid, which is a precursor of superabsorbent polymers. We still have a fair amount of work to do before the process is commercially ready, but this is a significant milestone, and we are confident that we can continue to the next level of scale-up for the entire process in 2014,” said Teressa Szelest, Senior Vice President, Global Hygiene Business, BASF. Acrylic acid is a high-volume chemical that feeds into a broad range of products. BASF is the world’s largest producer of acrylic acid and has substantial capabilities in its production and downstream processing. REPEAT ORDER

Praj receives repeat order for zero liquid discharge solutions

Praj, a global process engineering solutions provider, offers innovative solutions to significantly add value in water and wastewater treatment plants, bio-ethanol and brewery plants, critical process equipment & systems. The company has received its second repeat

14 | Chemical & Process World | July 2013

order for Zero Liquid Discharge (ZLD) application from the Common Effluent Treatment Plants (CETPs) based in Tirupur textile belt. The first two orders were from Veerapandi Textile CETP and the third one from Sirupooluvapatti CETP, Tirupur, Tamil Nadu. Successful operation of first ZLD system at Veerapandi CETP, Tirupur, led to the repeat order. Praj successfully commissioned a 100 kilolitre per day ZLD system based on multieffect evaporation technology at Veerapandi, Tirupur. The entire plant was designed, engineered, fabricated and erected by Praj on turnkey basis.


News, Views & Analysis

Water chemicals

Kemira Oyj to acquire 3F Chimica SpA, Italy Kemira has signed an agreement to acquire 3F Chimica SpA (3F), a privately owned company, headquartered in Sandrigo, Italy, excluding certain part of their assets in the US, for Euro 85 million. The acquisition is subject to fulfillment of certain conditions, and closing of the transaction is expected in the fourth quarter of 2013. 3F produces dry and emulsion polyacrylamide polymers and related process chemicals. Their polymer production is supported by

backward integrated key intermediates, such as bioacrylamide and cationic monomers. The acquisition includes two manufacturing sites in Italy (San Giorgio and Sandrigo) and one manufacturing site in USA (Aberdeen, Mississippi). “The acquisition of 3F accelerates our strategic plan and secures our position as a leading global polymer producer. It also supports Kemira’s future growth by providing additional polymer capacity and by enabling

us to close technology gaps in monomer and polymer production in Europe and the US,” said Randy Owens, President-Oil & Mining and Region Head (North America), Kemira. Polymers are forecast to grow above-the-market and are highly synergistic with Kemira’s other differentiated process chemicals. Besides the strong strategic fit, the transaction is expected to result in substantial synergies through raw material, logistics and fixed cost savings.

EPC CONTRACT

Aker Solutions delivers Åsgard template to Statoil Aker Solutions has delivered the steel frame for the world’s first subsea gas compression facility to be installed at the Statoil-operated Åsgard field. The installation, set to come onstream in 2015, will enable the recovery of an additional 280 million barrels of oil equivalents. The 1,800-tonne steel frame will be installed on the Åsgard field seabed to form the base of the world’s first subsea gas compression facility. It is the largest template manufactured by Aker Solutions, measuring 74 metre in length, 45 metre in width, and 26 metre in height. “The Åsgard project is a game changer for the entire industry. The technology has the potential to change offshore gas field developments worldwide and I am pleased that we have delivered this part of the project on schedule,” said Per HaraldKongelf, Regional President, Aker Solutions, Norway. Reservoir pressure at gas-producing fields drops over time, reducing output. Gas compressors are used to raise the pressure and extend the life of a field. Such compressors have typically been installed on platforms over sea level. CONFERENCE

Honeywell recognises performance achievements of Asia-Pacific Channel Partners Honeywell has concluded a three-day AsiaPacific Channel Conference to recognise the contribution of its partners to its regional process solutions business. More than 100 business partners from India, China, Korea and Southeast Asia attended the annual conference, which focussed on the importance of mutual growth and success for Honeywell and its partner community. The conference featured sessions on new initiatives, best practices and channel

management programmes for 2013. Awards were presented in four categories: Regional Partner of the Year 2012, APAC Line-ofBusiness (LOB) Partner of the Year 2012, APAC Emerging Partner of the Year 2012 and APAC Channel of the Year 2012. The winners were chosen on the basis of their overall business achievement in 2012, customer service track-record and compliance with various commercial, legal and contractual commitments while dealing with Honeywell.

ThyssenKrupp Uhde and Bayer launch new technology

A new technology from ThyssenKrupp and Bayer, which was commercially launched worldwide, enables the production of chlorine with significantly less electricity. Its widespread use would enable economically significant savings of energy. The new Oxygen Depolarised Cathode (ODC) technology is used for the electrolysis of table salt, by which means 95 per cent of all chlorine is produced.

Clariant launches ingredients for homecare products

Clariant, one of the global leaders in specialty chemicals, launched TexCare SRA 300 F – an innovative soil release polymer for powder detergents that removes stains and helps keep fabrics clean and white. According to the company, the product matches consumers’ preference for convenience from their laundry experience.

Technip awarded contract for a new calcination unit in Abu Dhabi Technip has been awarded a significant contract comprising technology, engineering services and supply of core equipment for Abu Dhabi Oil Refining Company – Takreer’s new coke calcination unit. This new unit is part of the Carbon Black & Delayed Coker project being implemented adjacent to Takreer’s existing Ruwais refinery located in the UAE.

July 2013 | Chemical & Process World | 15


Technology & Innovation

New enzyme technology increases ethanol yield from corn Novozymes has launched a new enzyme technology that can increase ethanol yield from corn by up to 5 per cent. The technology also increases corn oil extraction by 13 per cent, while saving 8 per cent energy. The efficiency improvements can be achieved when two new enzymes, Spirizyme Achieve and Olexa, are used together with another Novozymes enzyme, Avantec. “These new enzyme innovations offer strong benefits to ethanol producers. It allows our customers to make more from less and substantially improve their profit margins,” said Andrew Fordyce, Executive Vice President-Business Operations, Novozymes. A typical US ethanol plant uses around 36 million bushels (9,00,000 tonne) of feed-grade corn per year to produce 100 million gallons of fuel ethanol; 3,00,000 tonne of animal feed (DDGS); and 8,500 tonne of corn oil. By using Avantec, Olexa and Spirizyme Achieve, such a plant can save up to 1.8 million bushels (45,000 tonne) of corn while maintaining the same ethanol output, increasing corn oil extraction, and generating up to $ 5 million in additional profit. Corn is the key raw material in biofuel production in the US, and by far, the biggest cost component for an ethanol plant. After the corn is harvested, the kernels are ground into corn meal and water added to make a mash. Enzymes convert the starch in the mash to sugar, which can then be fermented to ethanol.

AMETEK’s next-gen combustion analyser improves process and safety functions

AMETEK Process Instruments, a leader in online analytical instrumentation, has introduced the next-generation in closecoupled extractive combustion analysers with the launch of the Thermox WDG-V combustion analyser for measuring oxygen, combustibles and methane levels in hot, wet flue gas. The WDG-V analyser provides a reliable and cost-effective solution for monitoring combustion, reducing excess oxygen, lowering emissions of NOx, CO and CO2 and improving operating

efficiency. The reliable detection of low-combustion oxygen or high or low combustibles (CO) in a fired heater or boiler is critical to the effectiveness of burner management systems. “We believe the WDG-V is the combustion analyser of the future. The role of combustion analysers in control and safety functions is evolving rapidly. Maximising fuel efficiency, while reducing emissions from combustion processes, requires utilising aggressive operating set points that dictate the need for additional layers of safety for risk reduction,” said Mike Fuller, Vice PresidentMarketing and Business Development, AMETEK Process Instruments & Analytical Instruments. WDG-V combustion analyser provides a layer of control and safety to a basic process control system, while significantly reducing the risk of an uncontrolled combustion event.

16 | Chemical & Process World | July 2013

Oven Industries, Inc, offers a wide variety of temperature sensor probes, right from thermistors and thermocouples, to resistance thermometers. By providing accuracy and ensuring that the high-quality sensor probes are easily integrated with other PID temperature controller systems, Oven Industries, Inc is leading the way with temperature sensors.

New varieties of temperature sensors from Oven Industries ensure accuracy Oven Industries website provides a useful ‘Temperature Sensor Selection Guide’, which can help with selection of the correct sensor probe for the right project. The guide shows the tolerance level, model number, temperature range and key details about the five sensors that the company offers. With a wide range of applications and versatility for temperature sensors, the company stands ahead of the competition. These sensors have a tolerance of up to ±0.1°C. As a full-service temperature control solution provider, the company also has a complete selection of other temperature control products. Capable of meeting every industry requirement, each sensor available can be customised. Highly skilled experts at Oven Industries offer help to business owners for building the optimum electronic control solution device for a wide range of needs and purposes.


Technology Transfer

Technology Offered As part of our endeavour to spread the technology culture, this section provides a means to promote and facilitate exchange of select technologies. We strive to bring together suppliers of such technologies with suitable users for negotiations and industrial collaboration. Activated carbon

Phosphate esters

An Iranian firm is willing to offer activated carbon from coconut shells.

An Indian firm is offering technology for manufacturing phosphate esters like tributyl phosphate.

Areas of application

Food processing, pharmaceuticals, etc

Forms of transfer

Technology licensing

Areas of application

Specialty chemicals

Forms of transfer Joint venture

Ethanol An Iranian company is offering ethanol from molasses using the fermentation of sacharomyces cerevisiae.

Areas of application

Chemical and energy industries

Forms of transfer

Technology licensing

An Iranian company is willing to manufacture sodium hydrosulfite using chemical compounds. It is widely used as a stripping agent in dyes and chemical industries.

Areas of application

Furfuryl alcohol technology An Indian firm offers technology for producing furfuryl alcohol from furfural by liquid hydrogenation as well as vapour hydrogenation, with a capacity of 6,000 tpa to 24,000 tpa.

Areas of application

Furan polymers, sealants & cements, urea-formaldehyde, and phenolic resins & foundry cores

Forms of transfer

Consultancy, technical technology licensing

Sodium hydrosulfite

services,

Chemical industry

Forms of transfer

Technology licensing

Sodium silicate recovery from rice husk ash An Indian firm is offering technology to recover sodium silicate from rice husk ash. The technology claims to offer better ROI than other processing methods.

Areas of application

Chemical industry

Forms of transfer

Consultancy, technical services, turnkey, etc

Precipitated calcium carbonate

Sodium sulfide

An Indian consulting company for the chemicals, minerals & food processing industries is offering precipitated calcium carbonate and turnkey projects for the same.

An Iranian firm is willing to offer sodium sulfide, which is used mainly in textile industry, paper mill, artificial silk and curriery.

Areas of application

Plastics, paper, paints, rubber, inks

Forms of transfer

Areas of application

Leather industry, textiles, curriery industries, paper mills, etc

Forms of transfer

Consultancy, technical services

18 | Chemical & Process World | July 2013

Turnkey

Synthesis routes for organic chemicals An Indian firm is offering consultancy in design of synthesis routes for organic chemicals.

Areas of application

Pharma industry, specialty chemicals, plant protection chemicals, etc

Forms of transfer Consultancy

Transformer oil unit An Indian company is willing to offer consultancy for making a transformer oil unit with domestic coal from its waste.

Areas of application Transformers

Forms of transfer Consultancy, technical services

Zinc phosphatiser/rust converter (Ferphos) An Indian firm offers technology to produce Ferphos – a unique chemical formulation that acts as a zinc phosphatiser cum rust converter. Ferphos is an innovation and improvement over existing phosphating products/technologies practised around the world. Ferphos solution does not die, ie even after prolonged use, and does not require daily addition of chemicals and hence it results in zero effluence. Ferphos solution also acts as a rust converter when brushed on rusted iron products. It is an ideal substitute for sane/ shot blasting.

Areas of application

All iron and steel products including aluminium, SS, GI products

Forms of transfer

Technology licensing


Technology Transfer

Technology Requested Activated carbon and sodium silicate A company from Thailand requires technology for manufacturing activated carbon and sodium silicate from rice husk & rice husk ash.

Areas of application

Manufacturing and construction industry

Forms of transfer Others

Glyoxal An Indian company is looking to switch the production technique for manufacturing 40 per cent glyoxal from its existing acetaldehyde-based method to the MEG-based glyoxal production.

Areas of application Pharma & textile

Forms of transfer Others

Inorganic chemicals An Indian company is interested in seeking the technology and process know-how for production of potassium nitrate, chromium acetate, and magnesium hydroxide suspension. The company already produces inorganic chemicals and wants to add several other items.

Areas of application

Chemical industry

Forms of transfer Others

Lime

Silica gel

An Indian company seeks to adopt new cost-effective technologies, which can reduce carbon emissions and earn carbon credits, for manufacturing lime.

An Indian firm is looking for new technology for manufacturing silica gel in which the wastewater discharge is minimum.

Areas of application

Quick lime and hydrated lime

Areas of application

For various industries and most importantly breweries

Forms of transfer Others

Forms of transfer Others

Phenolic and phenol formaldehyde resin An Indian company needs the technical know-how for producing phenolic and phenol formaldehyde resins.

Areas of application

Foundry, rubber adhesives, rockwool, abrasives, plywood, etc

Forms of transfer

Small-scale environmentfriendly chemical technology An Indian company is looking out for an economically viable smallscale environment-friendly chemical technology useful in the textile sector as well as in pharmaceutical sector.

Areas of application

Others

Textile and pharmaceutical industry

Forms of transfer

Quaternary ammonium chloride

Others

An Indonesia-based company is planning to diversify into manufacturing of quaternary ammonium chloride. It is seeking technology along with the supply of critical plant and machinery for the manufacture of the chemical 3-chloro-2hydroxypropyl trimethyl ammonium chloride that is produced from epichhlorohydrin.

Areas of application

Chemical industry

Solvent dyes An Indian company has recently installed a manufacturing capacity of 2,400 mtpa and is looking to diversify its product range by including various solvent dyes in its product portfolio. The company is seeking process consultancy for this project.

Areas of application

Plastics, petroleum, solvents, etc

Forms of transfer

Forms of transfer

Technical know-how, consultancy

Others

Information courtesy: Dr Krishnan S Raghavan, In-Charge, Technology Transfer Services Group, Asian and Pacific Centre for Transfer of Technology (APCTT) of United Nations Economic and Social Commission for Asia and the Pacific (UNESCAP), APCTT Building, C-2, Qutab Institutional Area, New Delhi - 110 016, Tel: 011-3097 3758 (Direct), 3097 3710 (Board), Fax: 011-2685 6274, E-mail: srinivasaraghavan@un.org, Web: www.apctt.org, For more information on technology offers and requests, please log on to www.technology4sme.net and register with your contact details. This is a free of cost platform provided by APCTT for facilitating interaction between buyers and seekers of technologies across the globe. After submitting technology offer or request to this website, you are requested to wait for at least two weeks for receiving a response from a prospective buyer/seeker through this website, before contacting APCTT for further assistance.

Share and Solicit Technology

The mission of Chemical & Process World is to spread the technology culture. Here is an opportunity to be a part of this endeavour by sending your technology on offer or technology requirements. If you belong to any of these two categories, you are invited to furnish the techno-commercial details for publication. The write-up needs to be as per the format of this section with information about the particular technology offered or requested, its areas of application and forms of transfer. Contact us: Chemical & Process World, Network18 Media & Investments Ltd, ‘A’ Wing, Ruby House, J K Sawant Marg, Dadar (W), Mumbai 400 028 Tel: 022-3024 5000, 3003 4672, Fax: 022-3003 4499, Email: chemedit@network18publishing.com

July 2013 | Chemical & Process World | 19


Photo courtesy: Akzo Nobel India

In Conversation With | Shrikant Kulkarni

We need to prove that we are responsible stakeholders ‌says Shrikant Kulkarni, Country Manager - Specialty Chemicals, Akzo Nobel India. In an interaction with Mahua Roy, he outlines the role of the chemical industry in promoting a responsible image and discusses the megatrends affecting this sector. What are your top priorities for the business of AkzoNobel in India? At AkzoNobel, we continue to be a reliable and preferred partner for our customers, working with them on value-additions and providing technical solutions wherever possible. In addition, safety and sustainability are important pillars of our strategy and we have adopted these as

part of our key best practices. Globally, AkzoNobel is a leader in sustainability, having been ranked first within the chemicals super-sector on the prestigious Dow Jones Sustainability Index (DJSI) 2012. We focus on the following areas of sustainability: Environmental impact by way of reduction in CO2; reduction in fresh H2O consumption; and community welfare. All our efforts are focussed on

20 | Chemical & Process World | July 2013

creating value for customers, employees, shareholders and other stakeholders.

Can sustainability and productivity go hand in hand? Sustainability and high performance is the combination that ideally serves today’s consumer demands, and the one that the chemical industry is actively seeking to achieve. Traditionally, however,


Shrikant Kulkarni

Up close and personal 

the two have been thought of as mutually exclusive. Latest developments show that being green and providing superior performance are not mutually exclusive. Intelligently designed and innovative products based on renewable resources can match, and in many cases, exceed the performance of the current market standards, resulting in attractive offerings. Within the broad framework of sustainable development, the government, academia and industry strive to maximise resource efficiency via conservation of energy and non-renewable resources, risk minimisation, pollution prevention, reduction of waste at all stages of the product lifecycle, and the development of products that are durable, reusable as well as recyclable. Therefore, given that sustainable chemistry involves the design, manufacture and use of efficient, effective, safe and environmentally sound chemical products & processes, it will be apt to say that all sustainability-related research in this industry is about sustainable chemistry.

work with reputed companies, which can offer complete solutions along with wide and high-performance product portfolio, superior technical service and safety support.

Which are the consumer trends you plan to tap?

Which are your star products in the Indian market?

The Indian chemical industry has emerged as one of the fastest growing industries in the country. This is mostly due to the increase in consumption of value-added products that use specialty chemicals. We see an all-round growth in the construction, retail and packaging segments that will boost the demand for specialty plastics. This is good news for many of our businesses like polymer and performance additives, organic peroxides, etc. Lifestyle products are becoming more popular and our range of ingredients for personal care products will benefit from this trend. Agro industry too is increasingly adopting best practices to improve yields. Many of our businesses such as ethylene amines, sulphur derivatives, surfactants, chelates and micronutrients find an important role in this segment. The quality standards across sectors have enhanced manifold and customers are looking to

We have a leading position in many product segments namely, organic peroxides, metal alkyls, performance additives, personal care ingredients, asphalt emulsions, paper chemicals, etc. Our R&D supports the introduction of new products that offer technical superiority in respective product applications.

Last motivational book you read...

I enjoy reading books on business management and spirituality. I am currently reading ‘Who Am I’ by Ramana Maharishi. The book helps me find purpose and internal peace.

Your all-time favourite movie...

‘Lagaan’ – for its emphasis on qualities of focus, determination, teamwork and leadership.

Your inspiration, every single day... Variety and challenges of life.

One business etiquette you always follow...

Punctuality – an individual must always be prepared to add value in any given situation.

The biggest strength, according to you, of the Indian chemical industry... Huge domestic demand and availability of skilled talent in the industry.

What are your views on the outlook for the specialty chemicals industry in India? The chemical industry forms as essential part of the economic development of the country, contributing to the growth of the manufacturing and agriculture sectors. With a shift in demand for chemicals across sectors, India is expected to emerge as a key sourcing market for chemical companies the world over. The chemical industry is gearing up to build an economy of scale that would cater to

both, the domestic demand as well as export opportunities. Along with that, several government initiatives to promote Special Economic Zones (SEZs) and Petroleum, Chemicals & Petrochemicals Investment Regions (PCPIRs) will boost investments by both local companies and MNCs looking to expand their presence in India. Emerging technologies and a breakthrough in untapped sectors such as fertilisers and pesticides would also prove to be a game-changer in the chemical sector.

What do you think about the challenges faced by the industry? The main challenge that the Indian chemical industry faces as of now is the need to address the issue of ‘Return on Investment’ as this industry is highly capital-intensive and needs to ensure sustainable profitability as well. The chemical sector has to make an extra effort to convince the society and address environmental concerns. We need to prove that we are responsible stakeholders. Another challenge is to continuously invest in R&D to upgrade technology, drive product introduction and stay ahead. Email: mahua.roy@network18publishing.com

July 2013 | Chemical & Process World | 21


Cover Story | R&D in specialty chemicals

Photo: Joshua Navalkar; Location courtesy: MicroChem Silliker Pvt Ltd, Mahape (Navi Mumbai)

Prasenjit Chakraborty

Recent investments in applications and research labs by both domestic and overseas specialty chemicals companies in India clearly indicate the enormous potential the Indian market offers to this sector. It is time to take the plunge to make the most out of the emerging opportunities.

CAGR of over 22 per cent. This clearly indicates that India is the flavour of the season,” he says. Although the major geographies accounting for specialty chemicals continue to be Europe and the US, Asia is the only region where sales grew 10 per cent, while the EU region and the US slipped by 12.5 per cent and 6 per cent, respectively during 2010-11. “Earlier, China was ahead of India. Now, India has surged ahead with its growth in the specialty chemicals sector,” points out Herlekar. India has slowly become a significant player in the international chemical market, with many companies intent on sourcing from here, which is amplified by another emerging trend – growing equity participation by multinationals in their Indian arms. As India’s edge in specialty chemicals is more visible, mergers and acquisitions (M&A) activity is likely to grow. And it is not just multinationals who are ramping up their sourcing plans from India, even home-grown firms are creating new capacity, increasing productivity and going in for acquisitions. Success in the niche specialty chemicals segment, unlike commodity chemicals, is governed by the ability to invent new, value-added molecules and invest in research and development (R&D) of new products. Also, with the erosion of margins and the shrinkage of markets for many of the niche chemicals, largely because of increased environmental awareness, the companies are solely banking on innovation as a vital tool to stay ahead of the curve.

In spite of strong global headwinds, He strongly believes that the sector the demand for specialty chemicals has is expected to grow at a CAGR of 15 continued to surge upwards. Evolving per cent – almost twofold growth of the megatrends are driving growth in this global industry. “Similarly, exports are also dynamic sector, which produces a poised to grow from $ 4 billion in 2007 Investment in R&D multitude of products used to enhance to $ 13.5 billion by 2014, representing a Competition in the specialty performance across widePravin S Herlekar segment is not on price or raw ranging industries globally. Chairman & Managing Director, materials front but on product According to Pravin S Herlekar, Omkar Speciality Chemicals Ltd technology and innovation fronts. Chairman & Managing Many companies in the Indian Director, Omkar Speciality We keep getting enquiries for the specialty chemicals industry have Chemicals Ltd (OSCL), development of next-generation decided to leverage the lower the specialty chemicals titans drugs and their intermediates on R&D costs in India, as compared of the West have set their eyes a regular basis. The R&D facility to Europe and the US, to on the Indian specialty mainly caters to these requirements. undertake intensive research for chemicals industry for its developing value-added products. colossal growth potential.

