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INDUSTRY WATCH - Chemical World
Land reforms: On a progressive path
or the Indian economy, this would be the right time to move away from the slumber of the recent months, which has been holding back investments into the country and has resulted in a drag effect on several sectors. In this context, the recent reshuffle in certain central ministries and clearing of some critical government legislations, which have been long due, perhaps could not have been timed better! Case in point is the recent clearing, by the Group of Ministers (GoM), of the Land Bill, a much-needed exercise on its 117-year-old extension that according to industry sources has been creating quite a lot of confusion, and worse, litigation related to setting up of development projects. The Bill in its new avatar (Land Acquisition, Rehabilitation and Resettlement Bill, 2011) requires the consent of only two-third of the people affected in private and Public Private Partnership (PPP) projects, instead of the earlier mandated 80 per cent. Hopefully, this will not only provide more clarity on project execution but also facilitate timely implementation thereof. According to a clause in the Bill, it is to be applied from an unspecified cut-off date. Although the cut-off date, as per official sources, is most likely to be decided before the Bill is cleared for introduction in the Winter Session of the Parliament, it has left most in the industry with fair amount of worries. Thankfully, the Bill, which initially had provisions for retrospective application of the law in cases where the land had not been awarded or where compensation had not been paid, does not have this clause any more. Thus, this prospective clause should be industry-friendly. While the less percentage of landowners’ consensus needed for clearing of land for projects seems to be a practical and forward-looking step, the amount of compensation and its impact on project cost remain a concern.
Editorial Advisory Board PothenP aul Former Chairman, Aker Powergas Pvt Ltd
Given the current gloomy global scenario, this as a whole is a welcome measure by the government since it not only sends clear and positive signals to the global investing community, but also boosts the business sentiment across the country. Concurrently, it is imperative to be proactive as well as address other ‘procedural’ challenges linked to the developmental projects in a time-bound manner so that the investment gets actually converted into operations as fast as it should.
D P Misra Director, TCE Consulting Engineers Ltd and Former Director General, ICC
P D Samudra Executive Director (Sales) & Member of the Board, Uhde India Pvt Ltd
Manas R Bastia email@example.com
November 2012 | Chemical World
Insight & Outlook: CSR Initiatives by Chemical Companies Corporate social responsibility ........................................... 38 Healthcare initiatives .......................................................... 40 Roundtable .......................................................................... 43 HSE strategy ..................................................................... 44
38 Cover visual: Mahendra Varpe
Lubricant industry .............................................................. 46 Pumps for O&G industry .................................................. 48 Industrial paints .................................................................. 50
Special Focus: Heating & Cooling Equipment Efficient boilers .................................................................. 26
Absorption chillers ............................................................. 28
Smart technologies: Aiding agility in business decision ................................................................. 52
Heat exchangers .................................................................. 30
Polyurethane ....................................................................... 32
Case Study â€“ Reliance Industries Ltd: Enhancing energy savings through process simulation ........................ 54
Policies & Regulations In Conversation With
Companies Bill, 2011: Should CSR be made mandatory? ................................................................ 56
Mark Zyskowski, Vice President - Global Sales, Honeywell Process Solutions ..................... 22
Strategy Dyes and dye intermediates: Charting new success plan amid challenging market conditions .......................... 58
Tips & Tricks Facility Visit: Novel Spent Acid Management Adding value to waste through recycling technologies ..... 34
Regular Sections Editorial ........................................................................ 5 News, Views & Analysis .............................................. 10 Technology & Innovation ............................................ 18 Technology Transfer .................................................... 20 Projects ........................................................................ 63 Tenders ........................................................................ 64 Event List .................................................................... 66 Book Review ................................................................ 74 Products ...................................................................... 75 List of Products .......................................................... 84 List of Advertisers ...................................................... 85
Risk-based inspection: Practical guide to proactive maintenance ................................................... 62