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R&D in specialty chemicals

Craig A Rogerson According to The Indian India it is about ` 120-125 crore. Chairman, President & CEO, Chemical Council (ICC), the The need for differentiated Chemtura Corporation specialty chemicals segment is products is boosting demand expected to grow at a rate of for pearl lustre effect pigments. The Indian market is important to us, 11-12 per cent in 2013. The Another specialty chemicals as is the broader Asia-Pacific, which growth rate will be maintained & materials company, is one of the fast-growing regions over the next 3-4 years. Also, Momentive Performance in the world. Our R&D expenditures the demand for specialty Materials Holdings LLC reached $ 44 million in 2012. chemicals is strongly hinged ( M om e n t i ve ) , re c e n t l y on the demand from the endopened Global Research and use industries. As they grow, Development Centre and OSCL’s client base includes all major the demand for specialty chemicals will business headquarters in Bengaluru domestic and global pharma MNCs. also rise. “I see growth opportunities in through its subsidiaries, Momentive “We keep getting enquiries for the almost every end-use sector as MNCs Performance Materials Inc and development of next-generation drugs plan to expand their manufacturing base Momentive Speciality Chemicals Inc. and their intermediates on a regular in India,” observes Herlekar. The Global Research and Development basis. The R&D facility mainly caters Centre is catering to the needs of India, Growth drivers to these requirements,” says Herlekar. Middle East and Africa (IMEA) region. There are several factors contributing Additionally, OSCL has targeted specific The new facility is located on a two-acre to the growth of the specialty chemicals areas for development of new technologies plot in Bengaluru and will initially house industry in India, and the country is for certain specialty chemicals. Apart around 100 associates. the third-largest market for specialty from this, it develops products through Research scientists based at the facility chemicals in Asia. The growth in innovative green routes of synthesis, will work on new global technology India’s specialty chemicals industry will which are eco-friendly. platforms and product development for be driven not only by underlying endSimilarly, Merck KGaA made its new and existing applications in diverse market growth but also by increased usage Indian Application and Technology industry segments, including personal intensity and new product specifications Centre lab a part of its global network. care, energy, healthcare, electronics, & standards. The intensity of usage “We have eight application labs automotive and construction. In of specialty chemicals in India is at a worldwide. Our aim is to facilitate addition, as Momentive’s regional much earlier stage of development than useful exchange among the network in headquarters, the facility will house its in Western markets and China, creating order to gain synergies and promote commercial, business support, business significant scope for growth. faster benefits of products to customers,” process and information technology In order to consolidate its position says Dr Matthias Lergenmüller, Senior functions. The Bengaluru facility will in the market, OSCL has invested Director - Business Field Cosmetics, be a key addition to Momentive’s global about ` 3 crore in setting up a Merck KGaA. Besides India, Merck network of research and development state-of-the-art R&D centre at Unit has application and technology centre centres located in strategic regions to III–B-34, MIDC, Badlapur (near in China, Thailand, and Japan in Asia. drive innovation for customers. “This Mumbai) which is recognised by The Indian centre, which is located at new Global Research Centre and regional the Department of Scientific and Nerul (Navi Mumbai), enables Merck headquarters represent an important step Industrial Research (DSIR), under the to offer customised application and in our continuing investment in India Ministry of Science and Technology, technology solutions to its customers in and demonstrates our commitment Government of India. The R&D centre fields ranging from drug discovery to to customers in the region and all is equipped to carry out an array of automobile and decorative paints. The over the world,” says John Dandolph, reactions with various unit operations lab is focussing on India-specific projects President, Silicones and Quartz Division, and processes. The R&D activities and also undertakes projects from other Momentive Performance Materials Inc. contribute towards: countries as well. He adds, “India’s world-class  Increase in sales of newly developed According to Dr Lergenmüller, technical talent, growing demand for new molecules Merck is the market leader in pearl applications enabled by our products, and  Development of intellectual properties lustre effect pigments with about 55 per strong growth opportunities combine to  Cost reduction cent marketshare globally. Pearl effect make this an excellent location to fuel  Quality enhancement pigments market is estimated to be about and support our growth plans.” All these  Trouble shooting Euro 600-650 million globally, while in clearly indicate the importance of India. July 2013 | Chemical & Process World | 23


R&D in specialty chemicals

Significance of Indian market As India emerges as potential market for specialty chemicals, MNCs have started focussing on its potential. Take the example of Chemtura, which is optimistic about the Indian market. Craig A Rogerson, Chairman, President & CEO, Chemtura Corporation, says, “The Indian market is important to us, as is the broader Asia-Pacific, which is one of the fast-growing regions in the world. Chemtura recently acquired the bromine assets in India of Solaris ChemTech, which provides our Great Lakes Solutions business with a cost-competitive bromine source closest to our growing customer base.” For Chemtura as a whole, this acquisition represents increased presence in this fastgrowing region and growth in our target industry segments of electronics, energy and agriculture. According to Dr Joerg Strassburger, Country Representative & Managing Director, LANXESS India Pvt Ltd, innovation will demarcate the long-term players from the small businesses and will also determine the growth of the industry. “As a reaction to economic slowdown, companies would usually cut costs; but the more effective way of looking at it would be to improve operational and process-related efficiencies in an organisation,” he says. It is also important to understand the future needs of the customer and tap the right products for the right market – this could be achieved by application-oriented innovation. High innovative capability is vital for OSCL as a leader in niche specialty chemicals industry. “We have combined different concepts for innovation, including ongoing development of products, processes and applications. We constantly evaluate long-term market trends to help derive new areas of growth for OSCL. Our R&D experts work closely with the marketing and the sales team. Therefore, our innovations

Dr Joerg Strassburger

Country Representative & Managing Director, LANXESS India Pvt Ltd

As a reaction to economic slowdown, companies would usually cut costs; but the more effective way of looking at it would be to improve operational and process-related efficiencies. are closely aligned to the needs of our customers, enabling us to enhance our competitiveness through new and improved products & applications,” points out Herlekar.

Innovation is key In a typical industry environment, innovation is the key for healthy growth. However, global recession forced most of the companies to embrace aggressive innovation to survive and to charter a growth strategy for sustainability. “While there is a tendency to reduce R&D spending during recession, some companies have focussed on driving innovation to find solutions. Companies have innovated not only in product development, but also in terms of strategy and approach,” observes Chemicals, Materials & Foods Practice team, Frost & Sullivan. Take the example of Chemtura Corporation – the company significantly increased its spending on R&D. “Our R&D expenditures reached $ 44 million in 2012; an increase of 16 per cent when compared with 2011,” reveals Rogerson. No wonder, BASF is implementing its global ‘We create chemistry’ strategy in Asia-Pacific with a set of ambitious targets and a focus on sustainability. Around 25 per cent of BASF’s global R&D will be conducted in Asia-Pacific by 2020, to develop innovative solutions that address the region’s challenges of resource efficiency, food and nutrition, and quality of life. “In the next decade, Asia-Pacific will face huge challenges while remaining the fastest growing market for the chemical industry. With

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our Asia-Pacific strategy, we are positioning BASF as the leading provider of sustainable solutions for the Asia-Pacific region,” says Dr Martin Brudermüller, Vice Chairman - Board of Executive Directors, BASF SE, responsible for Asia-Pacific.

Looking ahead into the future

Due to recession, some of the major companies, especially in North America and EU, started carving themselves out from commodities to specialties. The companies started positioning themselves from scale and commodity operators to specialty and services operators. This kind of paradigm shift was essential for survival as most of the commodity companies have shifted their production base to low-cost regions such as East and Middle East Asia. India is certainly going to benefit from this as it offers volume in every segment. However, the prospects of Indian chemical industry, to a large extent, depend on the government policies. “Government has a substantial role to play in facilitating the growth of the Indian chemical industry. The long-term growth will depend on the effectiveness of government policies. Unfortunately, the present policies and regulations are not investor-friendly, when it comes to both local and foreign companies. Increasing burden in terms of taxes, rise in gas prices, high logistics and infrastructure costs and non-uniform compliance to environmental regulations are some factors, which are making India unattractive for investments,” observes Strassburger. Infrastructure development for chemicals parks, PCPIRs have a long way to go, which means that the companies have to invest more with regard to compliance and sustainability requirements. Government support is quintessential on all these fronts; else the economic crisis may turn out to be a long haul for the industry. Email: prasenjit.chakraborty@network18publishing.com


An invite to share with the industry Dear Reader, ‘Chemical & Process World’ solicits original, well-written, application-oriented, unpublished articles that reflect your valuable experience and expertise in the chemical process industry (CPI). You can send us Technical Articles, Case Studies and Product Write-ups. The length of the article should not exceed 1500 words, while that of a product write-up should not exceed 100 words. The articles should preferably reach us in soft copy (either E-mail or a CD). The text should be in MS Word format and images in 300 DPI resolution & JPG format. The final decision regarding the selection and publication of the articles shall rest solely with ‘Chemical & Process World’. Authors whose articles are published will be sent a complimentary copy of that particular edition. Brought out by Network18 Publishing, ‘Chemical & Process World’ is one of the leading monthly magazines exclusively meant for producers and user fraternities of the CPI. Well supported by a national readership of over 80,000 and our strong network of 26 branch offices across India, this magazine reaches out to key decision makers among the Indian CPI. Moreover, it offers a broader platform facilitating effective interaction among several fraternities of these industries by enabling them in reaching out to their prospective buyers & sellers through better trade contacts and more business opportunities. So take this opportunity and send your articles, product write-ups, etc… Thanking you, Sincerely,

Manas R. Bastia

Senior Editor Chemical & Process World Network18 Media & Investments Limited ‘A’ Wing, Ruby House, J K Sawant Marg, Dadar (W) Mumbai 400 028 India

D +91 22 3003 4669 T +91 22 3024 5000 F +91 22 3003 4499 E manas@network18publishing.com W www.network18publishing.com


Special Focus

Supply Chain Management for Chemicals With growing demand for chemicals worldwide, logistics form a key aspect of the chemical industry as production and consumption locations are mostly separated by hundreds of miles. This calls for efficient, competitive and sustainable logistics for the future development of industry. Taking cue from the latest trends in the logistics arena globally, chemical companies are experimenting with various strategies to synchronise their transportation assets, and exploring avenues for implementation of IT in logistics. Moreover, the Indian chemical industry is focussing more on innovations to produce environment-friendly technologies and products. All these will go a long way in aiding the chemical logistics segment to take the green route and reduce its carbon footprint.

July 2013 | Chemical & Process World | 27


Special Focus | Chemical SCM

companies are thus adapting logistics strategies subsequently. Elongation of supply chain: Global sourcing has become a key strategy adopted by most chemical companies to ensure high-quality assurance and product integrity. This has led to longer and more complex supply chains. As a result, one faces higher logistics costs and constant pressure on transport capacity. “Increasing congestion, more restrictions and continued lack of investment in logistics infrastructure have led to more congestion and reduced supply chain reliability. Increased competitive pressures for constrained logistics capacities, coupled with a broader geographic scope and increased need for risk management, are leading to challenges,� adds Ramanand Gupta, Managing Director, Revex Plasticisers Pvt Ltd. Clustering: Another important trend is the development of chemical industrial clusters in many parts of the world. This trend brings out positive infrastructural capabilities in the manufacturing zones;

Global megatrends bolstering

logistics strategies

Mahua Roy

Globalisation and consolidation in the chemical industry are leading to magnification of megatrends. Logistics is a key area, which is directly impacting margins. So how is the chemical industry managing this situation? What are the top strategies being devised globally? In a product as simple as your shampoo, you will see a host of ingredients. The sodium lauryl sulfate may have been produced in Taloja, Mumbai; while the glycol distearate may have come from Gujarat. The dimethicone and panthenol in your conditioner might have been sourced all the way from Singapore; while the cetyl alcohol would have come from Europe. All these get processed at an FMCG unit in India and then

distributed to the remotest of locations in the country. The factor connecting the seamless execution of production is logistics. While productivity and, thereby, bottom lines are majorly getting enhanced, logistics is an area that is facing a huge impact.

Megatrends affecting logistics The chemical industry is witnessing the following megatrends globally, and

28 | Chemical & Process World | July 2013

however, the consumer cluster is situated quite farther from the production area. This in turn strains the logistics even more. Tapping new markets: As a result of slowdown globally, emerging markets have suddenly captured worldwide attention. “Chemical majors are heavily concentrating on tapping the opportunities in these regions, starting from the logistics strategies from scratch. This again opens up whole new plans of


Chemical SCM

Ramanand Gupta action for making the most in the transport cost is a big Managing Director, Revex Plasticisers Pvt Ltd these key geographies,” explains challenge. However, effective Siddharth Paradkar, Principal – and sustainable management Logistics & SCM, TSMG. of logistics not only provides Increasing congestion, more Sustainability and enormous opportunities for restrictions and continued lack of safety: “Apart from delivering future development of products, investment in logistics infrastructure on-schedule and promising but also helps in keeping a tab have led to more congestion and efficiency, another key on the cost involved,” says Seth. reduced supply chain reliability. responsibility for the logistics Best practices across sector is concentrating on safety, the industry concentrate on security and sustainability of the realigning the strategies to transit operations. In fact, it is the most expected to offer some relief to the logistics manage skyrocketing logistics costs. important consideration today when costs worldwide. Apart from this, the One of the key actions that help control going green is the buzzword across the logistics industry faces inherent problems the logistics cost includes setting up of industry. This megatrend is expected to of its own. “Among the various factors that warehouses closer to the customer base. transform the way one looks at logistics affect the transport costs in the chemicals Seth adds, “This in turn offers a synergy strategies,” observes Paradkar. sector are fluctuation in fuel rates, poor between cost optimisation and maximum quality of roads, inadequate training of capacity utilisation of the transport. Unusual demand-supply scenario transport personnel, poor maintenance of Monitoring the last mile delivery of our in the industry vehicles, multi-level local taxes and check products to the customer also helps in As an outcome of the trends enumerated posts, which hamper seamless delivery of time and resource management.” above, most chemical companies are products to the factory and economical Better management of complaining that their logistics costs delivery of products to the customers,” warehouses are outweighing the manufacturing states Suyog Seth, Production Head Another big trend in the industry costs at times. One of the most unusual – Mahad, Specialty Chemicals, Akzo globally is pertaining to the management observations is that 2009 was an incredibly Nobel India. of warehouses. All chemical companies, bad year, and the volumes for chemicals Managing the cost factor whether or not they outsource logistics went down globally. Subsequently in Ensuring prompt and economical delivery services, are gradually streamlining 2010, volumes came back suddenly due of chemical products is a challenge in operations. “Chemical manufacturers face to inventory rebalancing, but availability India. Unlike European or other Asian a lot of issues unique to their business. of logistics to support the skyrocketing countries, India has limited number of Managing a large product catalogue demand was not there. The industry cost-effective and quick alternatives. The with descriptive features and disparate quickly faced a capacity issue and pricing logistics industry is still dependent on production sites, while at the same time soared. As there was no forecasting, surface transportation. Road transport trying to improve production efficiency shippers were not ready for the demand. accounts for 70-85 per cent of domestic and respond to market demand, form Chemical transportation companies supply chain. Coastal waterway systems a set of problems that we have to face are not sure what approach to take. are still in a primitive stage, whereas their simultaneously,” says Gupta. Should they keep hiring drivers and operational cost is 50-60 per cent lesser Companies are experimenting adding assets to their fleets to keep up than road transportation. The wide Indian with various strategies to synchronise with current demand? Or should they rail network is still unable to provide their transportation assets. Rather than be cautious in case the economy sinks effective service to the industry. Such investing in a big warehouse, they are once more, dragging chemical shipments underdevelopment adds up to the cost going directly from the production line downhill yet again? However, production in a big way. However, the government’s to the rail car or tanker truck, skipping trends are improving globally with most initiative to invest in the development of the intermediate storage area. As Seth companies announcing greenfield and arterial roads connecting major parts of agrees, “Transporting chemicals directly brownfield expansion projects, thereby the country has resulted in strengthening to the customer is always advisable on spelling good news for logistics providers. of the road network each passing year, account of safety. The railway system in Optimistic growth has been forecast in and so things are improving, although the country is not geared to provide the the sectors such as plastic resins, synthetic they are still far from optimal. effectiveness and safety required to deliver rubber, man-made fibres, industrial gases, “Logistics is a key component of chemical products of volatile nature.” pharmaceuticals, consumer products and Email: mahua.roy@network18publishing.com the chemical industry. Often, reducing adhesives & other specialties. This is July 2013 | Chemical & Process World | 29


Special Focus | Reducing carbon footprint

Leaving a green mark on supply chain Rakesh Rao

To make their business sustainable, chemical manufacturers are taking several steps to reduce carbon footprint in the supply chain. While companies are banking on technologies to make their supply chain clean, they are also offering training programmes to their suppliers to make them partners in this green journey. The carbon emissions in supply chain are not handle the increasing amount of material flow and reduce only costs but also future liabilities for the the GHG emissions and consumption of resources at sustainability of any business. In the chemical the same time. The regulations around emissions industry, sustainability is often viewed as within are becoming stringent day by day; and it has the fence issue of the manufacturer; it is also become important for companies to find new a  critical differentiator for supply chain. Sanjay ways to remain compliant and cost-effective in Choudhary, Chief Technology and Sustainability order to make their business more sustainable.” Officer, Tata Chemicals Ltd, says, “In the Simplifying complexity chemical supply chain, the largest environmental Supply chain in the chemical industry is often impact is, without a doubt, from transportation. complex, and hence adequate steps need to be The reduction of carbon emissions will get to top taken to reduce carbon footprint during the transit of the agenda for distribution in view of the cost of chemicals. Complexity of chemical logistics is and consequences of disruptions due to environmental increasing with geo-shifts of production due to impacts related to climate change.” globalisation, leading to significant increase in global Supply chain and logistics affect the success of trade; and different models are evolving over the time chemical industry because they have a high share to meet the market needs with collaboration across the of cost in the bottom line and are critical for supply chain. service level and top-line; and the cost represents The chemical industry is highly regulated about  10 per cent of revenues, which is material and fragmented in a country like India, plus the to profitability. Rajendra Jog, Associate Director transportation mix is different than most other industries, - Supply Chain, Dow Chemical International Pvt with higher percentage of rail and ocean shipments Ltd, says, “Nowadays, the scale of operations in due to increasing global trade in chemicals. “Real-time chemical plants is becoming bigger. This means that tracking & tracing,  multi-echelon planning tools, cloud globally the demand is  met  from fewer plants around computing, etc are providing the world. This has obviously led Sanjay Choudhary some answers. Chemical industry to rapid increase in the amount Chief Technology and Sustainability Officer, needs to use the integrated of material flow worldwide and Tata Chemicals Ltd planning to improve logistics therefore, the volume of traffic productivity and reliability, as well.” The reduction of carbon emissions will which will help in reducing Currently, the volume of get to top of the agenda for distribution carbon footprint significantly. traffic is one of the key factors in view of the cost and consequences It is driven by  economies causing the highest amount of disruptions due to environmental of scale, making  logistics an of greenhouse gas (GHG) impacts related to climate change. essential part of the industry,” emissions. Jog says, “A big opines Choudhary. challenge for the industry is to

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Reducing carbon footprint

For the chemical industry, in chemical logistics reduces both Rajendra Jog Associate Director - Supply Chain, rail transportation is a low risks and costs.” Dow Chemical International Pvt Ltd carbon option compared to Tracking the right path road transportation, especially Tracking of performance will bring Growing complexity has led within  the country. However, the best out of any system and supply to the development of many the limited number of rail tracking and tracing technologies, carriers in any particular chain is no exception. Unnecessary which play important role in geographic area has distorted waste of energy can be avoided, if we making supply chain greener rail market. Choudhary says, track and control such wastes. and cleaner. Jog says, “Tracking “Transportation by rail is of performance will bring the often constrained and delayed best out of any system and because of priority to moving packaging, storage in warehouse and supply chain is no exception. Unnecessary food and other more important resources transportation to reverse logistics. At waste of energy can be avoided, if we track as the rail is dominated by sole national every stage, there is scope to reduce the and control such wastes. Currently, Dow rail ownership. The situation becomes GHG emission.”  Chemical International Pvt Ltd (DCIPL) more complex as chemical plants are The value chain sustainability has an internal tool, which allows GHG often located in remote places close strategy is a significant undertaking that emission to be monitored.” to raw material sources without rail can generate savings and stakeholder Chemical companies, whether or not connectivity.” confidence across the chain. For all the they outsource logistics, need to streamline partners in the  chemical supply chain, it Supplier, the critical link and integrate their operations and logistics has become increasingly important, from Global chemical manufacturers need to assets. Some of the choices to be made the business and branding perspective, work closely with their suppliers (who are either to focus on warehousing or to operate in a sustainable way. There is are spread across the world). Given this go directly from the production line growing engagement with Responsible background, ‘supplier training’ programme to the rail car or tanker truck. “For Care, which is a voluntary initiative of the is gaining importance in the chemical effective co-ordination for loading, global chemical industry for  addressing industry for green supply chain. Jog avers, unloading, and other associate operations, the safety and environmental impact  in “It is important to educate our suppliers chemical companies are turning to the supply chain, with a focus on to follow green supply chain. Suppliers Transportation Management Systems product stewardship. should be aware of the impact from the (TMS) for optimum transportation Communication of sustainability initial stage of designing the product, networks. TMS automate key elements strategies is often overlooked and  the manufacturing process, material purchase, of logistics infrastructure from  strategic supply chain partners training programme and operational perspectives, network on green supply chain will be of great layout design, execution and monitoring, value.  Each of the partners needs to invoicing, billing, and settlement etc,” provide a vital link for a sustainable value observes Choudhary. chain and share the information up and Chemical companies also use down the supply chain for sustainability Jog believes that in order to reduce carbon technologies such as RFID and GPS management. Choudhary elaborates, “This footprint, one must first identify the various for ensuring efficient shipping and is central to the new global product strategy carbon reduction opportunities that are on-time delivery as well as cutting costs. announced under Responsible Care, which available. The industry, according to him, Choudhary says, “These technologies give redefines the relationship producers can look at the following steps: real-time visibility and help to comply have with distribution and the supply  As much as possible, move the product with government regulations related to chain. This has broadened the product in bulk rather than smaller quantities safety and security concerns, and provide stewardship espoused under Responsible  Move the product in a concentrated support for insurance settlements. Other Care earlier, which focussed on risk form, as a diluted product will have key benefits include improved asset management to include risk reduction with more volume  Move the product through pipeline for management, achievement of the best the emphasis on finding safer and greener short distances wherever possible overall transportation cost, and quick options. This is where distribution and  Use of efficient vehicles with higher response to changes with agility to logistics companies play an important role. carrying capacity stay cost-competitive in view of the Reducing the distances shipments travel,  Multiple deliveries during a single global overcapacity.” the amount of handling that occurs, and shipment rather than multiple shipments Email: mahua.roy@network18publishing.com the number of people and steps involved

Carbon reduction avenues

July 2013 | Chemical & Process World | 31


Special Focus | Chemical manufacturers

Strategic moves to attain supply chain efficiency

the distinct competitive advantage of having presence in the global trade flows resulting in lower transport costs and logistic carbon emissions. Choudhary explains, “This is aligned to the imperative of a cohesive and consistent approach to sustainability stated by the Chairman of Tata Group in his message: As we look to grow in the next decade, it is important to reiterate that continuing responsible growth can only be achieved through a ‘Sustainable Tata Way’. We take a long-term approach in our strategy, and as an empowered part of society, we take our roles and responsibilities seriously while working towards shaping our shared future.”

Multi-pronged approach

Rakesh Rao

In order to achieve their sustainability goals, chemical manufacturers are leaving no stone unturned. Here are a few examples of how companies are achieving their green objectives. Tata Chemicals Ltd, one of the leading chemical companies in India, has redefined the product portfolio and LIFE (Living, Industry and Farm Essentials) chemicals, and is internalising sustainability in the strategic planning. As part of the carbon strategy, the company has set the goal of 20 per cent reduction in the carbon intensity of the products by 2020 over the 2008 baseline. “The carbon intensity also includes the carbon footprint associated with the logistics. The logistics process is carbonconscious and the company is considering the low energy and low carbon options such as the mix of rail, road and shipping as part of planning for primary and secondary transport of the products. Some of the measures such as returnable jumbo packing and bulk transport of the products are towards carbon reduction,” says Sanjay Choudhary, Chief Technology and Sustainability Officer, Tata Chemicals Ltd. Tata Chemicals has, over the years, done strategic acquisitions of soda ash production facility across the globe, which gives it

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Similarly, other companies are adopting multiple ways to reduce carbon footprint in their supply chain. Rajendra Jog, Associate Director - Supply Chain, Dow Chemical International Pvt Ltd (DCIPL) emphasises, “At DCIPL, we are serious about reducing our carbon footprint.” In keeping with Dow’s 2015 sustainability goals, some of the measures taken by the company are as follows:  Multimodal operations: Here, more than one mode of transportation is used.  In our case, we use road-rail-road where the first and the last link in the supply chain is road and majority of the movement happens through rail. This leads to lesser Greenhouse Gas (GHG) emissions as compared to direct road movements.   Bigger capacity vehicles: With infrastructure development and widened roads, many service providers have started providing higher capacity vehicles and this helps in reducing the number of deliveries.  Earlier, the deliveries used to happen in 9 MT truck load for packed cargo and, nowadays, the capacity has increased to 16 MT and, in the near future, this will increase to 21 MT. For bulk shipments, the industry has moved from 10 MT to 16 MT and, currently, 32 MT capacity vehicles are deployed  Bulk storage of products  Converting drum customers to bulk customers to help reduce the number of deliveries  Sharing best practices among business partners (transporters, warehouse service providers, etc) to minimise GHG emissions In addition, the company has initiated The Dow S4TAR Programme – a mutually beneficial initiative from the Dow Business Services Group in India to promote business growth for both DCIPL and its supply chain partners, in a sustainable manner. “The S4TAR Programme is designed to encourage sustainability excellence in DCIPL’s supply chain partners. It provides a specific framework to recognise our partners who exhibit exceptional performance. Each year, through fair and transparent quarterly and yearly evaluations (which are based on pre-set measurements that are communicated to our partners), the S4TAR awards are presented to the best carrier, best warehouse, and best freight forwarding service,” says Jog. Email: mahua.roy@network18publishing.com


Supply chain dynamics | Special Focus

As the Indian chemical industry taps opportunities in emerging markets, both domestically and internationally, and maintains a strategic sourcing plan, the logistics is getting more and more complex. In transit, chemical products are subjected to varying degrees of impact, vibration, compression and other adverse effects as well as exposure to the harmful external environment. Other crucial factors such as improper packing of the contents or poor storage may also lead to release of chemicals to the environment resulting in emergencies such as fire, explosion or even toxic release. Hence, sustainability of the desired supply chain strategy needs to be taken into account to avoid unwanted exposure to a maligned brand value.

On the Mahua Roy

to some of the gains in eco-friendly and sustainability-focussed progress that is being made in the global marketplace. Now when carbon footprint indices are available for calculation, it is only a matter of time when the trend will catch up on a global scale and become an important attribute towards purchasing decisions, especially while choosing logistics vendors in the highly competitive B2B marketplace. Since logistics is still viewed as a cost centre by most organisations, any player that commits to reducing this head, but with efficient performance, will eventually prove to be the winner. Besides, international regulations and trends will make sure that the industry is in a position to adapt to the changing marketplace. “Responsible

or ‘streamlining logistics strategies’. These concepts are slowly catching up,” says Paradkar. To effectively promote green logistics in India, the service providers must be able to communicate the value proposition that the client will derive from implementing green logistics. A detailed cost-benefit analysis can prove to be an effective tool for promoting green logistics. Today, the Indian chemical industry is focussing more on increasing innovations to produce environmentfriendly technologies and products. Not just depending on stringent regulations, there is also a huge need to educate all the stakeholders associated with the chemical and allied industries. “People associated with the industry have

transformation mode

Logistics accounts for nearly 40 per cent of the costs in the Indian chemical industry today. Given that the technology adoption towards sustainable and efficient operations has not penetrated enough, what will be the future of chemical logistics in the country? What efforts can be taken to make this a cost-efficient proposition? Also, logistics brings with it high levels of fuel consumption, which strains the economy to a large extent. While rising oil and natural gas prices increase fuel surcharges for shippers, the upward energy spiral presents a double shock to chemical manufacturers. That is because chemical companies need to pay for crude oil as a key ingredient in a wide range of products, as well as for use in the vehicles that transport their raw materials and finished products.

Mirroring global best practices As per a recent global survey by TUV SUD, it was concluded that 84 per cent of consumers was prepared to pay an average 27 per cent premium for green products and services. Consumer demand and awareness appear to be contributing

Care and REACH regulations promote discipline as exporters need extensive documentation. This will make sure that sustainability is promoted in the logistics industry,” adds Siddharth Paradkar, Principal – Logistics and SCM, TSMG.

Regulation and education There are regulations in place that are gradually warming up this sector and sensitising it towards the harmful environmental impact, thereby heavily promoting green logistics in India. “Because of these regulations, logistics service providers have taken brilliant initiatives in this regard, though currently it is at a nascent stage. But the change is a welcome one, where the logistics service providers have at least started to use terms like ‘reducing carbon footprint’,

to understand the dynamics of supply chain, only then the objectives of such regulations will be materialised. Since the majority of chemical manufacturers in India fall under the SME category, we do not expect them to change their attitude towards transportation overnight. They need to understand the impact that can be created by going green when it comes to logistics,” explains Paradkar. And this change will come soon. The global majors, who set an example about best practices, will play an influential role in trickling down the strategies in the entire industry. The transformation will be gradual, but profound. Looking at the growth of the chemical industry, the implementation process of such regulations has to be expedited. Email: mahua.roy@network18publishing.com

July 2013 | Chemical & Process World | 33


Special Focus | Roundtable

How important is logistics efficiency to the Indian chemical industry? With the Indian chemical industry actively setting up manufacturing bases in various locations, logistics is the biggest point of consideration. Mahua Roy interacts with key players in the industry to gauge the importance attributed to logistics. Dr Swapan Kumar Ghosh

Director, Nova Surface-Care Centre Pvt Ltd

Suyog Seth

Production Head – Mahad, Specialty Chemicals, Akzo Nobel India

Often, reducing the transport cost is a challenge across all industries. However, effective and sustainable management of logistics not only provides good opportunities for future development of products, but also helps keep a tab on the cost involved. We have ‘Distribution risk assessment’ procedure that is implemented to ensure safety and security during handling and distribution of chemical products. We review this procedure frequently and extract an improvement plan each time. The offsite mock drills also help increase our preparedness of handling emergencies during transit, if they arise. However, there is a definite need to bring more awareness among the highway handling crew as well as highway users.

Siddharth Paradkar

Principal (Logistics & SCM), Tata Strategic Management Group

Logistics cost in India is estimated at about 14 per cent of GDP, which is high as compared to developed countries. With the exposure to global best practices in the country, there has been a definite push towards benchmarking offerings against world-class standards and integrating the complete supply chain resulting in increased demand for third party logistics services and fuelling the growth of the industry. The logistics industry in India lags behind other countries when it comes to technology adoption and investments. However, as more international players enter into this industry in India, we may see a change in the adoption of best practices.

Logistics, as a business tool, is often underrated when it comes to strategies for regions and markets. The question in the past was: How to be part of the growth story of emerging markets. And now that this has been established by most companies, today’s big question is how to organise production and distribution. Optimum logistics management is a key strategy. With harmonised production cycles, transparent order processing and integrated logistics, one can achieve business objectives. Safety and sustainability continue to be high up on the agenda. Chemical companies need to actively assess their transport operation risks. The winners in this industry will be those that manage the increasing complexity through better process and system integration, effective partnering along the supply chain and advanced technology deployment.

Logistics is still considered to be a cost centre by the chemical industry. It has still not opened up to adopting sophisticated technologies for improving safety aspect and efficiency of transportation. However, as this industry expands, there will be more penetration of advanced technologies.

34 | Chemical & Process World | July 2013


Facility Visit | Kirloskar Brothers Ltd

The facility of KBL is located at Kirloskarvadi in Sangli district, Maharashtra. With its expertise, KBL has emerged as a pioneer in pump and pumping systems. It manufactures a wide range of pumps for a variety

with different requirements. There are four manufacturing units located in Kirloskarvadi; and one of the units involved in pump manufacturing mainly for the chemical industry is known as KPD unit.

View of KPD unit

KBL has brought in major changes in the areas of machining and testing. “We have changed in the entire layout to have uni-directional material flow and optimum space utilisation. While achieving this, we wanted to create

View of split case type pump shop – machine shop, assembly & testing

Pumping in process efficiency for high productivity Prasenjit Chakraborty

Kirloskar Brothers Ltd (KBL), a market leader in pump and pumping systems, has brought in certain changes to make its manufacturing process lean and productive. Besides, it has introduced innovative manpower training that helps the company significantly attain its productivity goals. of applications required in chemical process industry. Process industry is driven by certain standards for compliance. “KBL process pumps comply with all major standards required for this industry, eg DIN 24256, ISO 2858, API 610 (different editions) and ISO 5199. Apart from compliance to these standards, major strength lies in unique hydraulics, which takes care of low-end, mediumend and high-end process segments,” says Dattatray Vetal, Senior Vice President and Head-Corporate Manufacturing, KBL. Thus, KBL offers highly efficient pumps catering to all chemical segments

Changes initiated In its endeavour to bring in more efficiency, KBL, of late, has brought in changes in the manufacturing set-up. Its manufacturing set-up is broadly categorised by the type of manufacturing processes being followed. Some examples are as follows:  Foundry: Pouring of castings  Machine shop: Machining of critical components  Assembly: Assembly of various types of pumps  Testing: Performance testing of pumps

36 | Chemical & Process World | July 2013

world-class manufacturing facility in the pump industry,” says Vetal. While redesigning the manufacturing processes, the focus was on simplifying the processes; eliminating non-value adding activities and movements; eliminating the fatigue of the operator; switching over and accommodating the operations being performed on conventional machines to existing CNC machines and removing old conventional machines; and reducing the number of set-ups. Vetal adds, “To improve the reliability of components for leakage testing, we have introduced hydro testing of bare casing to the higher pressures.”


Kirloskar Brothers Ltd

The other areas of focus Manpower training Dattatray Vetal In any organisation, providing included: Senior Vice President and Head-Corporate Manufacturing  Innovating and designing training to the people plays a composite tools on CNC vital role in ensuring radical While developing new product, we machines to achieve closer growth. KBL offers training to geometric accuracies and its employees – both staff as well systematically follow the process multifold productivity. as workmen category. It includes of understanding customer needs.  Implementing the concept technical that is knowledgeAnd then conceptualise the right of Single Minute Exchange based, and behavioural, which product for their application. of Dyes (SMED) to its true is personality-based. Most of meaning, resulting in easy the time, external faculties are changeovers and reduced hired, who are well-known in which facilitates the company to take inventories. This has also resulted their field. Volunteer trainers are also control on all manufacturing processes in reduction in throughput time to developed within the organisation. in foundry, machine shop, assembly, facilitate faster deliveries. “We have pioneered a kind of performance testing and coupling  Multi-tasking for the operators training programme, which we have with the prime mover. “In machine to operate 2/3 work stations named as Out Bond Training (OBT). shop, we have installed different types simultaneously based on Standard This is one-of-its-kind programme and of CNC machines from renowned Work Combination Chart (SWCC). no one other than Kirloskars has tried it,” manufacturers, which are capable of says Vetal. Started way back in 2000, this delivering geometric accuracies to the Uniqueness of KPD unit training has been imparted to the entire tune of microns. We follow Kirloskar KBL, as an organisation, has group of employees, who are working in Production Systems (KPS) meticulously established competency in designing a team on common objectives/tasks. This in all our manufacturing plants, and producing world-class hydraulic unique programme has transformed their thereby exhibiting lean manufacturing,” solutions for the chemical industry overall behaviour and thought process says Vetal. and other sectors. “While developing inside and outside of the organisation. KBL is also equipped with various new product or upgrading existing OBT is a Self Soul Seeking Programme, test facilities for non-destructive testing products, we systematically follow in which the participants are isolated of the components and test beds for the process of understanding the from their workplace and home. OBT performance testing of pumps. needs and expectations of customers. programmes are designed to include the Machines installed in KPD And then conceptualise the right classroom sessions as well as some games KBL’s approach is to make optimal use product for their application. The and role plays. of CNC machines or semi-automatic process also involves design, Getting to the core machines, wherein the manual work development and testing of the same KBL is aggressively marketing its contents are very less. “This not only to fulfil the application requirements,” process pumps in chemical industry for reduces the fatigue to the operator but says Vetal. core applications. There is a separate also eliminates the subjectivity in the KBL is equipped with its own segment, which specifically focusses quality of components produced on it,” captive foundry for various special on chemical process industry. Its points out Vetal. ferrous and non-ferrous materials, wide network of dealers, distributors Machines used in KPD shop of KBL and regional & zonal offices addresses the needs of the chemical industry. Machines Quantity Used for “Today, the marketshare of KBL process Heller make horizontal machining centre 1 Casings pump is 20 per cent. Of this, core Doosan make horizontal machining centre 1 Casings chemical process pump constitutes 7.5 Hydro testing rig 1 Casings per cent. This year, 15 per cent growth KWS make C500 turning centre 3 Impellers is expected in core chemical process pump segment by way of innovative HMT make turning centre 2 Impellers product range added in the recent past,” Horizontal broaching machine 1 Impellers asserts Vetal. Dynamic balancing machine 1 Impellers Component washing machine

1

Casings and impellers

Photo: Joshua Navalkar

Email: prasenjit.chakraborty@network18publishing.com

July 2013 | Chemical & Process World | 37


Insight & Outlook

Petrochemicals The petrochemicals industry in India is one of the fastest growing verticals with growth rates of approximately 10 per cent being witnessed since 2010, which is expected to sustain till 2015. However, for this industry, the main areas that demand attention revolve around overcoming economic difficulties and energy concerns. But the good news is that the rising demand for plastics is facilitating the growth of the petrochemicals industry in India. India has inherent competitive advantage in the downstream petroleum product manufacturing. These factors indicate a bright future for the petrochemicals sector in the times to come.

July 2013 | Chemical & Process World | 39


Insight & Outlook | Petrochemicals

Prasenjit Chakraborty

The rising demand for plastics is facilitating the growth of the petrochemicals industry in India. Currently, the per capita consumption of plastics is quite low when compared with that of China. This also provides further scope for the petrochemicals industry to leverage the potential. The investment by reputed companies in this sector is an indication in this direction.

The Indian chemical industry ranks 12th in the world in terms of production volume, generating an annual revenue of over $ 30 billion. The petrochemicals industry in India is one of the fastest growing verticals with growth rates of approximately 10 per cent being witnessed since 2010, which is expected to sustain till 2015.

Plastics-infused growth Apart from basic chemicals and intermediates, petrochemicals include polymers such as Polypropylene (PP), High Density Polyethylene (HDPE), etc. According to Chemicals, Materials & Foods Practice team, Frost & Sullivan, India currently produces approximately 7.5 million metric tonne of polymer products per annum and this is estimated to increase at a CAGR of 9 per cent till 2016.

kg against China’s 46 kg and a global average of 28.9 kg, highlighting the immense potential for growth. Owing to this, many Indian companies such as GAIL, IOCL, MRPL, have started investing in petrochemical projects,” says the Frost & Sullivan team. According to Biswanath Bhattacharya, Director, KPMG in India, growth in petrochemical industry is driven by higher consumption of plastic products across various endusers. “Indian consumption of plastics is estimated to be 12.5 million tonne in 2013 and is expected to double in Courtesy: CN Moulding the next 12-15 years. GDP growth, While India exports polymers, it also higher disposable income, urbanisation imports a sizeable amount of polymers have created high demand for plastic for domestic use. Furthermore, it is products in industrial goods segments estimated that for key polymers such as like consumer durables and automobiles; HDPE, Linear Low Density Polyethylene consumer goods & services such as (LLDPE) and Polyvinylchloride (PVC), packaging, retail, technical textiles and demand is expected to outstrip supply healthcare. Higher demand for food by 2016. Demand for these polymer production necessitates more use of products is expected to be driven by plastics in agriculture,” says Bhattacharya. industrial segments such as automotive, In spite of the high growth observed in construction, white goods, packaging, consumption of plastics in India, the per etc. “As of 2012, India’s per capita capita annual consumption is still 8-10 consumption of plastics is a mere 7 kg per annum, which is much lower than the global average consumption. Biswanath Bhattacharya “This provides a significant Director, KPMG in India opportunity for growth in plastics and petrochemicals industries,” he adds. Indian consumption of plastics Indian polymer is estimated to be 12.5 consumption pattern has shown million tonne in 2013 and is a northward trend for several expected to double in the next years. Major drivers for polymer 12-15 years. use have been packaging, automotive and electronic

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Petrochemicals

Savan Godiawala appliances. “Healthcare-hygiene, petrochemical s e c t o r, Senior Director, agriculture, infrastructure and especially in terms of new Deloitte Touche Tohmatsu India Pvt Ltd construction sectors have also processing facilities and contributed to the increasing domestic gas production. Through R&D efforts and processing demand. With rise in disposable Domestic opportunities and techniques, eco-friendly polymers income, consumption of infrastructure development have been developed, which support commodity plastics such as in the sector are attracting the overall systems of environment polythene bags, food packaging investments from Indian in a balanced way. etc is rising significantly. companies as well as global Engineering plastics like polyplayers. A major initiative, inter carbonate, poly-amide etc is alia, taken by Government of relatively smaller share of total polymer posting strong growth due to technology India to give boost to petrochemical consumption. “Depending on the advancement and substituting wood sector is promotion of Petroleum, application, plastics can be made either and metal in many cases,” says Savan Chemicals and Petrochemicals by injection moulding, blow moulding Godiawala, Senior Director, Deloitte Investment Regions (PCPIRs) for or extrusion. Extrusion accounts for Touche Tohmatsu India Pvt Ltd. With planned establishment of manufacturing majority of the total capacity, injection economic development, consumption facility for domestic and export-led moulding is second in volume in terms pattern would continue to grow with production. Several billion dollars of route of processing while the rest come per capita consumption of plastics in is proposed to be invested through under blow moulding type. The share of India being lower than in China or the PCPIR route to increase petrochemical injection moulding has increased over the global average. production capacities leading to improved years at the cost of extrusion capacity,” trading of feedstock, intermediates and Downstream plastic processing says Bhattacharya. final products. As downstream plastic processing In the recent years, most capacity “Public sector companies such as industry in India is fragmented in addition has been seen in the commodity IOCL, GAIL, MRPL and private sector nature, majority of units are small-scale plastics segment following the domestic companies like Reliance Industries, in nature; hence they account for a market trend. Low level of technology in GSPC etc are investing in PCPIR. the small-scale sector is being overcome MNCs such as ExxonMobil, Itochu, with investment attracted through Shell, etc have their plans to participate MSME Act 2006, which has improved in the region. Clustering of process the average capacity per machine, units would also result in reduction of  India has inherent competitive advantage leading to increase in productivity, higher operational costs and risks associated in the downstream petroleum product manufacturing energy efficiency and competitiveness. with transportation of raw material,  The country has low unit labour costs As far as changes in downstream plastic giving competitive edge to the industry,” and the demographic potential for a processing are concerned, Godiawala points out Godiawala. large and capable skilled/managerial feels that polymers have been a subject Additionally, factors such as workforce matter of innovation for long time. increased domestic gas production  Geographically, India’s West Coast is “Through R&D efforts and processing due to gas found in KG Basin; talent strategically located directly facing the techniques, eco-friendly polymers have pool available in India for developing Persian Gulf across the Arabian Sea, been developed, which support the R&D; use of advanced technology by from where over 40 per cent of the overall systems of environment in a the players; and large-scale production world’s sea-borne crude oil originates  In addition, the Middle East’s refined balanced way. Plasticulture, term used could be instrumental in leading India as product demand is growing rapidly for plastic use in agriculture application, emerging export hub for petrochemicals.  India is also strategically placed has witnessed important technology “Integrated PCPIRs have been proposed between key global crude producers developments in downstream plastic to reap the benefits of networking and in the Middle East and the growing products such as soil fumigation films, efficiency through use of common consumption centres of East and polytunnels, greenhouses, drip tubing infrastructure and support services. Southeast Asia. etc,” he says. Master plan for PCPIRs in Kerala,  There have been policy support Andhra Pradesh, Orissa, Gujarat, recently to make India a petrochemicals An export hub for petrochemicals Tamil Nadu is underway,” concludes manufacturing hub, including an intent Over the years, India has witnessed Bhattacharya. to achieve significant exports Email: prasenjit.chakraborty@network18publishing.com significant developments in the

Advantage India

July 2013 | Chemical & Process World | 41


Insight & Outlook | Petrochemical processing

Inherent

approach for a safer tomorrow

P Vijayaraghavan

The process safety culture of an organisation determines how process risk control issues are handled. In the long-term, processes will be made inherently safer through the elimination of hazards rather than their control. As a result, the use of inherently safer process and techniques is the best approach to ensure safe operations in petrochemical industry. “The concern for man himself and his safety must always form the chief interest of all technical endeavours. Never forget this in the midst of your diagrams and equations.” This statement by Albert Einstein is more relevant in the aftermath of what went wrong at the Union Carbide’s Pesticides Unit (UCIL) at Bhopal about three decades ago whenever any talk of development and progress centres around business growth through industrialisation. Scientific discoveries and technological innovation have always been instrumental in many ways for prosperity and enhancement of quality of life. However, with each innovation, there comes a heavy price tag of safety concern. It is never too early to integrate productivity with process safety and be prepared to bring out changes and value-additions with respect to hazard identification and risk assessment, which can act as an effective means towards accident and loss prevention. The Bhopal disaster that occurred in December 1984 at UCIL plant is one of the world’s worst industrial catastrophes. Water ingress into the storage tank caused a massive chemical runaway reaction and consequent over-pressurisation/ release of methyl isocyanate vapour, heavily polluting air, water and land with casualties of over 5,000 in the vicinity, led to serious domino effects. This raises an important question as to ‘have we learnt our lesson from Bhopal?’ Are we confident that such incidents

will never ever happen? The answer could be yes and no.