Event Preview o Engineering Expo Chennai 2012: Offering a competitive advantage................................................ 68 o IPVS 2012: All pumped up for novelty in fluid control ............................................................ 70
Event Report Engineering Expo Ahmedabad 2012: Epitomising entrepreneurial excellence .................................................. 72
Highlights of Next Edition Special Focus: Filtration & Separation Insight & Outlook: Asset Optimisation
Details on page no. 59, 66
Note: ` stands for Indian rupee, $ stands for US dollar and ÂŁ stands for UK pound, unless mentioned otherwise November 2012 | Chemical World
Business Insights Technologies Opportunities
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November 2012 | Chemical World
NEWS, VIEWS & ANALYSIS
PRODUCT DEVELOPMENT RECOGNITION
Merck’s application lab to be part of global network
Forbes Marshall bags BEE’s energy-efficiency rating
Merck KGaA will make its Indian network,” said Siddhartha Sengupta, Head Application and Technology Centre lab - Performance Materials, Merck Ltd. a part of its global network. “We have Merck businesses are organised eight application labs worldwide, which in four divisions – Merck Serono (for are in the process of becoming a part of innovative prescription drugs of chemical global network. India application lab will and biotechnological origin), Consumer be a part of this network by Healthcare, Merck Millipore January 1, 2013. Our aim is and Performance Materials. to increase exchange among According to the network in order to gain Dr Lergenmüller, Merck is the synergies and promote faster market leader in pearl lustre benefits of the product to effect pigments with about 55 the customers,” disclosed per cent marketshare globally. Dr Matthias Lergenmüller, Pearl effect pigments market Senior Director - Business is estimated to be about Euro Field Cosmetics, Merck 600-650 million globally, Dr Matthias Lergenmüller KGaA. while in India it is about Besides India, Merck has application & ` 120-125 crore. The need for differentiated technology centre in China, Thailand, and products is driving the demand for pearl Japan in Asia. The Indian centre, which is lustre effect pigments. In cosmetics, located at Nerul (Navi Mumbai), enables it provides end-to-end solutions for Merck to offer customised application manufacturers, right from active ingredients, and technology solutions to its customers pigments to brand protection. “For cosmetics in fields ranging from drug discovery to application, we are offering a wide range automobile and decorative paints. of products. With our products, cosmetic “Right now the lab is focussing on manufacturers can use raw materials with India-specific projects, but once it becomes proven efficacies and by using our pigments a part of global network it will undertake they can develop differentiated products to projects from other countries as well. At compete successfully in the marketplace,” present, we are upgrading the lab to meet added Dr Lergenmüller. Rakesh Rao the standards of being a part of global
Forbes Marshall has been recognised as an Energy Service Company (ESCO) by Bureau of Energy Efficiency (BEE), Ministry of Power, Government of India, and assigned a Grade 1 rating by CRISIL under the BEE scheme. The grading is based on an intensive scrutiny and is in the range of 1-5 (with 1 being very high and 5 being poor). Forbes Marshall is one of the ten companies that has got high grade out of about a hundred organisations enlisted by BEE. BEE is promoting energyefficiency measures in the country under the Energy Conservation Act, 2001. In order to encourage energy conservation measures in existing facilities and buildings, BEE has shortlisted organisations through the ESCO route. The actual rating is done by CRISIL, a Standard & Poor’s company, and is valid for two years. The Grading of ESCOS by CRISIL is done on three broad parameters, track record, market position, and organisational & financial risks. The data on these parameters is obtained from the applicants and meetings are held with key officials in the technical, marketing and financial functions. Feedback is also taken from customers as well as bankers. The score for Grade 1 is 85 and higher, which reflects very high ability to carry out energy audits and implement energy-saving projects.
Balaji Amines to set up new manufacturing facility Balaji Amines Ltd (BAL) recently announced the development of new plants for manufacturing of dimethyl amine hydrochloride (DMAHCL) and dimethylformamide (DMF) at MIDC (Chincholi, Maharashtra), both of which will be commissioned during FY 2012-13. The plants are in advanced stages of commissioning with installed capacities of 18,000 MTA and 30,000 MTA respectively.
AkzoNobel inaugurates new India Analytical Centre
Graeme Armstrong (centre) inaugurating AkzoNobel’s India Analytical Centre
Chemical World | November 2012
AkzoNobel’s India Analytical Centre (IAC) was recently inaugurated in Bengaluru by Dr Graeme Armstrong, AkzoNobel’s Executive Committee Member responsible for Research, Development and Innovation (RD&I) and Director on the Board of Akzo Nobel India Ltd. The IAC at the Bengaluru lab will leverage AkzoNobel’s global and local resources to provide high-
quality analytical services for fulfilling the needs of all coatings business in India, be it decorative, industrial, protective or automotive coatings. The IAC will also have process capability to evaluate and certify raw materials, intermediates, and products in India, thus enhancing the operational excellence of Akzo Nobel India’s manufacturing units.