Existing safety governance attributes in India Safety management has always been highly dynamic, and therefore, requires continual improvement through review/ revision/amendment on sustainable basis besides introduction of emerging ideas with reference to Process Safety Management (PSM).

Statutory provisions Basically, all industrial establishments are covered under various statutory provisions pertaining to labour safety/ welfare and health surveillance besides technical safety concerns involving hydrocarbons, pressure vessels (static/ mobile), boilers, prime movers, gas cylinders, explosive materials, hazardous wastes and a host of other activities affecting environmental quality. An effective compliance of all the above statutes can accelerate the process of safety governance. Till recent times in most organisations, safety was handled by a welfare officer along with a safety person, probably with an industrial safety diploma, an industrial hygienist and/or a joint participative safety committee. They used to concentrate mainly on prevention/reduction/control of shop injuries, which are frequent but of low severity or lesser consequential impact. The response was also limited to

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shop floor worker amenities and use of Personal Protective Equipment (PPE). This was definitely a good foundation of workplace safety and a system for process safety can be built on top of that. This makes line management more responsible with better focus on behavioural issues along with systems and procedures looking beyond regulations. As the name indicates, petrochemicals include both hydrocarbons and allied chemical units. Basically, they are the downstream of the oil and gas industry – an industry whose products are a part of our daily lives commencing with milk pouches, bottles, carpets, synthetic clothing, fertilisers, tyres, paints, pharmaceuticals, cosmetics and many other applications. This unit generally comprises different areas – processing, purification, blending, packaging, storage, transfer, loading/unloading, transportation etc, involving hazardous chemicals. The Chemical Process Safety Management (CPSM) system starts with documenting the physical and chemical properties of these chemicals and ensures that all stakeholders are aware of its properties/hazards before use.

Chemical hazards and risk assessment All activities involve hazards, and risk is a likelihood of the damage by an incident that escalated from the hazard during the activity. It is beyond human control to eliminate them but


Petrochemical processing

Major incidents in chemical industry in different parts of India effective CPSM guides that Location Year Origin of Chemical involved Number of the risk can be controlled and incident Deaths Injured Evacuated the hazard can be managed New Delhi 1985 Release Sulphuric acid 1 340 >10 to avoid any catastrophe. So, Mumbai 1988 Fire in refinery Oil 35 16 hazards involved in these Nagothane 1990 Leakage Ethane and propane 32 22 different activities are identified LPG 60 31 15000 and the risks are assessed. Visakhapatnam 1997 Refinery fire Vellore 2003 Explosion Explosives 25 3 Consequently, elaborate systems Jaipur 2010 Fire Motor spirit 13 150 and procedures are built to Hazira (Surat) 2013 Fire Motor spirit 5 None Not warranted contain these risks within acceptable levels. This exercise Identify potential change; evaluate leadership; high-performance standards is done methodically covering all areas  Developing process safety culture risk to allow the change of manufacturing such as raw material Zero tolerance for willful violations; receipt and storage; process units where Developing process safety culture reward PS performance these chemicals undergo different unit  Compliance against process safety The process safety culture of an processes & unit operations at different standards organisation is a significant determinant temperature and pressure conditions; Standard owners of how we approach process risk control product storage and loading; waste  Process safety competency issues and how we behave when no one disposal/effluent treatment units, Improving knowledge updates on is watching. Incidents are system failures etc. The chemical reactions may be PSI; apply the learning that can often be linked to such cultural exothermic in nature, which can result  Workforce competency deficiencies. It has strong systems such in any unfavourable consequences, if Confident, disciplined and as Permit to Work (PTW). No job can not controlled, for which such exercise enlightened shop floor workforce be performed without it coupled with becomes immensely beneficial. Thus, it  Understanding hazards and risks strong management Technical Authority helps to first recognise and subsequently Identify process risks and risk control Limits (TAL), etc, and provides a CARE manage the risks involved in each step measures culture – Counsel, Appreciate, Reprimand of a manufacturing cycle.  Process knowledge and management and Enforce. The hazards associated with any Catalog, protect, update and use In the long-term, the focus will be on process typically result from either the process knowledge inherent safety by way of hazard elimination fundamental chemical characteristics  Risk management rather than its control. This approach relies of the process materials (eg, toxicity, Improved procedure related and upon the intrinsic safety characteristics flammability, reactivity, exclusivity), the administrative controls of the people, process and equipment to physical conditions under which the  Operating procedures prevent injuries, environmental damage, materials are handled (eg, temperature Identify procedures required; develop, and property damage rather than on and pressure), the characteristics of the use and maintain procedures control systems, interlocks, or procedures process equipment, or a combination of  Safe work practices that prevent, stop or mitigate incidents. these factors. Control non-routine jobs It is essential for industry practitioners, Risk is calculated by identifying  Asset integrity and reliability research professionals and academicians probable consequences and their Identify in-scope equipment; to fulfil their responsibility by learning frequency of occurrence and multiplying maintain knowledge, skills, procedure and propagating PSM. This change is these two to get a risk score. Both and tools; ensure continued fitness for probably little slow for altering the course routine and non-routine activities are purpose; address failure; analyse data of occasional incidents and a lot more subjected to hazard identification and  Management of outsourced needs to be done. It is a huge effort; and risk assessment and high score activities activities the best part is that it is happening. are reviewed further for incorporating Conduct work activities; monitor measures to reduce the risk. This forms P Vijayaraghavan, a Chemical Engineer, has total contractor management system the backbone of a good CPSM system.  Training 42 years of experience in petrochemical sector. The Centre for Chemical Process Safety Identify training needs; provide He retired as Site President and Factory Manager (AIChE) describes various elements and at the Baroda Unit of Reliance Industries Ltd effective training; monitor principles as follows.  Commitment to process safety (PS) (erstwhile Indian Petrochemicals Corporation Ltd). performance  Management of change Using PS as a core value; strong Email: pvrags@gmail.com

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Insight & Outlook | Detergent market

Surfactants adding to the bubbly prospects

cost factor. The percentage of LAS in liquid form varies depending upon the cost of bars and powder detergents. Industrial, institutional and commercial cleaners account for most of the other applications, but LAS is also used as an emulsifier (eg, for agricultural herbicides and in emulsion polymerisation) and as a wetting agent. LAS competes with several other major surfactants for use in household detergents. Some of the competitive surfactants have higher hard-water tolerance and better compatibility with enzymes and are milder than LAS. Historically, however, LAS has most often been lower in cost and has had other favourable properties compared with competing surfactants. Although consumption of LAS is likely to stabilise

Piyush Agrawal

The detergent market is one of the segments in the FMCG market in India that has high growth potential. However, the type of detergent preferred by rural and urban consumers varies. And surfactants form a major constituent in detergents, which play a vital role when it comes to applications of detergents in various areas. Detergents are classified under two broad categories – oil-based laundry soaps, and synthetic detergents, including bars, powder and liquids. The detergent market is mainly concentrated in urban areas, but gradually penetration in the rural areas, over the last few years, has been good.  The Indian detergent market is expected to grow at 7-9 per cent pa in volume terms. HLL, Nirma and P&G are the major players in the market with 82 per cent of the marketshare; HLL dominates the premium segment and Nirma is the leader in the popular segment. The demand for detergents has been growing at an annual growth rate of 10-11 per cent during the past five years. Where an urban consumer prefers washing powder and detergents, a rural consumer is more inclined towards washing cakes and bars. But, over the

last few years, rural consumers are gradually shifting from detergent bars to detergent powders. Rural India is rapidly becoming target market for most of the brands in the country. The contribution of rural markets in the FMCG sector is growing faster than urban markets. Rural consumers are upgrading their lifestyle with shifting preferences from non-branded and local products to the branded ones.

Surfactants, the major constituent of detergents  Linear Alkylbenzene Sulfonate (LAS) is the world’s largest-volume synthetic surfactant and is widely used in household detergents as well as in numerous industrial applications. About 82-87 per cent of LAS is used in household detergents, including laundry powders, dishwashing liquids and other household cleaners in varying proportion based on

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or decline slightly in the highly developed regions, it will increase by 2-4 per cent in the less developed regions, such as the Middle East, Africa, India and China, as well as Southeast Asia. As a result of the rapid growth in demand for LAS in the Asia-Pacific region, it is expected that by 2016, the region will account for more than 50 per cent of global demand. Worldwide, growth in demand for LAS is expected to average about 2 per cent per year during 2011-2016. It will be negatively impacted by the efforts of the detergent manufacturers to reduce the active content in their surfactant formulations. LAS is the most cost-effective surfactant as compared to other products. It can be manufactured cost-effectively, if large-scale super phosphate manufacturers starts making LAS by wet route. Spent sulphuric acid, a by-product of LAS plant, can be used in super phosphate


Detergent market

manufacture as raw material.This will give cost benefit for the product as well as avoid transportation of hazardous chemicals.

Liquid detergents The liquid detergent is as effective as the powder detergent. What makes liquid popular is the ease of operation and improvement in productivity with the automated dosing system. Powder is manually dosed and is susceptible to error, leading to inconsistent results whereas liquid is automated and more reliable. Solid detergents contain solid fillers to reduce the cost, which ultimately get either deposited on cloth or add up TDS loading on wastewater. The dosages of the liquid detergents are controlled and are not subject to human intervention. This brings in consistent cleaning performance to the linen day in and out. In fact, the cost of liquid detergent is higher compared to powder. But, when it comes to the productivity and consistent wash results, the liquid detergent is cost-effective. In case of India, with the awareness about the liquid system increasing, several customers are shifting to liquid laundries. Detergents primarily have three roles – to improve wetting ability of water; to loosen & remove soils; and to emulsify, suspend or eliminate soils in the washing solution. It is basically the customer’s choice between liquid and powder detergents, as both have their own features and limitations. As far as product stability is concerned, powder detergent may become lumps or cakey when stored in high humid area due to its hygroscopic nature and get wet during rainy season. Liquid detergents may solidify or separate out as they are temperature-sensitive. Actually, both powder and liquid detergents contain several ingredients such as builder, anti-re-deposition agent, water conditioning agent, corrosion inhibitor, opacifiers, fabric softening agent, fragrance, digester and

enzymes. Liquid detergents are not necessarily effective in all cases, but they work better on typical stains and do not harshly affect the fabric if designed with balanced surfactants. These detergents are better options from the environment point of view and hence gaining momentum in India due to ease of handling for working class.

Advantages of liquid detergents The packaging material cost (such as HDPE jar) and the high price of surfactants also influence the overall cost of liquid detergents. But, product wastage is minimal with liquid detergent applications and it is a value-addition to the fabric. Good liquid detergents are phosphate free and do not contain major inorganic constituents. With better foam and better results, it is recommended for soft & premium fabrics and for those that are not colour fast. Sometimes powder detergents may leave residue on the clothes, which can be avoided using liquid detergents with a proper dosing system. The newly developed professional laundry machines have inbuilt design of dosing system, which makes things easier. Dosage depends on laundry cycle, usage of additional booster, softeners, biocides, whitener, bleaches and neutralisers. Indian customers demand resultoriented products at minimum cost. Liquid detergents will take time to become popular considering the Indian environment, available water quality and product cost. These are available in various scents and colours, whereas powdered detergents may not be as versatile. Liquid detergents are becoming popular around the world due to its convenience in dispensing, easy dispersion and dissolution in the wash water. These are most common in bigger laundries where they have auto-dosing system. Further mixing of chemicals with liquid detergent becomes much easier as it is aqueous-based.

Other surfactants There are other categories of surfactants as well. Sugar-based surfactant development is currently gaining ground. Growing demand for Alkyl Polyglucoside (APG) – a nonionic surfactant made from vegetable oils and starch – is driving new developments and increasing marketing for other sugar-based surfactants. These products could replace traditional petroleum and even other natural oilbased surfactants. Methyl Ester Sulfonate (MES) is not ideal for liquid products, due to the stability at low temperature. Unlike LAS acid, MES is not as flexible and easy to adopt into the final detergent product. It has high detergency at low surfactant concentration or low detergent dosage, even in high calcium-contained washing water. In this respect, it is rather easy to make concentrated powder detergents with MES.

Research and technology advancements Although technological developments and growing understanding of chemical processes had improved the industry’s ability to restore soiled garments and other objects to their presoiled condition, available soaps and detergents still failed to achieve perfect results. Chemical scientists, therefore, continue to work on developing innovative laundry additives such as new enzymes and oxygen bleaches. Zeolite, sodium citrate, sodium carbonate, and sodium nitrilotriacetate were under investigation as possible builders to replace phosphates. Other questions being addressed include product safety, water quality, chemical disposal, the ability to wash in unheated water, and indoor air quality. Piyush Agrawal has 35 years experience in operation management in fertilisers and petrochemical industries. He retired as Vice President (Corporate Affairs) from Advance Surfactant India Ltd. Email: pda200@yahoo.com

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Insight & Outlook | Gas analysers

Effective tool to monitor air quality Prasenjit Chakraborty

Gas analysers play an important role in addressing environmental issues. Besides, these, to some extent, help in promoting workplace safety in chemical plants. Such analysers also caution the plant’s control centre about the build-up of gases that can create a potentially dangerous and explosive environment. Air analysers indicate the level of pollutants to the process ensures maximum output to protect workers from chemicals that in the atmosphere. These pollutants have and product quality. Protecting expensive pose threat to their health. Air analysis varying levels of impact on human beings, catalyst beds from contaminants also also alerts the plant’s control centre about plant and animal life. The pollutants are help producers avoid undue production the build-up of gases that can create a emitted by process plants by wind effect expenses. “Producers have incorporated potentially dangerous and explosive and dispersion move and hence, have solutions from Agilent Technologies and environment. Fence line monitoring of detrimental effect in the vicinity of the its channel partners to monitor production production facilities helps to protect the plants and beyond. In order to control the processes through at-line and in lab local community from the release of, or pollutants, estimation becomes essential analysis. The global reach of the chemical build-up of, potentially toxic chemicals and here is where analysers (as sensors) industry and its impact on consumers into the atmosphere. “As concerns about provide a valuable help in the design of necessitates standardisation of material global warming increase, environmental pollution control equipment. specifications and compliance methods to regulators may require that industrial According to Craig Marvin, Solution ensure consistent product quality as well gas producers monitor the release of Business Manager (GAS Phase Division), as facilitate contract negotiation between greenhouse gases into the atmosphere. Agilent Technologies, several chemical parties within the industry,” states Marvin. This analysis will involve measurement manufacturers monitor production of gases As a technology leader, Agilent and reporting of CO2, CO and NO2 and other gases in stack and other plant to verify process efficiency by employing Technologies has a 40-year history of emissions,” says Marvin. various technologies. “These systems are collaboration with American Society not routinely used to monitor air quality for Testing and Materials (ASTM) Level of adoption within the plant. Monitoring the quality International for industry standards Process efficiency and product quality drive of air in and around the plant usually and methods development. Scientists profitability for companies in the chemical requires a system that measures volatile from Agilent actively monitor emerging industry. Ensuring that raw materials meet organic components. Depending on the requirements and trends to increase purity requirements prior to introduction required reporting limit, such systems may visibility of industry requirements or may not use pre-concentrators to ASTM. Through these Craig Marvin to concentrate volatiles prior to efforts, Agilent brings Solution Business Manager sample injection and analysis,” AST M solutions and (GAS Phase Division), Agilent Technologies says Marvin. experience for the benefit of its The number of sampling customers worldwide. It offers As concerns about global systems tied to the analyser will analytical instrumentation that warming increase, environmental depend on the required frequency provides producers with tools to regulators may require that of sampling and reporting. Plants monitor process efficiency; industrial gas producers monitor monitor Benzene, Toluene, evaluate product quality; and the release of greenhouse gases. Ethylbenzene and Xylenes protect expensive process (BTEX) and other volatiles components through the

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Gas analysers

determination of trace level contaminants in difficult matrices. “Analytical solutions built around laboratory GC for low level lab or at-line analysis and Micro GC rapid analysis facilitate process monitoring and product quality evaluation. Recent developments with the Agilent portfolio include solutions for analysing natural gas, refinery gas, and trace contaminants in high purity gases,” says Marvin. Giving an Indian perspective, Dr N Anantharaman, Professor, Chemical Engineering Department, NIT, Trichy, says that in the past two decades, due to legislation brought in by Indian government, there is a significant improvement in the level of awareness. “Today, the companies aspire to get EMS certification, and for this they need to adhere to the specified norms. This has really made companies to think about the use of devices to estimate and control the pollutants,” he observes.

Gas analysis Chemical producers interested in monitoring process efficiency through gas analysis should consider the following points:  Representative sampling: Getting a sample that accurately represents the process to the analyser can present a challenge to chemical producers. Planning sampling and analysis schemes should take into account the stability of the sample, ease with which samples can be collected, transport to the analyser, and injection into the analytical system.  At-line versus laboratory-based analysis: Some processes and matrices are not conducive to transportation of samples to the analyser due to analyte stability, or other factors. Such processes may require at-line analysis. Processes for which sampling and transport of samples do not present a problem allow for laboratory analysis.

 Controlled

or non-controlled locations: Within the chemical industry, plant safety represents a significant concern. Analysis of processes in controlled environments will require ATEX or Div 1, Class II certified enclosures for the analyser. Laboratories or monitoring stations operated in noncontrolled environments allow use of conventional bench top or at-line equipment. Dr Anantharaman strongly feels that the government should make the companies take ISO certification on EMS. “Also, people should look at eco-labelling and purchase items. Once awareness is created among the public automatically, companies will come forward for maintaining a clean environment and also adhere to the norms prescribed by pollution control authorities,” he concludes. Email: prasenjit.chakraborty@network18publishing.com

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Insight & Outlook | R&D

innovation, in other words, cannot be bought. It can lead to a waste of resources on increasingly marginal products. The solution to innovation anaemia is in reassessing the effectiveness of base line spending and increasing the return on innovation investment (ROII). The company’s ROII must be lifted.

The innovation effectiveness curve It is important to understand the innovation curve of any company and its economics. Innovation is embodied by a product or service offering that contains significant element of newness. ‘New’ may not mean entirely new to the world, of course, since line extensions of existing brands are frequently a profitable form of innovation. True innovation can take the form of a new product, technology process, content, or even the presentation and marketing of existing products or services.

Triggering innovation for better returns Dr Mosongo Moukwa

The pace of corporate R&D spending, especially in chemical companies, is expected to accelerate as they believe that enhanced innovation is required to fuel future growth. However, R&D cannot be seen as a separate function in the innovation chain; it merely acts as a catalyst to stimulate innovative ideas. Major US chemical producers are likely to increase their spending in R&D this year. While the increase may be smaller than in earlier years, it could still have an impact on broader industries. R&D spending by chemical companies is expected to create a ripple effect that generates more innovation, and results in expansion in the downstream sectors, such as paints and coatings industries.

One-tenth of all patents filed in the US are from the US chemicals and advanced materials sectors. Spending more in R&D does not necessarily create innovation. Data suggests that there is no direct relationship between R&D spending and common measures of corporate success such as growth, profitability and shareholder returns. Profitable

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Incremental innovations are subject to diminishing returns. Each additional dollar spent on new product development ultimately yields a lower return. This makes sense. Spending beyond a certain point on any development portfolio results in lower returns, since a company will naturally invest in the best projects first, the next best after that, and so on, until it is tossing good money


R&D

Marginal Return on Innovation Investment

Figure 1: The Innovation Effectiveness Curve away on more and more more flexibility in selecting Company A dubious projects. a launch date and more Large projects, poor project This is perhaps best time to devise & execute depth (too few viable projects) illustrated in Figure 1 where the commercialisation plan. two companies A and B and It also keeps the spending Company B their marginal ROII are down. Time to market is Small projects, good project depth (many projects shown. The area under the critical for some projects than generate acceptable returns) curve gives a sense of the others. Delays in new product effectiveness of innovation. introduction directly affect The larger the area under development costs and returns. the curve, the better is Cost of capital On the innovative path the company’s innovation Total Innovation Total Innovation Efficient project management effectiveness. Each company Investment by B Investment by A is another requirement. has an intrinsic innovation Innovation Investment It eliminates waste and effectiveness curve, which Source: Booz Allen Hamilton duplication. Most efficient can be drawn easily by organisations are lean with plotting the ROII of each strong cross-functional teams project in the development Addressing the entire innovation including manufacturing and R&D, pipeline and the cumulative innovation value chain and able to run processes in parallel. investment. The curve predicts the Raising the inherent innovation Commercialisation capability must be company’s future revenue, profit and effectiveness curve requires senior core, coupled with a strong sales forecast growth derived from new products. The management to understand that capability. Current incentive structures company’s innovation effectiveness is innovation is not a discrete activity, but often encourage marketing and sales surprisingly stable, even when projects a multifunctional capability that requires personnel to be too optimistic in their within the portfolio change. The intrinsic several types of competencies. Innovation projects, and this must change. curve limits the return it achieves from must be seen as an expression of a wellThe key question to address is the marginal investment in innovation. organised value chain, with four set of overall culture of the organisation. The first The law of diminishing return in capabilities: ideation, project selection, step is to change the innovation culture. innovation effectiveness explains the development and commercialisation. The This is where the top management comes numerous cases in which increase in R&D innovation effectiveness curve cannot be in. They need to lead the shift in mindset so spending does not significantly improve raised unless all four elements are mastered; that innovation is the centre of everything sales or growth. These companies are not a chain is only as strong as its weakest link. in that company. For many companies, this raising the curve, but rather riding the It has been noticed that the silois not easy. It will require a phase change curve. They are probably spending on idea ization of ventures is a challenge in project to the creative economy. It also means generation and new product development, selection. Often, investment decisions specific management changes and focus on without altering the processes, systems are made individually. The best approach innovation to add value for the customers. and structures, or capabilities that really is to assess projects within the context Management has become the art and determine their ROII. of the whole portfolio, since all new science of generating continuous supply of The results of raising innovation product candidates are competing for the additional value. R&D cannot be seen as a effectiveness can be profound. same pool of resources (both people and separate function in the innovation chain. Companies increase the return on their money). Net Present Value (NPV) cannot It is merely an input to innovation. base innovation spending (more highbe the sole criteria for ranking projects. quality, new product at faster rate and Dr Mosongo Moukwa is Vice Instead, companies with the highest lower cost) and get an option to invest President (Technology), Asian ROII incorporate a number of relevant more while maintaining a high level of Paints Ltd, Mumbai. He was Vice metrics such as strategic fit, risk adjusted return. The height of the curve defines President (Global Technology), NPV, new product portfolio balance and the company’s overall innovation Reichhold, North Carolina. He prioritisation, and current & near future effectiveness. Companies within the is a member of the American Chemical Society, resource availability by geography, skills or same industry can differ widely in the Commercial Development and Management functional area. their innovation effectiveness; it is clear Association and the Licensing Executive Society. Some projects need to be put through that firms must raise the innovation Email: mosongo.moukwa@asianpaints.com their pace quickly, which allow companies return curve.

July 2013 | Chemical & Process World | 49


User-industry Monitor | Textile industry

Adding new colours to dyes and pigments sector Avani Jain

Being a leading player in textiles, India has created a major demand for colourants, including dyes and pigments, which find wide applications in textile industry. Hence, dyes and pigments constitute one of the core areas of Indian chemical industry coupled with high export potential.

Colouring matters, which may be classified as dyes and pigments, have been exploited by man for their aesthetic values and used to embellish various articles including clothes. Starting with Indigo, the oldest known dye, originating from India; the royal Phoenician’s dye, Tyrian purple (or Royal Purple) of the ancient city of Tyre; Alizarin, among the Turkey people; to Cochineal of the European and Mexican dyers, indigenous dye-yielding plants have been discovered in almost every region of the world. Dyes are soluble substances used to pass colour to the substrate and find applications primarily in textile industry. There are several types of dyes; however, in India, disperse, reactive and direct dyes are most commonly used. Pigments are insoluble substances and could either be in powdered or granular form. They impart colour by reflecting only certain light rays. Pigments can be broadly classified as organic and inorganic.

Global scenario The global market for dyes and pigments is forecast to reach 9.9 million tonne by 2017 and touch $ 26.53 billion, driven by the growth in key end-user industries. Additionally, market demand is rising from stringent and increasingly rigorous quality, performance and environmental standards. Increasing consumer preference for environment-friendly products, which in turn is driving the consumption of high-performance dyes and organic pigments, is expected to provide stimulus to the pigments and dyes market globally.

India story Traditionally, India has been a major manufacturer of textile dyes, tracing its history to the rise of textile industry in the early 1900s. If we look at the more recent facts, following the decline of the traditional producers in the developed world, particularly in Europe, the simultaneous ascent of new ones in Asia,

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particularly India and China, is arguably one of the most significant changes ever seen in this industry. The shift has been quite swift and followed the migration of end-user industries, notably textiles and leather, to low-cost economies of Asia such as India. Thus, currently, the Indian dye and pigment industry is a major player in the global supply chain for textiles. Manish Kiri, Managing Director, Kiri Industries Ltd, notes, “The dyes and pigments industry is mainly dependent on the consumption levels in the textile industry. Since the textile industry is rising in India, the demand for dyes and pigments is increasing as well. Further, the industry in India is mainly export dependent. Around 70 per cent of the products are exported.” The dyes and pigments industry constitutes nearly 950 small-scale units and 50 large units manufacturing dyes, dyestuffs and pigments, with a total capacity of 1,60,000 tonne. Of this, the production capacity of pigments is estimated at 40,000 tonne per annum (tpa), half of which is in the small-scale sector. Two states – Maharashtra and Gujarat – account for around 90 per cent of the total dyestuff production in the country. The dyestuff industry has forward and backward linkages with many sectors but the major being textiles. In fact, the textile sector consumes around 80 per cent of the total production due to high demand for polyester and cotton, globally.


Textile industry

Textile industry: Boosting demand Dyes currently used in the textile industry are mostly synthetic. They are derived from two sources – coal tar and petroleum-based intermediates. These dyes are marketed as powders, granules, pastes or liquid dispersions. The concentration of active ingredients typically ranges from 20-80 per cent. The textile dye segment is characterised by new dyes regularly developed for meeting the demands of new technologies, latest fabrics, detergents, advancements in dyeing machineries, along with overcoming the serious environmental concerns posed by some existing dyes. With the fast changing product profile of the textile industry, from highcost cotton textiles to the durable and versatile synthetic fibres, the pattern of consumption of these dyes is also going

Manish Kiri

Managing Director, Kiri Industries Ltd

Since the textile industry is rising in India, the demand for dyes and pigments is increasing as well. Further, the industry in India is mainly export dependent. through rapid changes. Nowadays, polyesters account for a major part of dye consumption. Due to wide use of polyester and cotton-based fabrics, there has been a shift towards reactive dyes, used in cotton-based fabrics, and disperse dyes, used in polyester. The demand for reactive and disperse dyes is expected to grow fast due to this trend. The textile industry will remain the largest consumer of dyestuffs. However, growth will be driven by markets such as printing inks, paints and plastics. These segments will also increase

the consumption of highperformance pigments, thus improving profitability.

Growth drivers

The demand for dyes and organic pigments is expected to grow at 11 per cent per annum till 2020 to reach $ 10 billion. However, the industry can aim to grow faster at 15 per cent to reach $ 14.5 billion. To achieve its aspirations, the industry needs to take efforts in critical areas and focus on innovations, with emphasis on R&D; optimise the product portfolio; and build better quality & high performance colourants. Further, improving environmentfriendliness of products & services, and ensuring compliance to international regulations to continue access to the exports markets will help provide a boost to the industry. Email: avani.jain@network18publishing.com

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Automation Trends | IT in logistics

Facilitating smooth and seamless transportation Mahua Roy

As India starts featuring on the global strategic map of MNCs, we see a lot of transformation in the outlook of the chemical industry. There is more adoption of automation and sophistication of technology. One of the crucial pillars holding this industry together is the logistics sector. Has it opened up to the opportunities IT can provide? The chemical industry is one of the top five revenue generators for the logistics sector in India. This industry today has a global supply chain, which brings along a new set of challenges, particularly in India. For example, on a daily basis, a chemical company has to deal with volatile fuel prices, increasing raw material costs and mounting price margin pressure, besides ensuring that materials are delivered to the factory for production, and then products are sent to the customers or warehouses on time. A mammoth task before the industry is making certain that all these processes take place seamlessly.

Adopting IT as a forward mindset The chemical industry worldwide is characterised by clustered production capacity and distributed consumption points. “Efficiency, competitiveness, agility, and sustainable logistics are thus important success drivers in this industry. Dependence on specialised service providers who can customise and deliver improved logistics services at reduced costs is on the rise,” says Asim Behera, General Manager – India, Swisslog. In this backdrop, IT is emerging as a key enabler of innovation, strategic transformation and operational excellence. Network expansion, process integration and risk reduction are three areas where IT can play the role of an enabler as well as accelerator. “Chemical manufacturers face several issues unique to their businesses.

Managing a large and complex supply chain with descriptive features and disparate production sites, while at the same time trying to improve production efficiency and respond to market demands, constitute a set of problems that we have to face simultaneously. One needs to learn to live with these issues, and also to cope up with the resources that are required to deal with these. IT, today, plays an integral role and if right IT solutions are implemented in the key area of logistics, chemical manufacturers can boost profits, grow their customer base and reduce wasteful practices,” says Ramanand Gupta, Managing Director, Revex Plasticisers Pvt Ltd.

Delivering safety and security The chemical industry has a high intensity

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of risks inherently attached to it because of the volatile and hazardous nature of products. This directly has an impact on the supply chain mechanism. Safety is an important aspect to consider during the strategic planning of transit. Along with safety, comes security. For example, the sea route to Africa is plagued with sea pirates. Ensuring safety of products and personnel thus comes with a cost, which is heavily justified. Here is where adoption of sophisticated IT software comes into play. The industry needs to understand the cost-benefit analysis of ensuring a safe and secure transit operation. “The use of new generation technology will give Logistics Service Providers (LSP) a lead over their competitors. This will also be essential in attracting higher outsourcing from overseas players. Usage of technology tools such as Global Positioning System (GPS), Radiofrequency Identification (RFID) will definitely help companies and markets to grow, but the stakeholders need to be made aware of the valueaddition done by technology adoption,” adds Behera.

Seamless integration “Creating chemicals is a complex process. Sequence-dependent production means there are numerous steps required to go from raw materials to a compound ready for sale, and then comes its distribution. When this is spread over several geographical locations, the chances of


IT in logistics

this process going wrong become much higher. All the work needs to be balanced in a hierarchical order too. Doing tasks like these manually is difficult and is much prone to mistakes. For example, if a specialised storage vessel is double-booked, it could result in delay of a customer order,” explains Gupta. For chemical shippers, technology is the key to reducing transportation and logistics costs. Transportation Management Systems (TMS), in particular, can provide chemical companies the visibility they need to manage logistics with an eye for efficiency and cost-effectiveness. TMS provides the granular detail that helps chemical shippers make decisions on how to manage the supply chain in the face of rising costs. To better coordinate loading, unloading and other operations, most companies are now turning to TMS to optimise their transportation networks. TMS products automate key elements of a company’s shipping infrastructure, including strategic and operational planning, network design, transportation execution and monitoring, invoicing, billing and settlements. Gupta further elaborates that without in-depth demand visibility, backed by a complete overview of the status of all the equipment needed to produce a particular chemical, the sales team simply cannot provide an accurate forecast of when customers can expect to receive their orders. This could result in customers choosing another manufacturer who can guarantee when the products they want will be delivered. And, this might severely hit production and revenues. “While many manufacturers might feel that they are working effectively without a specialised system, the initial investment will be repaid many times by the increases in efficiency delivered. So to ensure that you excel in the future, it is important that you invest in the right technology and foresee its benefits,” adds Gupta.

Ensuring productivity Besides, IT can significantly hasten the process of scaling the intermodal networks – for example, efficiency and risk-based network design. It also helps in accelerating the operationalisation of warehouses, integrating processes for execution and co-ordination, enabling higher productivity and throughput, lowering unit cost by optimising asset utilisation and cargo planning, enhancing operational control by generating continual visibility to consignments and their status. “We can expect to see the Indian chemical industry pushing for more global products to reduce portfolio complexity, and customers from emerging markets will expect Western standards of product quality and sophistication. Successful logistics providers will have to provide advanced storage, product handling and transport equipment. They will also have to supply cleaning facilities in line with producers’ global SHE policies to support local production and imported flows of product. This can be ensured with deeper penetration of IT solutions,” concludes Behera. Email: mahua.roy@network18publishing.com

July 2013 | Chemical & Process World | 53


Sustainability Mantras | Bio-refining

Combining profitability with environmental benefits Prasenjit Chakraborty

It is high time for India to provide a major thrust to the usage of bio-fuels for effectively combatting energy crisis. India can make a significant progress in this arena as it has plenty of residual biomasses such as straw and bagasse. Adoption of right technology and necessary government support could make the segment a vibrant one. The bio-fuels are gaining momentum the world over, including India, mainly due to depletion of oil resources and increased oil prices; mitigation of CO2 emissions & climate change; and reduction of dependence on imported oil & petroleum products. Currently, the biggest demand is for advanced biorefining, ie production of biofuels and chemicals from cellulosic biomasses. There are significant technological and cost differences between the biofuel generation technologies. “Currently, commercial bioethanol is produced by first generation (1G) technology from food crops. The second and third generation (2G and 3G) technologies use nonfood, lingo-cellulosic biomasses and are on the threshold of commercialisation. The unique advantage of Chempolis’ 3G technology is the selective fractionation of biomass resulting in reduced requirement for costly enzymes and high purity of products,” says Pasi Rousu, President, Asia & Pacific, Chempolis. It is important that biomass is put into sustainable use, such as biorefineries, as this will be highly beneficial to the society. For 1G ethanol producers, the use of non-food biomasses along with the existing capacity would give both profitability as well as creditability with respect to environmental and social sustainability. In India, the 3G technology

would provide approximately three-fold revenues from the use of bagasse when compared to current use in co-generation at sugar mills.

Technology edge In general, cellulose, hemicelluloses and lignin are the main components of all cellulosic biomasses. The 2G biorefining technologies typically aim at converting

both cellulose and hemicelluloses into cellulosic ethanol while the remaining biomass fractions are utilised for lower value-added products. Principally, the bulk of lignin-rich slurry containing significant amount of water is intended for production of energy. So far, high enzyme costs and complicated fermentation have stressed the profitability of these technologies in which both cellulose

54 | Chemical & Process World | July 2013

and hemicelluloses are simultaneously enzymatically hydrolysed and further fermented in the presence of lignin. “However, the enzyme costs can be significantly reduced when biomass fractionation is carried out selectively and one gets to feed a pure cellulose fibre into enzymatic hydrolysis. Further benefits are gained when the resulting pure glucose can be conventionally fermented to ethanol,” points out Rousu. When compared to 2G biorefining technologies, the main advantage of the 3G technology is the selective fractionation of cellulosic biomass and the possibility to produce pure cellulose, hemicellulose and lignin fractions. The fractionation enables co-production of multiple value-added products without generation of waste, reduced operating costs (especially enzyme cost), higher revenues and a full recovery of chemicals and water. “Moreover, high pressures and temperatures, characteristics for 2G technologies, are not needed due to the innovative and fully recyclable biosolvent,” he says.

Cellulosic biomass as a raw material Biorefining – converting of biomass into fuels, chemicals, and other value-added products – is already a major, established industry. Citing an example, Rousu explains, global annual production of 1G


Bio-refining

biofuels for transportation is around 100 million tonne, and production of pulp for papermaking is almost 200 million tonne. In addition, recently, governments around the world (including India) have made strong mandates for increasing the consumption of biofuels. Such mandates and related incentives are promoting the expansion of biorefining. However, the role of advanced biofuels using cellulosic biomasses as raw material is still expected to grow. Currently, first such kind of production facilities are being built and brought on-line in the US and EU; but the progress has been slower than expected few years ago. “Governments have created certain incentives for the production, but the support should be clearly stronger to enable advanced biorefining as an essential tool for sustainable development,” says Rousu.

Where India stands India is facing energy crisis due to increasing population and hence, the

dependence on imported foreign fossil energy sources is also increasing. New renewable energy, fuels and non-fossilbased chemicals are needed to meet the economic growth. The current situation consuming a significant share of the Gross National Product (GNP) for the import of oil is not sustainable in any way. “India is a rich country when it comes to the availability of residual biomasses, such as straw and bagasse. These biomasses are generated annually over 400 million tonne in India. Using 30 per cent of these available residues in 3G biorefining would enable bioethanol production of 20 million tonne per annum,” notes Rousu. The possibilities to choose environmentally benign alternatives must be made easy and attractive. This can be enabled by governmental policies, such as feed tariffs, subsidies, grants and tax incentives. Educating people about clean energy benefits in day-to-day life is important. “We expect a tremendous

change in advanced biofuel business to take place in near future. 1G ethanol has to give place for non-food solutions, and usage of molasses just cannot fulfil the targets. We offer a 3G non-food, biorefining platform, which produces pure cellulosic sugars, biochemicals and solid biocoal,” he points out. Biomass is selectively fractionated with a recyclable biosolvent while all the biomass components are processed into valuable products. When it comes to India, the main challenge for advanced biorefining is to establish first reference projects of commercial production. “India has several advantages and it certainly can be at the forefront of biorefining, because Indian companies already have a tradition to utilise residual biomass from agriculture, especially combustion of sugarcane bagasse and production of electricity. The country also has existing production of ethanol and related infrastructure,” points out Rousu. Email: prasenjit.chakraborty@network18publishing.com

July 2013| Chemical & Process World | 55


Policies & Regulations | Chemical clusters

Today, there is an urgent need to build better infrastructure and provide adequate resources such as power, water etc, to support industrial growth. The chemical industry faces various challenges related to safe transportation of products, proper storage facilities etc. Infrastructure is also inadequate for facilitating seamless exports. Investments are needed to develop roads, railways, waterways, ports, and warehouses, among other requirements, to support the overall industrial growth. Further, chemical units are dispersed throughout the country due to incentives offered by different State Governments. Thus, there is a need to form clusters, with provision of common infrastructure facilities, to address the constraints of

reduce costs, proximity of suppliers/ buyers, thereby improving co-ordination across players and availability of trained & industry-specific skilled manpower. There are various other benefits offered by chemical cluster, the major being that it will provide a boost to SMEs in the sector, which lack adequate funds, infrastructure and technology. Further, clusters can work to obtain clearance from regulatory agencies in export markets. Companies can get easy access to common services such as power, transportation infrastructure, legal services for patent and intellectual property rights-related queries, and a well-equipped laboratory for quality checks as well as compliance-related

clusters, especially at Ankleshwar, Panola, Vapi, Vatva, Jhagadia, Dahej etc, have facilitated rapid development. At present, Vapi is one of the country’s largest chemical clusters. It mainly comprises small and medium players. It consists of about 1,300 industrial units, of which about 1,900 are involved in chemical and pharmaceutical processing. Further, Petroleum, Chemicals and Petrochemical Investment Region (PCPIR) – a specially delineated investment region planned for the establishment of manufacturing facilities for domestic and export-driven production of chemicals and petrochemicals – at Dahej is spread over 453 sq km of brownfield area in the coastal belt of

Yet to make a difference! Avani Jain

The chemical industry in India is growing at a rapid pace. In order to add impetus to this growth, and provide a boost to the Small and Medium Enterprises (SMEs) in the sector, chemical clusters have been created. However, the extent of the impact of cluster development policy on the chemical industry is often debated. common effluent treatment, transport linkages, including roads, power supply, water facilities, etc. Jaimin Vasa, President, Gujarat Chemical Association, and Managing Director, Vasa Pharmachem Pvt Ltd, says, “A cluster-based approach will help the industry to grow and the government will also be able to provide basic amenities to all the companies in a particular area. This will encourage planned development in the state, besides giving a boost to the chemical industry there.”

issues. This will also save transportation costs of companies by easily connecting them with the key raw material suppliers, giving them tremendous logistics benefits and operational flexibility. The clusters can set up their own common waste disposal plants like the effluent treatment plants. However, in reality, the success of the cluster development policy is often debated as the industry experts believe that they have not contributed much in driving the growth of the chemical industry.

Cluster development

Case study: PCPIR

Industry clusters are establishments where several players set up plants around an area to reap the benefits of co-location. Some of the major benefits of chemical clusters include sharing of resources to

The presence of chemical manufacturing mega-estates at several industrial clusters in Gujarat has promoted the growth and expansion of the industry by providing an appropriate business ecosystem. Chemical

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the Gulf of Khambhat. With a capacity of 22 million metric tonne per annum (MTPA), it is in the vicinity of the Dahej port. The PCPIR offers scope for future expansion possibilities to augment capacities to 30 MTPA for catering to LNG, dry bulk and liquid chemicals.

Issues to be addressed While everything seems positive about the pace at which the PCPIR is being developed in the state, there are few points, which the government needs to keep in mind. Vasa observes, “It is necessary to landfill the area in order to increase its height by 1.5-3 metre. This is due to the reason that a large portion of area where the proposed PCPIR has to be built turn into a wetland during monsoon season. Government also needs to ensure


Chemical clusters

effective effluent disposal scheme in the proposed PCPIR. Considering the scenario, the treated effluent will have to be discharged in the deep sea, which will attract a sizable capital and recurring cost that an individual or an association cannot meet alone. Thus, the government has to provide support in this area also. These steps will pave the path for a clean environment in the chemical zone.” The proposed industrial Special Economic Zone (SEZ) in this PCPIR will include petrochemicals and downstream petrochemical, synthetic organic chemicals, industrial gas producing and other small industries. “Since there will be many major industries in that area, there needs to be a specific zone-based incentive scheme and soft loan from financial institution for chemical-based SMEs,” says Vasa. He adds, “The government needs to ensure that everyone gets access to the common amenities like basic infrastructure. Moreover, it has to look at assured water and power supply for

all. Efforts should be taken to shift the existing chemical companies to this area as this will help them to better utilise the facilities that are meant for them.” Thus, in simple words, the cluster development policy has yet to prove its worth for the industry. As a result, the Government of India has developed ‘Industrial Cluster Upgradation Scheme’ to facilitate the growth of all industries including the chemical. The proposed scheme primarily focusses on developing and upgrading industrial infrastructure at existing clusters. The overall objective of the scheme is to influence efficiency and enhance competitiveness of companies located in such clusters. The scheme covers areas such as infrastructure support, market intelligence, technology transfer, human resource development etc.