NEWS, VIEWS & ANALYSIS
OCCUPATIONAL SAFET Y RECOGNITION
UBM organises first edition of OSH India
Uhde India wins ICC award for plant design & engineering Uhde India was conferred an award for excellence in chemical plant design & engineering for the year 2011 by the India Chemical Council (ICC) at the association’s annual competition for the chemical process industries. ICC conferred the award on Uhde India in recognition of the excellent engineering and project implementation carried out on the Indian Oil Corporation’s VGO-HDT, FCC LPG and ATF Merox project at the oil refining major’s Koyali refinery in Vadodara, Gujarat. Meanwhile, as a recognition (for being selected for ICC award), Process Plant & Machinery Association of India (PPMAI) also accorded a special award to Uhde India. The award was given for outstanding exports in 2010-11.
OPTICAL BRIGHTENING AGENTS
Deepak Nitrite’s new plant to be completed by February 2013 Deepak Nitrite Ltd (DNL) has commenced the pre-commissioning activities of part facilities at its greenfield project for Optical Brightening Agents (OBA) in Dahej. This will help the company to test all the project plant facilities and operability of utility systems. The entire project is expected to be completed by February 2013 in phases. With the completion of Dahej, DNL will be the only fully integrated player to complete vertical integration from toluene to OBA, globally.
V B Sant (third from left) during the traditional inauguration ceremony
The first edition of OSH India, a conference and exhibition aimed at the Occupational Safety and Health (OSH) sector, was recently held in Mumbai. The event was inaugurated by V B Sant, Director, National Safety Council along with Michael Duck, Senior Vice President, UBM Asia. Also present were V S Moray, Director, Industrial Safety and Health, Maharashtra; D C Chaudhari, Director, Industrial Safety and Health, Gujarat; P T Shah, Director, Gujarat Safety Council, Gujarat; and Jime Essink, CEO, UBM Asia. Sharing his views on the importance of OSH in the chemical industry, Sant said,
“The current challenge in the chemical industry is two-fold. One is pertaining to contract workers whose level of awareness and preparedness for handling chemicals is lower than permanent employees, and the other part is contradictorily regarding regular employees, who are skilled, aware and competent, yet they become complacent on account of permanency. However, due to recent consolidations taking place in the chemical industry, there has been a marked change in OSH standards and compliance to them, since the large companies ensure that OSH standards are followed even in the smaller ones being taken over.” The event saw participation from more than 50 premier suppliers of products and services to the OSH market. Adrian Newton, Group Director, Safety & Building Management, UBM, commented, “The Indian edition of OSH is one of the most successful of the various editions held across the globe. With world-class brands on display there is participation from wellknown companies and eminent speakers at the various forums within the event.” Manas R Bastia
COMMUNIT Y SERVICE
Dow Corning organises Fascinating Silicone Science Day for school children in Pune Dow Corning opened up the fascinating world of silicone for school students in Pune. For over five consecutive years, Dow Corning, a global silicone leader, has been organising a Fascinating Silicone Science Day for school children at its manufacturing plant in Ranjangaon, Pune. This year as well, more than 40 students of the Shree Bhairavanath Madhyamik Ani Uchamadhyamik School at Karde village visited the Dow Corning plant, along with their teachers, to explore the fascinating world of silicones, and learn how silicones help improve the quality of lives.
Insecticides India and Otsuka AgriTechno to set up R&D JV In its endeavour to provide the latest technology to farmers, Insecticides India Ltd (IIL) has formed a joint venture ( JV) with the Japan-based Otsuka AgriTechno Co Ltd (OAT) for research and development (R&D) of new products. Under the terms of the JV, both the companies have agreed to establish a 4,000 sq m research centre in Bhiwadi, Rajasthan. Rajesh Aggarwal, Managing Director, IIL, said, “The JV will help IIL to move up in the value
Chemical World | November 2012
chain and own intellectual property. The new products invented in the research centre will help farmers to increase their crop yield multifold.” Akihei Mori, President, OAT, added, “This JV will be a new milestone for our company. The products that will be invented at the new research centre will immensely benefit farmers in India, Japan as well as in other parts of the world.”
NEWS, VIEWS & ANALYSIS
ENGINEERING & CONSTRUCTION
ThyssenKrupp Uhde receives three mega orders
Momentive opens global R&D centre in Bengaluru
ThyssenKrupp Uhde has received orders for three big projects in fertiliser and mining sector. While the two projects relate to construction of fertiliser plants in the US, it has been contracted for building a low-density ammonium nitrate plant in Vietnam as per the third order. OCI Construction Group has selected ThyssenKrupp Uhde for an engineering and procurement contract for the construction of one of the world’s largest single-train liquid fertiliser plants to be built in the US. ThyssenKrupp Uhde was awarded the contract for the design and supply of a liquid fertiliser plant, which will be built near Wever, Iowa in the US. ThyssenKrupp Uhde received its second order from CF Industries Holdings, Inc for the design and construction of fertiliser plants in Port Neal (Iowa, US) and Donaldsonville (Louisiana, US). Combined, the two orders exceed Euro 1 billion. Similarly, Mining Chemical Industry Holding Corporation has awarded a contract to a consortium consisting of ThyssenKrupp Uhde, Toyo-Thai Corporation Public Company Ltd, Toyo Vietnam Corporation Ltd and Lilama 69-1 Joint Stock Company to build a plant for lowdensity ammonium nitrate, which is used in construction and mining industries.
HEAT TRANSFER EQUIPMENT
HRS Process to offer novel solutions at Paper Plus 2012 The heat transfer specialist, HRS Process Systems Ltd (HRS PSL) will showcase latest technology at the second Paper Plus 2012 to be held in Coimbatore, Tamil Nadu, from November 24-26, 2012. HRS PSL offers cost-effective heat transfer solutions through application engineering and design expertise for optimal energy consumption in paper manufacturing processes such as cellulose production, pulp production, heat recovery and wastewater treatment.
Chemical World | November 2012
Dr Pavneet Mumick addressing the media
Momentive Performance Materials Inc and Momentive Speciality Chemicals Inc – subsidiaries of Momentive Performance Materials Holdings LLC – have opened a new global research and development (R&D) centre and business headquarters for the India, Middle East and Africa (IMEA) region in Bengaluru. The new centre, which has been built with initial investment of $ 4.35 million, will work
on new global technology platforms and product development for new and existing applications in diverse industry segments, including personal care, energy, healthcare, electronics, automotive and construction. Dr Pavneet Mumick, Chief Technology Officer, Momentive Performance Materials Inc, said, “Our researchers are driving tremendous value for our customers through product innovation and new advanced technology platforms. This new centre will help us attract and retain the top talent needed to continue and accelerate these efforts.” Speaking about the advantage to Indian business, he added, “We are working here on several global technology platforms. We will also focus on turning those global platforms to develop innovative products for the Indian market.” Rakesh Rao
ICC organises Responsible Care conference in Mumbai Indian Chemical Council (ICC), the apex body of the chemical industry in India, recently organised a Global Conference on Responsible Care, which has the support of Ministry of Chemicals & Fertilizers, Government of India. The list of speakers included eminent L-R: R Parthasarathy, immediate past dignitaries such as Prasad Chandran, Chairman President, ICC; Prasad Chandran; Jose & Managing Director, BASF India Ltd; Debra Cyriac; Nikhil Meswani, Executive Director, Reliance Industries Ltd; Debra M Phillips; M Phillips, Managing Director, Responsible and Yogesh Kothari, President, ICC Care, American Chemistry Council, USA; Jim Pesek, President (HSE), Reliance Industries Ltd; R Mukundan, Managing Director, Tata Chemicals Ltd; Ravi Kapoor, Managing Director, Heubach Colour Pvt Ltd; Ken Tsang, Sr Advisor, Responsible Care, Association of Chemical Manufacturers, China; and Shankar Venkateswaran, Director - Sustainability Services, PwC. Jose Cyriac, Secretary, DCPC, Ministry of Chemicals & Fertilizers, Government of India, said, “I personally and on behalf of Government of India appreciate the members of Responsible Care Leadership Group (RCLG) for conducting the meeting in India. I am sure that this will boost more chemical companies in India to adopt Responsible Care.” Mahua Roy
Hikal wins ICC’s Aditya Birla Award for Responsible Care Hikal Ltd won the prestigious award for the ‘Best Responsible Care Committed Company for 2011’ at the Annual Indian Chemical Council (ICC) Awards function held in
Mumbai. The award was presented to Hikal by ICC in the presence of the International Council of Chemical Association (ICCA), Responsible Care Leadership Group.