Gauging the future The chemical industry in India is wellestablished and has recorded a steady

growth over the years. It offers a wide scope for development that contributes positively to economic growth and regional development. The outlook for the industry is bright with positive developments expected in various chemical sub-sectors. In order to promote investment in this sector and make the country an important hub for both domestic and international markets, the government has decided to set up chemical clusters so as to attract major investments, both domestic and foreign. However, the chemical clusters need to leverage individual capabilities and unique selling points to attract businesses. Clusters need to be projected as a single destination for potential buyers of chemicals catering to the needs of all buyers. Thus, it can be said that the chemical cluster can aid the growth of chemical industry and can be a viable option for the industry, if the concerns are addressed as soon as possible. Email: avani.jain@network18publishing.com

July 2013 | Chemical & Process World | 57


Strategy | Management degree

Joseph Wharton founded America’s first business school at the University of Pennsylvania in 1881. Few decades later, in 1964, the UK government set up the London Business School and Manchester Business School. Since then, the MBA degree has become the most sought-after degree worldwide. But is this degree over-rated? Does the industry prefer the degree more than technical expertise? What relevance does this qualification have in the hardcore sector of chemicals?

The crucial decision after engineering The dilemma faced by an engineer on completion of the engineering degree is whether to seek an advanced engineering degree or an MBA. “ Technical professionals who opt for an MBA believe it would give them the potential to achieve higher pay, allow them to move

Examining the MBA degree Global recruitment firm Randstad went deep into the CVs of CEOs in India to compile a report conducted among the BSE 100 firms. It found that 45 per cent of them were equipped with engineering degrees at the undergraduate level. Of this, 78 per cent had gone on and completed post-graduation as well. What is significant, though, is that 64 per cent of those who pursued a post-graduate degree went for an MBA. Additionally, 42 per cent of the CEOs finished their MBA from top management schools such as the IIMs, XLRI, Harvard, Stanford and Wharton. Within this universe, 70 per cent of CEOs had post-graduation degrees while only 30 per cent were undergraduates. An analysis of the undergraduate degrees of all the CEOs showed that 45 per cent of CEOs had pursued engineering.

Is it a necessity in chemical sector?

Mahua Roy

“Many employers will take an MBA degree in lieu of experience A long-standing debate deliberates what and this can help one to promote more quickly in a different field. relevance does an MBA degree has to the If one prefers to work as a consultant in his/her area of expertise instead of doing hands-on work, an MBA degree can give him/ highly technical skills of a professional her the required credibility. For instance, some technical experts engineer; and is there a real need for like to become consultants for businesses, explaining to clients how to change or improve their technology. An MBA degree engineers to pursue MBA? would help these consultants in their role because it would teach them how to understand the Dr Pranabesh Ray more easily into management entire business picture. People Dean – Academics, XLRI arena within the technology would also take the consultants department, obtain employment more seriously with an MBA at a preferred company or land; degree along with their technical An engineer will need to know how and work in a new, businesscertification,” adds Satindra Sen, to look at his/her technical skills oriented technical role,” says Co-Founder and Director, Exper from a business perspective, and Dr Pranabesh Ray, Dean – Executive Education Pvt Ltd. how to channelise the knowledge Academics, Xavier Labour As is the general consensus, if into profitability and productivity. Research Institute, Jamshedpur one does not have a lot of work (XLRI). experience, but wants to promote

58 | Chemical & Process World | July 2013


Management degree

out of the current work position, are honed in an MBA degree Satindra Sen one may want to consider an programme,” says Dr Ray. Co-Founder and Director, Exper Executive Education Pvt Ltd MBA degree. Taking the decision of Having already obtained whether to get an advanced The strong analytical capability a technical degree, an MBA engineering degree or an MBA completes one’s education in will mean taking a hard look that engineers possess is highly the wider areas of management at personal goals. An MBA valued in the business world; but it is that usually includes subjects complements most other degrees. imperative that they also understand such as finance, marketing, However, the reality is that most the other, more qualitative aspects. human resource management, individuals feel like they are time organisational behaviour and or resource constrained and can management strategy. This is only afford one advanced degree. management degree lies solely with a also important because the role of the In that situation, the answer to the question person’s future goals. If one plans a startengineer is changing; within an industry, regarding whether engineers should obtain up of consulting or manufacturing, an an engineer is likely to be a manager an MBA versus an advanced engineering MBA degree could be a valuable asset. who has to implement new practices and degree is completely dependent on future An engineer will now need to understand technologies, or manage a set of people in aspirations. Sen concludes, “The strong more than just technical architecture. the field, be it sales or even manufacturing. analytical capability that engineers possess “He/she will need to know how to look Thus, the engineer often becomes the is highly valued in the business world; but at his/her technical skills from a business primary manager of change within the it is imperative that they also understand perspective, and how to channelise modern organisation, which again requires the other, more qualitative aspects. These the knowledge into profitability and specific skills and learning. qualitative skills are what engineers productivity. An engineer will learn how stereotypically lack; we like black and Seek your future goal to market his/her skills to prospective white answers, but in the business world, The answer to the crucial question of customers and how to manage finances it is not typically that simple.” Email: mahua.roy@network18publishing.com choosing between an engineering and when he/she is on a job. These skills

July 2013 | Chemical & Process World | 59


Tips & Tricks | Personal protective equipment

Practical guidelines

for right selection Personal Protective Equipment (PPE) assumes high importance in various industries, especially chemical, as often the raw materials and processes involved are highly hazardous. Appropriately designed PPE plays a vital role in preventing/reducing/controlling injuries/ disabilities in the chemical industry. However, proper selection of PPE, depending on the nature of work, is essential; and here are some tips for getting it right.

1

Various nuances with PPE commence with management policy on PPE, needbased identification, budget allocation, selection, procurement of user-friendly/standard appliances, proper distribution, inventory management, upkeep/maintenance, various procedural aspects on training, participative techniques, motivation, control system, and the best suited/appropriate enforcement strategy.

2

Bureau of Indian Standards (BIS) or equivalent overseas standards/guidelines from developed countries offer detailed specifications on PPE with respect to hazard resistance properties/characteristics, user comfort, design, size, strength and durability.

3

Attention should be paid to the variety of PPE, which can be used. Some of the examples include helmets, regular footwear (safety shoes), goggles, gloves, aprons, coats, respiratory masks (other than dust/mist filters), breathing apparatus, and fall protection devices (safety belt lifelines/harness/fall arrestor units).

4

One should take into account the nature of job while deciding on the PPE. Different types of equipment are used in various work situations, ie manufacturing/operation/ maintenance activities, material handling, etc. There are different materials, which are used for making varied types of PPEs. Depending on the nature of work, the material for PPE should be carefully selected. Periodicity of jobs – continuous, occasional, intermittent or emergency – also helps in choosing the right PPE.

60 | Chemical & Process World | July 2013

5

For selecting the headgear – the most primary PPE – one should ensure the basic point that it is dome-shaped without any metallic component attached or lined below or insulated above (for reinforcement). The surface of the helmet should have a smooth finish and should be free from burrs, sharp edges, etc, along with an aesthetic look.

6

When it comes to protective gears for arms, for instance, gloves, canvas-cumleather (leather for the palm section and canvas for the outer) should be selected for valve operations, material handling, etc. Full leather gloves can be used for gas cutting. There are other materials, eg, wool-lined aluminium foil fabric, which are also available to suit the needs of various applications.

7

Protective gears for ears assume high importance and are among the most primary PPEs. The various types of hearing protection devices include enclosure (helmets designed to fully cover both head and ears), aural (ear insert similar to the cotton buds being worn by air passengers also known as ear plugs), and ear muffs.

8

The maintenance/upkeep of PPE is especially critical and those meant for common use (such as breathing apparatus, safety harness) must get top priority. The engineering/ design aspect and costs of all types of PPE should be thoroughly explained, so that employees are well aware and also use these types of equipment voluntarily. Email: avani.jain@network18publishing.com


As told to Mahua Roy

July 2013 | Chemical & Process World | 61


Projects

Ammonia

Rashtriya Chemicals & Fertilisers Ltd Project type

New facility

Project news

Andheri (W), Mumbai-400053 Maharashtra Tel: 022-26747900 Fax: 022-26736193/78 Email: enquiry@punjabchemicals.com ................................................................

Rashtriya Chemicals & Fertilisers Ltd is planning to set up a 2,700 MTPD capacity ammonia plant inOdisha.

Phosphate

Project location

Project type

Talcher, Odisha

New facility

Not known

BEC Fertilizers (Unit of Bhilai Engineering Corporation Ltd) is planning to set up a new chemical plant in Chhattisgarh. The project involves manufacturing of boronated single super phosphate.

Project cost

Bhilai Engineering Corporation Ltd

Project news

Implementation stage

Planning Contact details: Rashtriya Chemicals & Fertilisers Ltd Priyadarshini, 10th Floor Eastern Express Highway Sion, Mumbai-400022 Maharashtra Tel: 022-25523057 Fax: 022-24045197 Email: mthyagarajan@rcfltd.com ................................................................ Ketosulfone

Punjab Chemicals & Crop Protection Ltd Project type

New facility

Project news

Punjab Chemicals & Crop Protection Ltd is planning to set up a new chemicals plant to manufacture ketosulfone in Punjab. Project location

Ropar, Punjab

Project location

Not known

Implementation stage

Planning Contact details: Punjab Chemicals & Crop Protection Ltd Oberoi Chambers II 5th Floor, 645/646 New Link Road

Not known

Implementation stage

Planning Contact details: Hindustan Chemicals Company 65, Free Press House 215, Free Press Journal Road Nariman Point Mumbai - 400021 Maharashtra Tel: 022-22853669 Fax: 022-22029430/61510900 Email: mktg@hcc-cyanides.com ................................................................ Refinery & Petrochemical

Hindustan Petroleum Corporation Ltd

Bilaspur, Chhattisgarh

Project type

Not known

Project news

Project cost

Implementation stage

Planning Contact details: Bhilai Engineering Corporation Ltd Hathkhoj Village, Industrial Area Bhilai-490026, Chhattisgarh Tel: 0788-4088100 Fax: 0788-2285499 Email: becinfo@bec-group.com ................................................................ Sodium cyanide

Hindusthan Chemicals Company Project type

Capacity expansion Project news

Project cost

Project cost

Hindustan Chemicals Company, (formerly known as Cyanides & Chemicals Company) is planning to expand its sodium cyanide manufacturing capacity from 5,400 TPA to 12,000 TPA in Gujarat. Work on the project will commence in 2014 and is planned for completion in 2016. Project location

Surat, Gujarat

New facility

Hindustan Petroleum Corporation Ltd (HPCL) plans to set up a refinery-cumpetrochemical complex at Pachparda in Rajasthan. The proposed refinery project will come up on around 3,700 acre of land. HPCL, through joint venture between its subsidiary MRPL and Cairn Energy, UK, plans to set up a nine million tpa petroleum refinery and petrochemical complex in Rajasthan. Project location

Barmer, Rajasthan Project cost

` 37,229 crore

Implementation stage

Planning Contact details: Hindustan Petroleum Corporation Ltd Petroleum House 17, Jamshedji Tata Road Mumbai-400020 Maharashtra Tel: 022-22863900 Fax: 022-22872992 Email: corphqo@hpcl.co.in

Information courtesy: Tendersinfo.com 1, Arch Gold, Next to MTNL Exchange, Poisar, S V Road, Kandivali (W), Mumbai - 400 067, Maharashtra, India Tel: 022 28666134 • Fax: 022 28013817 • Email: parmeet.d@tendersinfo.com

64 | Chemical & Process World | July 2013


Tenders

Latest Popular Tenders brought to you by www.tendersinfo.com Oxygen analyser

Org : Bharat Petroleum Corporation Ltd TRN : 16820976 Desc : Supply of Ametek oxygen analyser BOD : July 22, 2013 Loc : Mumbai, Maharashtra BT : Domestic

Nitrogen plant

Diaphragm pump

Fluid extraction unit

Org : Bharat Petroleum Corporation Ltd TRN : 16820972 Desc : Supply of diaphragm pump BOD : July 22, 2013 Loc : Ernakulam, Kerala BT : Domestic (NCB)

Hydrogen plant

Org : Centre for Aromatic Plants TRN : 16803365 Desc : Supply and installation/ commissioning of super critical fluid extraction unit BOD : July 25, 2013 Loc : Dehradun, Uttarakhand BT : ICB

Org : Heavy Alloy Penetrator Project TRN : 16279396 Desc : Designing, manufacturing, supply, installation & commissioning of nitrogen plant BOD : July 25, 2013 Loc : Tiruchirappalli, Tamil Nadu BT : Domestic (NCB)

Org : Heavy Alloy Penetrator Project TRN : 16279629 Desc : Designing, manufacturing, supply, installation & commissioning of hydrogen plant BOD : July 25, 2013 Loc : Tiruchirappalli, Tamil Nadu BT : Domestic

Multiple parallel autoclave system

Planetary ball mill

Org : Indian Oil Corporation Ltd TRN : 16744327 Desc : Supply of multiple parallel autoclave system BOD : July 26, 2013 Loc : Faridabad, Haryana BT : Domestic

Org : Indian Institute of Technology Bhubaneswar TRN : 16763884 Desc : Procurement of planetary ball mill BOD : July 26, 2013 Loc : Bhubaneswar, Odisha BT : Domestic

Reciprocating piston pump

Org : Pakistan National Shipping Corporation TRN : 16794233 Desc : Supply of reciprocating piston pump BOD : July 26, 2013 Loc : Karachi, Pakistan BT : ICB

Nitrogen plant

Org : Ordnance Factory Board TRN : 16428815 Desc : Designing, manufacturing, supply, testing and commissioning of nitrogen plant BOD : July 30, 2013 Loc : Tiruchirapalli, Tamil Nadu BT : Domestic

Org: Organisation’s name, TRN: Tendersinfo Ref No, Desc: Description, BOD: Bid Opening Date, Loc: Location, BT: Bidding Type Information courtesy: Tendersinfo.com 1, Arch Gold, Next to MTNL Exchange, Poisar, S V Road, Kandivali (W), Mumbai - 400 067, Maharashtra, India Tel: 022 28666134 • Fax: 022 28013817 • Email: parmeet.d@tendersinfo.com

July 2013 | Chemical & Process World | 65


Event List

National The trade exposition on chemical plant, equipment and process industry; February 2014; at Surat International Exhibition & Convention Centre, Surat, Gujarat For details contact:

Network 18 Publishing

Ruby House, A-Wing, 1st Floor, J K Sawant Marg, Dadar (W), Mumbai-400028 Tel: 022-30034651 • Fax: 022-30034499 Email: b2b@network18publishing.com

Pune

Maharashtra October 18-21, 2013 India’s premier industrial trade fair on products and technologies related to Machine Tools, Hydraulics & Pneumatics, Process Machinery & Equipment, Automation Instrumentation, Packaging & Auxiliaries, IT Products, Electrical & Electronics, Material Handling and Safety Equipment.

Chennai

Tamil Nadu November 14-17, 2013

Aurangabad Maharashtra January 10-13, 2014

Indore

Madhya Pradesh Jan 31-Feb 03, 2014

Jaipur

Ludhiana

Kolkata

Ahmedabad

Punjab Rajasthan Nov 29 - Dec 02, 2013 December 20-23, 2013 West Bengal February 21-24, 2014

Gujarat March 7-10, 2014

For details

Network18 Media & Investments Ltd

Ruby House, 1st Floor, J K Sawant Marg, Dadar (W), Mumbai 400 028. • Tel: 022 3003 4651 • Fax: 022 3003 4499 • Email: engexpo@network18publishing.com

PetroWorld India

India Chem Gujarat

What : An event showcasing novel technologies in oil & gas sector When : August 22-24, 2013 Where : Bombay Exhibition Centre, Mumbai

What : The exhibition will showcase the latest products, machinery, equipment and developments in the chemical industry When : October 24-26, 2013 Where : Gandhinagar, Gujarat

For details contact: Inter Ads Exhibitions Pvt Ltd Tel: 0124-4524200/4201 Email: siddharth@interads.in ...........................................................................

INDIA OIL AND GAS REVIEW SUMMIT AND INTERNATIONAL EXHIBITION

For details contact: Federation of Indian Chambers of Commerce & Industry Tel: 011-23738760/8770 Email: ficci@ficci.com ...........................................................................

analytica Anacon India 2013

What : An event that will highlight the latest developments in anti-corrosion & corrosion control systems, compressors, exploration and production technology, environmental engineering, systems & equipment, fire prevention, gas processing equipment etc When : September 03-04, 2013 Where : Taj Lands End, Mumbai

What : International trade fair for laboratory technology, biotechnology & diagnostics When : November 12-14, 2013 Where : Bombay Exhibition Centre, Mumbai

For details contact: Oil Asia Publications Pvt Ltd Tel: 022-66814900 Email: info@oilasia.com

What :

For details contact: MMI India Pvt Ltd Tel: 022-42554710 Email: avisha.desai@mmi-india.in ...........................................................................

CHEMICAL EXPO

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An event for chemical equipment, environment & safety, plastics & packaging, electric & electronics, petroleum & gas, etc

When : December 07-10, 2013 Where : AIDS Ananpura, Ankleshwar, Gujarat For details contact: Better Deal Tel: 09979871798 Email: info@chemicalexpo.in ...........................................................................

PETROTECH What : The event will showcase power generation tools, oil and gas machinery, engineering equipment and pollution control tools etc When : January 12-15, 2014 Where : India Expo Centre and Mart, Greater Noida For details contact: Petrotech Society Tel: 011-23355072 Email: info@petrotechsociety.org ...........................................................................

PROCESS ENGINEERING EXPO What : An international exhibition and conference on process technologies When : September 04-06, 2014 Where : Hyderabad International Trade Exposition Centre (HITEX), Hyderabad For details contact: HITEX Tel: 040-23112121/2122 Email: pr@hitex.co.in ...........................................................................

INDIA CHEM 2014 What : An international exhibition on chemicals, petrochemicals, pharmaceuticals, technologies, process plant machinery and control & automation systems When : October 09-11, 2014 Where : Bombay Exhibition Centre, Mumbai For details contact: Federation of Indian Chambers of Commerce & Industry Tel: 011-23738760/8770 Email: ficci@ficci.com


Event List

interNational CHINA (GUANGZHOU) INTERNATIONAL ELECTRONIC CHEMICALS EXHIBITION What : Focussed event on cathode and anode material, electrolyte battery additives, intermediates, etc When : August 15-17, 2013 Where : Canton Fair Pazhou Complex Area B, Guangzhou, China For details contact: Guangzhou Zhenwei International Exhibition Co Ltd Tel: + (86)-(20)-84120362 Email: lwy@zhenweiexpo.com ...........................................................................

SARAWAK OIL & GAS EXPO What : Focussed event on oil & gas technology and conference where prominent speakers will highlight the latest developments in the sector When : August 20-22, 2013 Where : Miri Indoor Stadium, Miri, Malaysia For details contact: Fireworks Event M Sdn Bhd Tel: +(6)-(3)-79830680 Email: my@asiafireworks.com ...........................................................................

VEHIGAS What : A specialised international event on natural gas and liquid petroleum gas organised every two years When : August 21-23, 2013 Where : Jockey Plaza Convention Center, Lima, Peru For details contact: Thais Corporation S. A. C Tel: +(51)-(13)-4443860 Email: thais@amauta.rcp.net.pe ...........................................................................

Dye+Chem Bangladesh 2013 What : International exhibition on dyes and fine & specialty chemicals

When : September 05-08, 2013 Where : Bangabandhu International Conference Centre, Dhaka, Bangladesh

Where : Bangkok International Trade & Exhibition Centre (BITEC), Bangkok,Thailand

For details contact: CEMS-Global Asia Pacific Pte Ltd Tel: + (65) - 6829 - 2144 Email: contact@cems-dyechem.com ...........................................................................

SPECIALITY & AGRO CHEMICALS AMERICA What : The event will showcase the latest and advanced products and services including adhesives, sealants, resins, agriculture, crop protection, biofuels, biodiesel, coatings, paints etc When : September 09-11, 2013 Where : Hilton Wilmington Riverside, Wilmington, USA For details contact: American Chemical Marketing Tel: 1-215-8829100 Email: tom.leahy@chemicalsamerica.com ...........................................................................

NEFTEGAS EXPO What : An international event for process industries that will showcase the latest trends and developments in the sector When : September 10-13, 2013 Where : Lenexpo Exhibition Centre, St.Petersburg, Russia For details contact: Restec Exhibition Company Tel: +(7)-(812)-3206363 Email: main@restec.ru ...........................................................................

ASIA PACIFIC COATINGS SHOW What : Leading coating show of Southeast Asia and will focus on raw material supply for plastics, inks and adhesive manufacturers When : September 12-13, 2013

For details contact: Quartz Business Media Lted Tel: +(44)-(1737)-855000 Email: kezchen@quartzltd.com ...........................................................................

China Adhesive What : Exhibition focussing on adhesive and sealant products When : September 25-27, 2013 Where : Shanghai Everbright Convention & Exhibition Center, Shanghai For details contact: CCPIT Sub-Council of Chemical Industry Tel: +(86)-(10)-64275419 Email: contact@chinaexhibition.com ...........................................................................

GASSUF 2013 What : Focussed event on gas and gas filling technology When : October 15-17, 2013 Where : VVC Exhibition Centre, Pavilion no 75, Moscow For details contact: MVK International Tel: + (7) (495) 9358100 Email: satarova@ite-expo.ru ...........................................................................

CHEM SHOW What : An exhibition that will showcase process plant & technology for chemical industry, process control instrumentation, pumps etc When : December 10-12, 2013 Where : Jacob K. Javits Convention Center, New York, USA For details contact: International Exposition Company Tel: +(1)-(203)-2219232 Email: rhalligan@h-a-intl.com

The information published in this section is as per the details furnished by the respective organiser. In any case, it does not represent the views of Chemical & Process World July 2013 | Chemical & Process World | 67


Event Report | Engineering Expo Hyderabad 2013

hyderabad May 31-June 3, 2013 HITEX Exhibition Centre

Invoking the ‘Andhrapreneurial spirit’ for Industrial Leap Debarati Basu Das

Post the IT revolution, Hyderabad has undergone a metamorphosis. Over the last few years, the city has been trying to give its manufacturing mettle a new global identity. Rising as a favourable destination for businesses in the south, the city already has global heads making a beeline for investments in the region. Giving impetus to this growth story, Engineering Expo made its debut in Hyderabad. A report… the city’s calibre in terms of innovations, products & technologies, diverse industry verticals and customised manufacturing. The event was hosted with value adding partnerships from FAPCCI (Federation of Andhra Pradesh Chambers of Commerce and Industry) and with co-operation from UNIDO-ICAMT (United Nations Industrial Development Organization - International Centre for Advancement of Manufacturing Technology); FIEO (Federation of Indian Export Organizations) and NSIC (National Small Industries Corporation); MSME (Micro, Small & Medium Enterprises) and was supported by Andhra Bank. Lighting the lamp (L-R): Ravi Ramana; Devendra Surana; Archana Tiwari-Nayudu, Editor, Network 18 Publishing; Ganesh Parthasarathy; and Nitin Kunjir, Deputy Manager – Marketing, Network 18 Publishing

While the industrial climate is conducive for growth and opportunities are rife in India, Andhra Pradesh, in general, and Hyderabad, in particular, are brimming with potential and possibilities. Andhra Pradesh’s manufacturing might has helped it emerge as a key state for the knowledgebased industry. And the mushrooming of MNCs is a clear reflector of the healthy FDI inflows that the state has attracted over the years. Among the other regions in the state, Hyderabad exudes tremendous potential owing to its strategic geographic

positioning, availability of low-cost, highly skilled labour and the presence of a strong SME circuit. Acting as a catalyst to help the engineering and manufacturing fraternity leverage on the Hyderabad advantage, Network 18 Publishing organised the maiden edition of Engineering Expo Hyderabad at HITEX Exhibition Centre from May 31 to June 3, 2013. The four-day Expo portrayed the best of Hyderabad’s industrial assimilation and perfected a platform for the industry to showcase

68 | Chemical & Process World | July 2013

Setting the stage Engineering Expo Hyderabad was inaugurated in the presence of esteemed dignitaries including Devendra Surana, President, FAPCCI; Ganesh Parthasarathy, CEO, Tussor Machine Tools India Pvt Ltd; and Ravi Ramana, Assistant GM, Andhra Bank. The most striking feature of the trade show was that over 60 per cent of the 130+ exhibitors were from across the country. It also witnessed delegations from Bharat Heavy Electricals Ltd (BHEL); Tata Projects; Defence Research and Development Organisation (DRDO); NSL Renewable Power; Vasantha Group and Amara Raja,


Engineering Expo Hyderabad 2013

among others. This unique blend of local There were other exhibitors who there are any such expos, the level of and national participation gave a special reiterated the fact that Engineering Expo participation is low. Interestingly, even on boost to the business dynamics that the Hyderabad gave them an opportunity to Day 1 of Engineering Expo Hyderabad, Expo offers. explore the region. Affirming the same, the participation of exhibitors and visitors Commemorating this fact, Surana said, B Mukherjee, Product Manager, Juaristi was encouraging, which is a rare sight.” “Such exhibitions ensure that we remain Oriental Engineering Services, a MumbaiEngineering Expo Hyderabad has updated about the latest happenings in based company, expressed, “Hyderabad is become a ‘myth breaker’ in the region. the domestic industry.” Parthasarathy, a one of the new areas that our company According to Rajshekhara T, Managerregular participant at Engineering Expo, wants to explore.” Engineering Expo Sales, Sai Engineering, a visitor, “Hyderabad highlighted, “There are many flagship Hyderabad had something for everyone; is a pharma-dominated industry. You do expos but most expos in India are not as it helped participants successfully generate not find many exhibitions that cater to well-organised as Engineering Expo. Today, more than 50 business leads per day. automotive and machining industries. Engineering Expo has become one of the Engineering Expo will break this myth; if it Visitors Optimise@Expo most important exhibitions in the country.” is organised on a regular basis, we will have Engineering Expo was visited by more Engineering Expo is India’s largest a good expo to look forward to. More so, than 10,600 people. The four-day event SME gathering on engineering and there are so many companies from Gujarat, manufacturing. The trade show Maharashtra and other states. This has always sought to provide gives us a holistic vision on all that SMEs – the small wonders that is happening in the industry across play a pivotal role in helping the the country. This will also help us  Pan India participation from 139 exhibitors country progress economically – a to understand the things that we  Spread over more than 50,000 sq ft stepping stone to success. Apart need to do to meet the demands of  10,638 business visitors across India from finding the right contacts, the industry outside Hyderabad.” SMEs need finances to thrive in The event also had visitors  Business transacted worth ` 70.85 crore* this competitive era. Commenting who hoped to make the Expo  7,457 business leads generated* on the need to finance SMEs, a base for their entrepreneurial  4,500+ products displayed from different industries Ramana, at the inaugural function, venture. Manohar M, a retired  More than 78,000 kg machinery moved in for display explained, “We feel that every industry personnel from the  78% exhibitors are satisfied with the visitors bank should understand SMEs’ plastics industry, was one such  80% exhibitors intend to participate next year potential and encourage them visitor. He commented, “I have financially.” retired from my services, but I  85% exhibitors recommended Engineering Expo to others am looking for options to start  82% exhibitors prefer Engineering Expo over other Opportunities for exhibitors my own business in the plastics industry exhibitions * Feedback received from exhibitors Engineering Expo Hyderabad industry. I am basically here to received an enthusiastic response look for the kind of products from exhibitors. Elaborating on on display to get a feel of the how the trade show has been a boon received an overwhelming response from industry’s need. This Expo is certainly the Hyderabad crowd who optimised for participants, Ilesh Pancha, MD, iPan worth an experience as there are a few Engifab, a Gujarat-based fabrication their visit. It had everyone, right from good companies that have displayed some firm, stated, “We have been dealing with entrepreneurs who wanted to strike good products in the plastics sector. This customers in Hyderabad but did not have deals and youth who wanted to learn will help me build contacts for the smalla proper avenue to exhibit ourselves in this about the various technologies available scale enterprise that I intend to start.” city. In this backdrop, Engineering Expo in the country to new entrepreneurs who A grand success… was the best medium for us to connect to wanted to build contacts for their future This maiden edition of Engineering Expo a larger audience in Hyderabad.” endeavours. Hyderabad proved to be a boon for the Similarly, Srinivas Kumar Twarakavi, Commenting from a visitor’s Hyderabad industry. It not only helped Founder & CEO, G4 Solutions & perspective, Suresh S, CEO, Excell the country understand and see the Applications Pvt Ltd, a Hyderabad-based Industries, stated, “I make it a point to visit capabilities that Hyderabad has but also company, averred, “This is a good platform expos across the country to know about took Andhra Pradesh’s entrepreneurial to connect with a national audience. We the latest technologies that are coming spirit one notch higher. are confident of taking our product to a up in the industry. However, Hyderabad Email: debarati.basu@network18publishing.com bigger platform at this Expo.” does not have many expos and, even if

Highlights of this edition

July 2013 | Chemical & Process World | 69


Event Report | Engineering Expo Hyderabad 2013 - Panel Discussion

Is Hyderabad ready for the industrial leap? Debarati Basu Das

Hyderabad is renowned for being the IT hub. But, over the years, the city has expanded its horizons to harness its manufacturing potential. However, it needs to make its mark on the global domain. In an attempt to help the region gain 3600 visibility, a panel discussion on the topic ‘Is Hyderabad ready for the industrial leap?’ was organised on the sidelines of Engineering Expo Hyderabad 2013, on May 31, 2013. A report…

The discussion comprised an eclectic mix of experts (L-R) Devendra Surana, Y Sreenivas Rao, Archana Tiwari-Nayudu (moderator of the panel discussion), M Sreenivasulu and Sreeram M M

Hyderabad is now going through its next phase of evolution by taking its potential to the world. Providing the platform for the right growth trajectory and understanding the need gaps, Network 18 Publishing organised a panel discussion on the sidelines of Engineering Expo Hyderabad 2013 at Aditya Sarovar Premiere, Hyderabad. The online partner of the event was Apex Auction. The panel discussion was conducted on the theme ‘Is Hyderabad ready for the industrial leap?’ This discussion was truly insightful and acted as food for thought for the more than 200 industry professionals gathered at the venue.

At the discussion… The discussion comprised an eclectic mix of experts including Sreeram MM, MD, Scarlet Industries Pvt Ltd; M Sreenivasulu, Dy Director (IMT), MSME - Development Institute; Devendra Surana, President, FAPCCI; and Y Sreenivas Rao, Project Director, DRDO. The panel discussion was

moderated by Archana Tiwari-Nayudu, Editor, Network 18 Publishing. Each speaker had a unique growth story for Hyderabad; however, they all agreed on one aspect – Hyderabad is destined to become an investment hub. Hyderabad not only manufactures world-class aerospace and defence products, the country’s demand for tooling accessories is also met by the city. All these are coupled with the advantage that the city gets from strong clusters of SMEs that are in every way capable of manufacturing world-class products. However, the speakers opined that even though the city has every possible advantage to grow, the opportunities are not being utilised optimally. Issues such as power outage and political uncertainty have handicapped the manufacturing sector.

What’s the solution? The discussion not just highlighted the problems but also gave solutions for the same. Every speaker expressed measures that need to be taken to regain growth. For instance,

70 | Chemical & Process World | July 2013

Surana pointed out, “Hyderabad already has a fantastic availability of manpower and entrepreneurial spirit. If these two problems are addressed, the city will grow at the rate of 15–20 per cent.” Rao opined, “We have to decongest Hyderabad. We need to have 7–8 clusters each with a nodal centre, which will have the technology. Each cluster should have proper infrastructure, export and marketing requirements and focus on a particular skill. This will enhance the manufacturing setup. We need to foresee 10 years ahead and project growth prospects,” he expressed. Sreenivasulu, on the other hand, talked about the various government schemes available for the growth of SMEs. He argued that human resource development and finance are the areas that need to be strengthened. Sreeram wrapped up the session by emphasising on the need for multiple financial cities in the country. “Hyderabad has the prerequisite infrastructure and knowledge base; it must be identified as a financial hub for national growth. SMEs have grown over the last 40–50 years and contribute 70 per cent to the state’s GDP. If we address these problems, Hyderabad will carve a place for itself on the global map,” Sreeram concluded.

Way to go… Every city has its roadblocks to opportunities. But for Hyderabad, what lies ahead are opportunities abound. The industry and government need to take collective steps to overcome the hurdles and carve the roadmap to global opportunities for Hyderabad. Email: debarati.basu@network18publishing.com


Book Review

Organometallics in Synthesis Edited by: Manfred Schlosser Price: ` 7,550

Organometallic compounds play an integral role in industrial chemical synthesis. More and more industrial processes rely on organometallic chemistry. As a result, readers will find the stepby-step instructions provided in this book essential in fields such as natural product synthesis, pharmaceuticals, fine chemicals, biotechnology, polymers and materials science. The book enables readers to conduct seamless synthetic reactions involving key organometallics. The interesting aspect of the book is that each reaction is presented in a lucid format so that readers can easily replicate the results. Each section offers handson guidance and practical examples illustrating the preparation of organometallics and their applications in organic synthesis. Salient topics covered in this book include organoalkali chemistry; organomagnesium and organozinc chemistry; organosilicon and related organotin chemistry; organoiron chemistry; and organopalladium chemistry. Readers are provided with detailed background information to learn more about the class of organometallics as well as mechanistic considerations. In addition to current applications, the book explores future research opportunities for each organometallic class. Available at: Wisdom Book Distributors, Hornby Building, 1st floor, 174, D N Road, Mumbai – 400001 Tel: 022-22074484/66318958, Telefax: 022-22034058 Email: thadam@vsnl.com

The book is the ultimate reference work for scientists and professionals looking for reliable information on chemicals, drugs and biologicals. The 15th edition contains up-to-date information about newest additions to the index. It enlists over 10,000 monographs with information related to compounds of significance in research, commerce and environmental impact. Over 35 per cent of the existing entries are updated. Along with this, more than 18,000 compounds with 50,000 synonyms are incorporated. The molecular weights are recalculated with the latest IUPAC standards. There is an inclusion of a new table showing non-proprietary name stems. There is a section for revised periodic table and atomic weight tables. The book serves as an essential reference for all scholarly and professional chemists, biochemists, pharmacists and toxicologists and is of interest to students, teachers, academic libraries, academic researchers, information professionals, solicitors, journalists and government agencies.

The Merck Index: 15th edition Published by: RSC Publishing Price: ` 8,800

Available at: Sci-tech Books & Periodicals, 414, Janki Centre, Veera Desai Road, Andheri (W), Mumbai – 400053 Tel: 22-26735260/66970507 Email: scitechbooks@gmail.com info@scitechbooks.co.in Reviewer: Tejas Padte, Lecturer, Department of Chemistry, Ramnarain Ruia College, Mumbai

July 2013 | Chemical & Process World | 71


Products

Food emulsifier

Flowmeter

Stephan Germany offers its multi-purpose, high-speed microcut emulsifiers MC 15, MCH 20K for continuous process and consistent size reduction. These are easily removable and consist of hard tipped, cutting rotors having no metal-to-metal contact – ensuring minimum product temperature rise and a long tool life. With the combination of the Stephan rotor/stator and the pre-cutting blade system operating at 3,000 rpm, a size reduction of 1:100 can be achieved in one process step. For example, vegetables in size of 35 mm can be reduced directly to 0.35 mm. The capacity available is 400–1,0004,500 kg/hr. The emulsifiers ensure low power consumption, with various infeed/discharge systems, inline units available to suit a process. These are ideal for fine pastes where protein swelling is an advantage. Besides, these are useful for grinding fish or chicken/skin for fat recovery, fish-head paste, sea moss, reduction for petfood, offal, feather for feed and chemical/pharma applications.

Correlated flowmeter is ideal for process plant applications and provides precise readings even in aggressive plant environment. Its correlated variable area is available in 65 mm or 150 mm scales. Common applications for these low-cost variable area flowmeter include air sampling equipment, chemical processing, metering of gases in chromatography systems, desalinisation equipment, gas analysers and water treatment systems. It can be used with gas or liquids and it is also available in a choice of materials, with or without control valves and range of flow tube sizes. It is available in aluminum body, brass body, 316 stainless steel body, high-precision valve flowmeter. This flowmeter uses a universal millimeter scale to allow the flowmeter to be used with a number of different fluids, at changeable pressure and temperature conditions, by cross-referencing the scale against a correlation data sheet. These flowmeters can measure liquids flow from 0.0002 ml/min to over 400 LPM and for gases from 0.02 ml/min to 700 m3/hour.

TRICON Pune - Maharashtra Tel: 020- 25652205/2451 Mob: 09890192832 Email: triconfood@gmail.com, trivedi@pn2.vsnl.net.in

Cole-Parmer India Pvt Ltd Mumbai - Maharashtra Tel: 022 - 67162209/2222 Email: response@coleparmer.in Website: www.coleparmer.in

Boron carbide abrasive grains These have high strength-toweight ratio and low thermal conductivity and it is ideal for a wide variety of applications. Thermal neutron capture crosssection is 600 bam. Grit sizes of available grains are # 80, 120, 150, 180, 220, 240, 280, 320, 360, 400, 500, 600, 800, 1,000 and 1,200. Application lies in aerospace; ballistic armor; blasting composites; ceramic composites; honing stones; lapping; metal matrix composites; nuclear technology; refractory shapes, cements; tool and die fabrication; ultrasonic machining; boronising etc. Examples of usage are lapping and polishing of hard metal carbides; ceramic parts – hot pressed or cold pressed; and sintering to make blasting nozzles, crush rolls and wear parts; refractory antioxidant in castables and cements; hard facing welding electrodes and coatings, etc. Tough Products Thane – Maharashtra Tel: 022-65616960 Email: info@toughgroup.in, sales@toughgroup.in Website: www.toughgroup.in

72 | Chemical & Process World | July 2013

Methyl methacrylate adhesive PARTITE Methyl Methacrylate Adhesives (MMA) fills in the gap where two-part epoxy adhesives and two-part polyurethane adhesives lack the performance required by the assembly industry. It provides cure-ondemand, excellent balance of adhesion and toughness, chemical resistance, long-term durability and requires minimal surface preparation. PARTITE 7300 is useful in fast assembly. It gives almost a full cure within 10 to 15 minutes after application. PARTITE 7390 is useful to bond larger parts. It gives a full, strong cure in 150 minutes. Unlike epoxies and polyurethanes, PARTITE MMAs are most suitable for bonding dissimilar substrates: metal-to-plastic, composites to plastic, etc. It helps industrial assembly-lines save lot of time, labour and capital cost by eliminating long fixture and surface preparation time while providing better performance to the finished products. The company offers 1:1 and 10:1 PARTITE Methacrylate Adhesives (MMA) as well as tailored solutions. Parson Adhesives India Pvt Ltd Vadodara – Gujarat Tel: 0265-2972191,6541638 Mob: 09428511765 ,09825299551 Email: sales@parsonadhesives.in, bijay@parsonadhesives.in Website: www.parsonadhesives.in


Products

Boron carbide paste Turbolap boron carbide paste finds applications in lapping and polishing of various components in the following industries – automobiles, compressors, ceramics, pumps and valves, tools & gauges and dies & moulds. It can cut three times faster than silicon carbide on hard metal and ceramic; hence it is superior than silicon carbide valve grinding paste. It features reduction in operating time due to fast and efficient cutting; high quality surface finish due to closely sized grains; resistance to temperature up to 350º C because of the binder used and no run-off or spread cut. Uniform polish is obtained even at high temperatures and low environmental impact. It can be used at application temperature up to 350º C with little pressure and it can be cleaned from lapped polished surface with the help of benzene of kerosene. Grit size of grains are available in # 80, 120, 150, 180, 220, 240, 280, 320, 360, 400, 500, 600, 800, 1,000 and 1,200; and standard packings of 200, 500, 1,000 and 2,000 gm. Tough Products Thane – Maharashtra Tel: 022-65616960 Email: info@toughgroup.in, sales@toughgroup.in Website: www.toughgroup.in

Waterproof multiparameter meter It is a waterproof multiparameter meter of the Testr 35-series from Oakton. A pocket-sized meter that measures pH, conductivity, TDS, salinity and temperature, it is perfect for water, wastewater, laboratory and plant-use. This pocket-sized meter has long-life pH electrodes and stainless steel conductivity sensors for a wider range of sample compatibility. It has easy-to-replace sensor modules, which can save money, and enable one to reuse the meter body. The operating procedure is simple and changing sensors for different measurements is not required. The meter offers multiple calibration options – single or multipoint, automatic or manual. Conductivity or TDS can be measured more accurately at varying temperatures with an adjustable temperature coefficient feature. Auto-ranging feature makes it more convenient for users with applications across broad measurement range. Unique sensor design provides faster ATC response and readings. Cole-Parmer India Pvt Ltd Mumbai - Maharashtra Tel: 022 - 67162209/2222 Email: response@coleparmer.in Website: www.coleparmer.in

July 2013 | Chemical & Process World | 73


Products

Airless paint spraying pump

Total water hardness test strip

This pump is suitable where better paint finish, gloss of paint and aesthetic results of the machine are prime requirements. It gives high output of paint and thus save time, manpower, paint & cost by giving high efficiency. It is also possible to spray high build paints for anticorrosive painting with airless pump.

Water hardness test strip is used for quick and easy determination of water hardness. The convenient dip and read procedure and the clear colour changing from green to red ensures reliable results within seconds. The water hardness depends mainly on the amount of calcium and magnesium salts within the water. The total sum of these salts determines the actual water hardness. The strips are used in a wide variety of industries and applications. Hard water may cause calcification and can thus damage machinery, appliances, pipes or heating units. In many industries, water hardness is an important parameter in process control and has to be monitored constantly. Some examples of industries include the textile industry, dyeing factories, large-scale laundries, water works, fish-farming and aquaculture. The water hardness test strips come in a wide variety of different gradations and packaging options catering to very specific or unique requests. These are the ideal choice to quickly, easily and reliably determine water hardness.