NEWS, VIEWS & ANALYSIS
PPMAI AGM APPOINTMENT
C E Fernandes re-elected as Chairman of PPMAI
K V Venugopalan elected as President of IAIA Indian Analytical Instruments Association (IAIA) announced its newly elected office bearers. K V Venugopalan has been unanimously elected as President, IAIA. Venugopalan, an electronics engineer with an MBA degree in marketing, has been associated with Waters India from 1983 and has presided over the company since 1997. C Ravindranath and Dr Ashes Ganguly were elected Vice Presidents of IAIA. And Gautam Ranjan was elected as Secretary of the organisation. IAIA, an exclusive professional body, was formed in 1996 with a vision to promote the growth of analytical instruments industry. The primary objective is to create and share knowledge leading to better relationships between all players. IAIA aims to be the premier body working towards policy making and planning, thus promoting welfare by integrating the entire analytical fraternity.
Clariant showcases ED pigments at Paint India 2012 Clariant, a world leader in specialty chemicals showcased the ‘Easily Dispersible (ED) Pigments’ range at Paint India 2012, Outreach Conference, Chennai. Nitin Vaidya, Head – Technical Services, Pigments – Coatings Business, Clariant Chemicals (India) Ltd, while talking on the theme of ‘Better Raw Materials for Better Coatings’, touched upon crucial points for the industry. Clariant’s special organic pigments can be easily incorporated into paint systems with a dissolver, lowering the manufacturing cost by reducing the grinding period, thus saving the energy. Similarly, in Ahmedabad (Paint India 2012), a presentation titled ‘Do I Need Biocides?’ was presented by Dr Alexander Snell, Head, ICS Business, Clariant Chemicals (India) Ltd.
Chemical World | November 2012
L-R: V P Ramachandran, Secretary General PPMAI, Anil K Modi, K Venkataramanan, C E Fernandes and Shishir Joshipura
The 48th AGM of Process Plant & Machinery Association of India (PPMAI) was held recently in Mumbai. The AGM unanimously re-elected C E Fernandes as Chairman of PPMAI for 2012-2013. He is also the Chairman & Managing Director of the Bhopal-based Gei Industrial Systems Ltd. At the AGM, Anil K Modi, General Manager, Manufacturing, Heavy Engineering Division, Larsen &
Toubro Ltd, and Vernon Francis Correa, Member of the Board & Director – Projects, Tecnimont ICB Pvt Ltd, were also re-elected as Deputy Chairman for 2012-13. K Venkataramanan, Chief Executive Officer & Managing Director, Larsen & Toubro Ltd, was the chief guest on this occasion. Speaking on the occasion, he gave an illustrative presentation with statistics on the present economy and the potential growth areas for PPMAI to ensure positive growth in business. Venkataramanan was felicitated by PPMAI for his immense contribution to bring the Indian EPCs and manufacturing companies at par with the reputed global companies. Shishir Joshipura, Managing Director, SKF India Ltd, and Past Chairman of PPMAI was the guest of honour.
SABIC sees growth potential in India’s petrochemical sector SABIC has expressed its confidence in India’s petrochemical industry growth opportunities, and its commitment to continue strengthening its market presence, at India Chem 2012. Representing SABIC at the event were Abdullah Saeed Bazid, Executive Vice President, Corporate Strategy & Planning; and Janardhanan Ramanujalu, Vice President & Regional Head, South Asia & Australia. Bazid said, “India’s Abdullah Saeed Bazid addressing the India Chem 2012 conference petrochemical & chemical industries have significant strategic growth aspirations and potentials. The industry has the potential to grow up to $ 300 billion by 2020.” He added, “As a global market leader in petrochemicals, SABIC has enjoyed strong double-digit growth in India. As we further our growth in India for long-term success, we remain firmly committed to contributing positively to both the economy and petrochemical & chemical industry.” NEW INITIATIVE
Siemens launches ‘Process Automation User Community’ first time in India Siemens recently launched Process Automation (PA) User Community page. This is an initiative aiming at fostering effective communication and knowledge sharing between Siemens and endusers. The community provides a forum that enables PA users to network, share information and stay updated about the latest news & events related to process
automation. The PA User Community is an online forum that facilitates information sharing and provides updates related to the latest advancements in the field of process automation. The PA User Community has a host of clients spread across verticals such as pharmaceuticals, chemicals, food & beverages, glass, cement and solar.
NEWS, VIEWS & ANALYSIS
Online SHE tool to be available across India Webstac, an indigenous online tool for compliance of all statutes – preferably those on Safety, Health and Environment (SHE), will be offering its complete services across India shortly. “Our first package BasIC (Basic Information in Compliance) came into market in August 2011. It is now available for all the industrialised states. SECT_e (Safety & Environment Compliance Tracker enterprise) for Maharashtra and Gujarat came in September 2012. By now packages are ready for states such as Maharashtra, Gujarat, Karnataka, Andhra Pradesh, Tamil Nadu and Rajasthan. By the end of 2012, we propose to have all the states on board,” said Vijay Bukkawar, Director, Webstac Software Pvt Ltd, and Advisor - SHE, Indian Chemical Council.
With pressure on the chemical industry increasing with regard to sustainability from customers across the globe, manufacturers are taking steps to adhere to stringent SHE norms. Webstac can help these companies in their quest for SHE compliance. “It can help all, irrespective of sector. Whether it is a small-scale or large organisation, one has to realise that the packages are best example of value for money. If used properly these have the potential to save many man-days, those are now spent in repetitive and associated paper work. This will be the thing of past. What is more, there is assurance on compliance and its monitoring at senior levels – even up to a Board Level,” added Bukkawar. Rakesh Rao
Crop World India held in Hyderabad
Dr B Saha welcoming participants
The 3rd annual Crop World India 2012 strategic conference was recently held in Hyderabad. The Chairman of the first day, Dr B Saha, Chief R&D Officer, Nagarjuna Agrichem Ltd, welcomed the delegates from India and abroad. Some of the other eminent speakers included Bhupen Dubey, Head - Integrated Business, United Phosphorus; Satish Sohoni, Head - Agrochemical Division, Hikal; Dr Peter Nightingale, President, Acoris Research; etc.
Beta Renewables and Novozymes to form strategic partnership in cellulosic biofuel market
Honeywell green fuel powers aircraft
Novozymes, one of the largest producers of industrial enzymes in the world, and Beta Renewables, a global leader in cellulosic biofuels announced an agreement to jointly market, demonstrate and guarantee cellulosic biofuel solutions. The partners will offer a combination of Novozymes’ Cellic enzymes and Beta Renewables’ PROESA engineering and production technology to customers looking to produce biofuels from agricultural residues, energy crops and other cellulosic feedstocks. Beta Renewables will embed Novozymes’ enzymes in the PROESA technology and guarantee biofuel production costs upon start-up of customers’ cellulosic facilities.
UOP LLC, a Honeywell company, recently announced that Honeywell Green Jet Fuel produced using Honeywell’s UOP Renewable Jet Fuel process powered demonstration flights by Gulfstream Aerospace at this year’s National Business Aviation Association (NBAA) convention. Each gallon on camelina-based Honeywell Green Jet Fuel burnt instead of petroleum reduces the net carbon dioxide equivalent emissions by 68 per cent. Depending on the feedstock, it can offer a 65-85 per cent reduction in greenhouse gas emissions relative to petroleum-based fuels.
Invensys appoints Rajat Kishore to head Indian operations
Oversupply of polycrystalline impacts Hemlock Semiconductor
Invensys Operations Management, a global provider of technology systems, software solutions and consulting services to the process and manufacturing industries, recently announced the appointment of Rajat Kishore as Managing Director of Invensys Operations Management India. In his new role, he will be responsible for spearheading the overall growth and profitability of the company within the region.