Synco Industries Ltd Jodhpur - Rajasthan Tel: 0291-2741571, Mob: 09829022258 Email: synco_2000@yahoo.com

Digital flow meter The paddle wheel insertiontype digital flow meter is a unique 2-in-1 combination, wherein the rotameter measures flow rate vertically. The water meter counts total horizontally and measures both the aspects. It is economical and used to match up with international standards. No external power supply is required. MTS Engineers Pvt Ltd Ahmedabad - Gujarat Tel: 079-26400063 Mob: 09879495924 Email: sales@mtsengrs.com, Website: www.mtsengrs.com

Vibro shifter Vibro shifter is known for its sturdy construction, corrosion resistant and durable features. It is highly resultoriented and offers best results in the usage. It is energy-efficient, has a long functional life and excellent performance. The vibro shifter is used for sieving and screening of chemicals, cosmetics and pharmaceuticals. Shefa Industries Mumbai - Maharashtra Tel: 022 – 25942473 Email: shefaindustries@yahoo.co.in Website: www.indiamart.com/shefaindustries

74 | Chemical & Process World | July 2013

Loba Chemie Pvt Ltd Mumbai - Maharashtra Tel: 022-66636663 Email: info@lobachemie.com, vic@lobachemie.com Website: www.lobachemie.com

Tube expander Tube expander forms a perfect mechanical seal between the tube and the tube sheet. The tube expander produces a smooth, unrigged surface in heat exchangers and condenser, oil and air cooler, preheaters, super heaters, radiators, boilers, economisers, juice heaters, evaporators, etc. It is designed for long service, and features an adjustable ball bearing thrust collar to eliminate frictional heat. Rolls have gradually tapered noses to eliminate sharp offsets in the rolled tubes and ensure uniform tube tightness throughout the thickness of the tube sheet. Adjustable tube expanders are available with 6.3102 mm OD tubes of various sheet thickness and fixed roller length tube expanders with 20-102 mm OD tubes and 26-95 effective expansion. The device can be used manually, with electric or with a hydraulic tube expansion equipment. Airxpa Engineers Mumbai – Maharashtra Tel: 022-25966053, 67993503 Email: sales@airxpa.com, airxpa_engineers@vsnl.net Website: www.airxpa.com


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Products

Water saver nozzle The cleaning gun/water saver nozzle is suitable for hot or cold water cip and cleaning jobs with options of two spray actions-cone and jet spray. A hose suitable for working temperature of 164oC and working pressure of 20 bar for the nozzle is available. Hose length of up to 40 mtr can be fitted with the nozzle and is supplied along with it for efficient working. It is highly efficient in saving water while performing cleaning jobs in food, pharmaceutical, dairy and milk plants, breweries, chemical, meat and poultry processing industries, big kitchens, canteens, mess, etc. Vijay Engineering Corporation Delhi Tel: 011-23215170, 09873426193 Email: sachin@vechoses.com Website: www.vechoses.com

AAS and ICP standard solution The new line of certified standards is dedicated to ICP and AAS. This inorganic ICP standard features extended expiration dates and is a reasonably priced alternative to others available today. Specific element standards for ICP analysis are available, which correspond to QC verification, interference checks and instrument control and diagnostics. Single element standards are available in 1000 µg/ml in 100 or 500 ml bottles, packed in aluminium bag with COA. The standard solution for AAS is prepared in HDPE bottles. It is traceable to primary certified reference materials (NIST, BCR). The accuracy of the concentrations is guaranteed to +/- 0.2% from the nominal concentration. Its shelf-life is 36 months from the date of production, closed bottle. Loba Chemie Pvt Ltd Mumbai - Maharashtra Tel: 022-66636663 Email: info@lobachemie.com Website: www.lobachemie.com

3/8" Inch Simplex Sprockets Roller chain drives require correctly designed and accurately cut sprocket teeth in order to give satsfactory service and quiet operation. Sprocket wheels are manufactured from

quality materials.Teeth are machine-cut for correct tooth from tooth thickness and profile. Machine tooth surfaces are smooth and providing full contact with chain rollers, assuring maximum life of chain and sprocket wheel. Albro Engineers Pvt Ltd Pune - Maharashtra Tel: 020-26169546 Mob: 9850062164 Email: albropune@yahoo.co.in Website: www.albroindia.com

Pneumatic conveyor The MiniVac pneumatic conveyor comes with a complete integral blower, which eliminates the need for an expensive plant air or a separate compressor. The regenerative blower increases operating efficiency. It lengthens filter life and maximises performance with a standard reverse pulse jet filter cleaning system that keeps the filter clean and at optimum operating efficiency. The standard size access doors allows for easy filter replacement in less than five minutes without the use of any tool. The compact and integral blower eliminates the need for air piping and makes installation easier. Hapman Systems Pvt Ltd Vadodara – Gujarat Tel: 0265 – 2517505 Email: info@hapman.in Website: www.hapman.in

Motor protection relay This instrument displays various parameters, trip count and trip data on 8-digit alphanumeric display, and has separate LEDs for individual fault indication. This is fouruser programmable output relay, it is built in self-supervision, and self-testing feature helps maintenance. It provides easy operation by 5 push buttons. It also has RS485 port for serial communication with ‘MSCOM’ user-friendly software. Larsen & Toubro Ltd Mumbai - Maharashtra Tel: 022-67054902 Email: karthikm@lntebg.com Website: www.lntebg.com

July 2013 | Chemical & Process World | 77


Products

Electronic humidistat and controller

Level leaf filter

Measuring range is from 30°C up to +80°C. Accuracy is <±2 per cent RH and <±0.5°C in the full measuring range. Each sensor comes with a calibration protocol for 0 per cent RH and 75.3 per cent RH. The sensor can easily be changed and after setting the calibration parameters on the display the <±2% RH accuracy is obtained again. A 10 m sensor cable and wall mounting device is included; 20 m sensor cable is optional.

Sharplex level leaf filters are used for polishing filtration in post filtration stage to trap the fine particles from the filtrate of main filter. The filter elements have filter surface at both the sides, and hence the filters become compact even at higher filtration areas. The filter medium can be cloth or paper. The filters are available from 2m2 upto 15m2.

Jay Jagannath Air Equipments Vadodara - Gujarat Tel: 0265-3913451 Mob: 09925003183 Email: bpathak81@hotmail.com Website: www.jjgroup.com

Alarm management device Alarm management system for the process industry is a measuring instrument with flexible programmable display, which provides new practical options in process monitoring. The measuring values do not have to be analysed first because the display indicates at a glance whether the preset measuring values are exceeded and immediate intervention is required. Baumer India Pvt Ltd Pune - Maharashtra Tel: 020-2528 6833, 09850688300 Email: sales.in@baumer.com Website: www.baumer.com

High pressure triplex plunger pump

37 litre per minute.

The high-pressure triplex plunger pump series 4500 with unloader and safety valve has an electric motor or diesel engine assembled with a centrifugal pump. It supplies pressurised clean water at pump inlet. The water inlet temperature is 50 0C, plunger diameter is 22 mm and holds

UT Pumps & Systems Pvt Ltd Mumbai - Maharashtra Tel: +91-022-32992488 Email: info@utpsl.in Website: www.utpsl.in

78 | Chemical & Process World | July 2013

Sharplex Filters (India) Pvt Ltd Navi Mumbai - Maharashtra Tel: 022-27696322/6339 Email: sharplex@vsnl.com Website: www.sharplex.com

Portable shot blasting machines S7-150 is recommended for light job and intermittent requirement of blasting. An economical model, light weight and mobile, it can be operated by one operator. S7-300R is recommended for medium production work and has all the features of production machines. For automatic start/stop, the machine can be provided with remote control unit. Synco Industries Ltd Jodhpur - Rajasthan Tel: 0291-2741571 Mob: 09829022258 Email: synco_2000@yahoo.com Website: www.synco.co.in

In-situ fermentor It offers computer compatible control system on request and has temperature, pH, O2 and pCO2, pressure and level as an option. Jacketed pressure vessel is made of stainless steel with standard ports. Audio visual annunciation system is provided to track parameter set point failures. It has double mechanical shaft seal with steam condensate and circulation ensureinglong life. It provides detachable modular 19" standard control rack and provides accurate controls with digital readout for aeration. Shree Biocare India Ahmedabad - Gujarat Tel: 079-40084116 Mob: 09898999146 Email: shreebiocare@gmail.com Website: www.fermentorsolution.com


Products

Air monitor The air monitor developed by UEPL is a microprocessorbased, non-dispersive spectrophotometer tailor-made for the analysis of the five pollutants SO2, NO2, NH3, Cl2, O3 at parts per billion levels. The instrument is light-weight and moderately priced. Ambient air is sampled for the required time duration, eg 4, 8 or 24 hours. The Uniphos air sampler can sample three different gases simultaneously using three impingers filled with recommended gas absorbing solvents. The solutions from the impingers are further treated with other reagents to form coloured dyes. The measurement of absorbance on this coloured dye is made on the Envirotrack. The analysis is simple and all the calculations are done by the microprocessor with results displayed on the instrument. The results can also be transferred to a computer or laptop with date, time, location and other identification using GUI software, which can be separately bought with the instrument. Uniphos Envirotronic Pvt Ltd Valsad – Gujarat Tel: 260-2730156/158 Email: cel@uniphos.com Website: www.uniphos.com

Reaction vessels These industrial reactors are fabricated to accuracy using qualitative material and are constructed either in MS or SS. These vertical reactors are provided with different capacities ranging up to 25 KL and comprise the following construction elements: sturdy construction, leak proof and durable and finds application in various industries such as pharmaceutical, fertilisers, food and dairy, petrochemical, pharmaceutical, pulp and paper, dyestuff and chemical engineering. The various types of vessels available are jacketted reactor, limpet coiled reactor and internal coil reactor. Aries Engineers Thane – Maharashtra Tel: 022 – 28555751 Mob: 09323649078, 09930992671 Email: ariesengineers@yahoo.com, info@ariesengineer.com Website: www.ariesengineer.com

July 2013 | Chemical & Process World | 79


Products

Safety switchgear The PSR is a comprehensive range of safety switchgear. In addition to the basic approvals for mechanical and plant engineering, the modules are also approved for process engineering, furnaces and shipbuilding. It offers high standard for monitoring safety relevant signals. All connections are pluggable, coded, and designed as both screw or twin spring-cage connection. With compact and space-saving design, the PSR modules offer increased isolation between input/output and enabling/signaling current circuits. It is controlled via one/two channels with or without cross-circuiting detection. Phoenix Contact (I) Pvt Ltd New Delhi Tel: 011-3026 2800 Email: response@phoenixcontact.co.in Website: www.phoenixcontact.co.in

Rotor units The high-quality stainless steel desiccant rotor cassettes provide greater flexibility to AHU manufacturers. Applications requiring air to be supplied at lower dewpoints can be effectively and efficiently achieved using cooling coils.Specifically designed for use in customised air handling units, all cassettes include the SSCR silica gel rotor, geared drive motor, rotor drive system, radial and peripheral seals. Its dehumidifying capacity is at 20째C/60 per cent RH. Jay Jagannath Air Equipments Vadodara - Gujarat Tel: 0265-3913451, Mob: 09925003183 Email: bpathak81@hotmail.com Website: www.jjgroup.com

Fuel pump Fuel pump has 600 models of fuel units to choose from. Small capacity burners are available from 10 to 1,000 kw for light oil, kerosene applications, pumps with or without solenoid valve. Singlestep or two-step operation models available are AN, AL, AS, AT, A2L. Medium capacity burner are from 400 to 3,000 kw for light oil

80 | Chemical & Process World | July 2013

or heavy oil applications. Pumps with or without hydraulic cut-off model are D, AJ, E, J. High capacity burner are from 3000 to 30,000 kw. Pumps with electric preheater facility for heavy oil applications models are T, TA etc. Classic Enterprises Mumbai - Maharashtra Tel: 022-22034496 Email: classic@bom3.vsnl.net.in Website: www.classic-combustion.com

Vertical pressure leaf filter Vertical pressure leaf filter is used for filtration of liquids with suspended solid contents up to 7 per cent. No filter cloth is required. It provides automatic dislodging of filtered cake by pneumatic vibrator or oscillating sluice header. Dry or wet cake discharge is possible. Filtration area is up to 120m2. The various application areas are resins, bleaching earth/activated carbon, crude oil, sulphur, ni-catalyst, glucose, fatty acid, brine, winterisation, electrolyte and beverage industry. Material of construction is CS, SS, SS904L, titanium, hastelloy, monel, polypropylene/teflon coated. Sharplex Filters (India) Pvt Ltd Navi Mumbai - Maharashtra Tel: 022-27696322/6339 Email: sharplex@vsnl.com Website: www.sharplex.com

Two wire temperature transmitters These transmitters LTX-3000-H-2 accepts (Pt-100) or thermocouple or variable resistance signal as the input and provides DC current output of (4-20) mA proportional to mV or resistance values. The transmitter is linearly calibrated to the signal produced by a thermocouple or RTD sensors and is not to the actual temperature. Libratherm Instruments Pvt Ltd Mumbai - Maharashtra Tel: 022-28963823 Mob: 09821136685 Email: libratherm@libratherm.com Website: www.libratherm.com


Products

Silicone transparent tubing

Ribbon blender

These transparent tubings are made from 100 per cent pure silicone rubber by using fully automatic state-of-the-art machineries and technologies. Silicone transparent tubings are manufactured under stringent quality control and having the following distinguished features: it is made from medical grade silicone rubber, which complies with USP Class VI requirement & FDA 21 CFR 177.2600, temperature resistant from -80°C to 250°C (-110°F to 480°F), non-reactive to body tissue and fluid, non-adherence to tissue. It remains unaffected by most water soluble materials and is sterilisable by steam, dry heat, ethylene oxide (ET) and gamma radiation, which resists oxidation, ozone and radiation. It has an indefinite shelf-life. Silicone sleeves are also manufactured. It finds application in food, pharma, chemical, medical, heavy engineering, thermal power stations and PSUs.

The ribbon blender is an efficient and versatile blending machine for mixing of dry granules and powders homogeneously. Approximately, twothird of the volume of the container of ribbon blender is filled to ensure proper mixing. The ribbon blender gives best result for mixing of dry powder and granules due to the design and shape of the mixing ribbon and product container. These are manufactured in a range of 25 kg to 5,000 kg batch capacity in mild steel and stainless steel. It features less working time, no dust formation, less maintenance cost, less service after sales. Application areas include food processing, pharmaceutical, chemical pesticides, fertilisers and cosmetic industries.

AMI Polymers Pvt Ltd Thane - Maharashtra Tel: 022-28555107/631 Mob: 09223290931 Email:amipolymer@vsnl.com Website: www. amipolymer.com

Aries Engineers Thane – Maharashtra Tel: 022 – 28555751 Mob: 09323649078, 09930992671 Email: ariesengineers@yahoo.com, info@ariesengineer.com Website: www.ariesengineer.com The information published in this section is as per the details furnished by the respective manufacturer/distributor. In any case, it does not represent the views of Chemical & Process World

July 2013 | Chemical & Process World | 81


List of Products

Product

Pg. No.

3/8” inch simplex sprocket................................. 77 Aas and ICP standard solution......................... 77 Acoustic enclosure............................................25, BC Air cooled heat exchanger.................................... FIC Air monitor.............................................................79 Air-cooled steam condenser................................. FIC Airless paint spraying pump....................................74 Alarm management device......................................78 Aluma coat................................................................3 Automatic filter press..............................................84 Bag filter........................................................... 57 Ball check valve.......................................................59 Ball valve........................................................... 17, 59 Ball valve - screwed end...........................................79 Ball valve - three piece design..................................79 Ball valve - teflon lined..............................................6 Basket filter.............................................................57 Bellow and dip-pipe..................................................6 Blender....................................................................51 Boron carbide abrasive grain....................................72 Boron carbide paste.................................................73 Bush .......................................................................59 Butterfly valve.................................................... 17, 59 Butterfly valves - teflon lined.....................................6 Cable management system................................. 47 Cartridge filter.........................................................57 Ceramic coating........................................................3 Check valve.............................................................17 Check valve - teflon lined..........................................6 Chemical process equipment...................................53 Chemical pump.......................................................73 Condenser...............................................................51 Continuous nitration system...................................53 Cooling tower....................................................... FIC Cooling tower solution............................................47 Diaphragm valve............................................... 59 Digital flow meter...................................................74 Dry van pump..................................................25, BC E/P positioner.................................................. 73 Elbow - butweld type..............................................79 Electronic humidistat and controller.......................78 End cap...................................................................79 Exhibition - Plastivision 2013.................................38 Fep/pfa/pvdf material................................ 59 Filter plate...............................................................84 Filter press...............................................................84 Filter press terminology...........................................84 Fitting.....................................................................59 Flow verturi tube.....................................................51 Flowmeter...............................................................72 Forged steel valve.....................................................17 Food emulsifier........................................................72 Foot valve - non-return valve...................................79 FRP cross arm.........................................................47 FRP epoxy pultruded profile...................................47 FRP/GRP handrail and fencing..............................47

Product

Pg. No.

FRP/GRP ladder.....................................................47 FRP/GRP moulded grating....................................47 FRP/GRP profile....................................................47 FRP/GRP pultruded grating...................................47 FRP/GRP step tread...............................................47 Fuel pump...............................................................80 Fully automatic robotic cloth washing system.........84 Gasket.............................................................. 59 Gate valve................................................................17 Globe valve..............................................................17 GMP and non-GMP..............................................53 Hastalloy.......................................................... 17 Heat exchanger.................................................. 51, 53 High heat transfer coefficient rate...........................10 High pressure triplex plunger pump........................78 High speed mixer....................................................53 Hope ball valve - flange end....................................79 Hydraulic filter press...............................................84 In-situ fermentor.............................................. 78 Large diameter welded pipe............................... 79 Level leaf filter.........................................................78 Light poles and utility poles....................................47 Limit switch............................................................73 Lined valve..............................................................17 Lined valve and pipe fitting.......................................6 Logistics solution.................................................BIC Long neck pipe end.................................................79 Low maintenance....................................................10 Manual filter press............................................ 84 Membrane holder....................................................57 Methyl methacrylate adhesive.................................72 Monel......................................................................17 Monoblock pump....................................................73 Motor protection relay.............................................77 Nickel aluminium bronze.................................. 17 Nitrogen plant manufacturer...................................35 Non metallic pump..................................................73 Non return valve........................................................6 Nut shell filter.........................................................57 P/P positioner................................................... 73 Pipe .......................................................................59 Piping system from polypropylene............................4 Plate & membrane type filter press.........................84 Plug valve.......................................................... 17, 59 Pneumatic conveyor.................................................77 Polypropylene process pump...................................73 Portable shot blasting machine................................78 PP butterlly valve - flange end.................................79 PP diaphragm valve flange end and screwed end....79 Pressure vessel.................................................... 51, 53 PTFE......................................................................59 PTFE lined valve and pipe fitting.............................6 Pump..........................................................25, 73, BC Pump for chemical equipment..................................5 PVDF pump............................................................73 Reaction vessel.................................................. 79

BC - Back Cover, BIC - Back Inside Cover, FIC - Front Inside Cover

82 | Chemical & Process World | July 2013

Product

Pg. No.

Reactor....................................................................53 Ribbon blender........................................................81 Rod .......................................................................59 Root blower......................................................25, BC Rotary gear pump.............................................. 55, 73 Rotary jocketed pump.............................................55 Rotary main oil pump.............................................55 Rotary monoblock pump.........................................55 Rotary tracodial pump.............................................55 Rotary twin gear pump............................................55 Rotor unit................................................................80 Safety switchgear.............................................. 80 Sampling valve - teflon lined.....................................6 Seamless pipe..........................................................79 Self priming mud pump..........................................73 Self priming sewage pump......................................73 Sheet .......................................................................59 Silicone FBD gasket................................................81 Silicone rubber braided hose...................................81 Silicone rubber compound.......................................81 Silicone rubber corona teater sleeve.........................81 Silicone rubber extruded gasket and profile.............81 Silicone rubber moulding........................................81 Silicone rubber sheet...............................................81 Silicone rubber sponge............................................81 Silicone rubber tubing.............................................81 Silicone transparent tubing......................................81 Sintered filter...........................................................57 Socket......................................................................79 Stainless steel pipe...................................................79 Sterility test kit........................................................57 Storage tank...................................................... 51, 53 Strainer......................................................................6 Super duplex............................................................17 Swing check valve....................................................59 Teflon lined valve and pipe fitting........................ 6 Tefzel hhs isotactic PP material.............................4 Thermoplastic valve...................................................4 Titanium.................................................................17 Total water hardness test strip.................................74 Trade show..............................................................62 Tube ................................................................. 59, 79 Tube expander.........................................................74 Two wire temperature transmitter...........................80 ‘U’ tube............................................................. 79 Vacuum booster pump.................................25, BC Vacuum system.................................................25, BC Valve .......................................................................59 Valve positioner.......................................................73 Vent filter.................................................................57 Vertical glandless pump...........................................73 Vertical pressure leaf filter........................................80 Vibro shifter............................................................74 Water saver nozzle............................................ 77 Waterproof multiparameter meter...........................73 Welded pipe............................................................79


List of Advertisers Advertiser’s Name & Contact Details

Aeron Composite Pvt Ltd

Pg No

47

T: +91-79-65258500 E :info@aeroncomposite.com W :www.aeroncomposite.com All India Plastics Mfrs Association

38

T: +91-22-28217324 E :pvi13@plastivision.org W :www.plastivision.org   Bhavya Polymers

81

T: +91-2762-224114 W :www.bhavyapolymers.com 62

T: +91-22-30034650 E :cpw@network18publishing.com Del PD Pumps & Gears Pvt Ltd

55

T: +91-2752-243047 E :rotodel_ad1@sancharnet.in W :www.delpump.com Dev Engineers

73

T: +91-79-26403839 E :info@devpumps.com BC

T: +91-11-45457777 E :info@everestblowers.com W :www.everestblowers.com Flucon Automation

73

T: +91-79-65722609 E :sales@fluconautomationinc.com W :www.fluconautomationinc.com G M Engineering

Hi-Tech Applicator

6

T: +91-08471021444

E :hitech@ptfeindia.com

E :cms@psanitrogen.net

W :www.ptfeindia.com

W :www.psanitrogen.net

HRS Process Systems Ltd

10

17

35

Sachin Industries Ltd

84

T: +91-20-66047894/95

T: +91-79-25832204

E :info@hrsasia.co.in

E :exports@sachininternational.com

W :www.hrsasia.co.in

W :www.sachininternational.com 3

Samarth Engineers

51

T: +91-253-2350120

T: +91-20-66300305

E :info@jyoticeramics.com

E :sanjayaut21@hotmail.com

W :www.jyoticeramics.com

W :www.samartheneers.com

KPC Filtech Pvt Ltd

57

Schenker India Pvt. Ltd.

BIC

T: +91-22-25669866

T: +91-124-4645000

E :sales@kpcfilt.com

E :infoindia@dbschenker.com

W :www.kpcfilt.com

W :www.dbschenker.com/in

Kwality Process Equipments Pvt Ltd

53

Supremo Polymer Industries

59

T: +91-250-2453438

T: +91-79-22205282

E :pdmakwana@vsnl.net

E :supremoproduct@gmail.com

W :www.chemicalequipments.com

W :www.supremoproduct.com

79

Suraj Limited

T: +91-79-22901027

T: +91-79-27540720

E :info@marvex.co.in

E :suraj@surajgroup.com

W :www.marvex.co.in

W :www.surajgroup.com

Paharpur Cooling Towers Ltd

FIC

Swam Pneumatics Pvt Ltd

T: +91-33-24792050

T: +91-120-4696222

E :pctccu@paharpur.com

E :sales@swamatics.com

W :www.paharpur.com

W :www.swamatics.com

Pentair Water India Pvt Ltd

5

UNP Polyvalves India Pvt Ltd

T: +91-120-4199444

T: +91-265-2649248

E :valve@gmengg.com

E :marketing.india@pentair.com

E :mktg@polyvalve.com

W :www.gmengg.com

W :www.pentair.com

W :www.polyvalve.com

T: +91-2827-287658

Pg No

PSA Nitrogen Ltd

T: +91-79-25833040

Marvex Polytech Pvt Ltd

W :www.devpumps.com Everest Blowers

Pg No Advertiser’s Name & Contact Details

Jyoti Ceramic Industries Pvt Ltd

E :bhavyapolymers@yahoo.co.in Chemical & Process World

Advertiser’s Name & Contact Details

Our consistent advertisers

Not applicable

79

25

4

BC - Back Cover, BIC - Back Inside Cover, FIC - Front Inside Cover

July 2013 | Chemical & Process World | 83



Chemical & Process World July 2013