According to Dow Corning’s press release announcing financial results for third quarter of 2012, polysilicon prices remained depressed due to industry oversupply, impacting the company’s Hemlock Semiconductor Group joint ventures. Hemlock Semiconductor Group comprises several joint venture companies among Dow Corning Corporation, ShinEtsu Handotai, and Mitsubishi Materials Corporation. “Our Hemlock Semiconductor joint ventures continue to be challenged by global oversupply in the polycrystalline silicon markets. Additionally, the economic and political uncertainty surrounding the solar industry is also impacting Hemlock Semiconductor’s performance,” said J Donald Sheets, Executive Vice President and Chief Financial Officer, Dow Corning, in a release. Dow Corning Corp has reported sales of $ 4.64 billion and net income of $ 288 million through the first three quarters of 2012. Its year-to-date sales and net income were down 5 per cent and 47 per cent, respectively, compared to 2011.
November 2012 | Chemical World
TECHNOLOGY & INNOVATION
Novel enclosures enable user protection Cole-Parmer has come out with Xpert Nano Enclosures, which are specifically designed for nanoparticle research and manipulation. XPert Nano is the first and only enclosure to be validated for nanomaterial containment, claims the company. These enclosures feature a space-saving design - no separate filtered exhauster is required and runs with low decibel-level operation. It provides user protection during nanoparticle manipulation and dry powder chemical handling. It functions as a class I enclosure - room air enters the front of the enclosure and passes through a filter prior to exhausting back to the room. By their nature, nano particles are small and prone to static charge. Three features address these nano characteristics - ULPA filter, stainless steel liner and ioniser. The ULPA filter is capable of capturing and containing very small particulates, 0.12 μm or larger, at 99.999 per cent efficiency and returns clean air to laboratory. The interior sides, baffle, air foil and integral work surface are made of 304 stainless steel. Stainless steel was chosen for its inherent ability to dissipate static charge. Nanoparticles are less likely to cling to its surface making it easy to clean. An optional builtin ioniser neutralises static charge on interior surfaces by emitting ions into the airstream, which helps reduce weighing errors and attraction of particles to the enclosure surfaces. The hood has a pre-wired fluorescent lamp and switches for blower and light. The front sash is 1/4” (0.6 cm) thick tempered safety glass. The ergonomic angled and hinged sash pivots upward, locks in the ‘up’ position, and has a wiping seal to contain contaminants. The 5’ and 6’ models incorporate an external gas-assist lift.
Chemical World | November 2012
Bulk bag discharging system to meet specific application requirement Material Transfer and Storage’s (MTS) material master bulk Bag discharging system performs many functions such as lifting, loading, sealing, and discharging flexible intermediate bulk containers of dried bulk materials. It can be configured to accept bulk bags loaded via integral hoist system, customer supplied hoist, or forklift. Integral hoist systems typically include a heavy-duty electric motorised hoist and trolley, and a Spider-Lift bag lifting frame for safe, efficient bag loading. The Spider-Lift bag lifting frame features continuously welded carbon steel pipe with heavy plate steel support gussets, safety strap stops, and a low profile design for reduced headroom. The system is also equipped with Mantis ultra-low headroom bag lifting frame for use in low clearance applications. All Spider-Lift bag lifting frames are available in carbon steel or stainless steel construction, finished to meet customers’ requirements. Electrically-driven explosion-proof hoists, intrinsically safe air-driven hoists, and low headroom hoists are available to meet application requirements. Hoist systems typically include a power junction box, pendant junction box, quick connect pendant, and MTS’s exclusive nylon energy chain system for protection of moving cables. The system also has a robust Flo-Lock Discharge Gate, which safely and quickly closes bulk bag discharge spouts for operator tie off, allowing partial bag discharging of materials. This robust gate is constructed from thick machined stainless steel or aluminium, machined UHMW, and is actuated by two large bore air cylinders. When the air cylinders apply force, the UHMW plates with a curved aperture move towards each other, cinching the bag discharge spout closed, and gathering it for easy operator tie off.
Sensorex launches easy-to-programme conductivity transmitter Sensorex has developed CX3000 conductivity transmitter which monitors changes in process fluids, displaying conductivity and temperature for more accurate control in water, chemical, electronics, food production, environmental and wastewater applications. Packed with powerful features, this unit offers an array of user selectable options including adjustable relay contacts, dual 4-20 mA outputs (one for temperature) etc. The line-powered CX3000 can be user programmed on-site to measure contacting conductivity sensors. Its dual output design, with an isolated (0)4 – 20 mA output for conductivity readings and one for temperature measurement, eliminates the need for a separate temperature transmitter. A large backlit LCD screen displays both parameters simultaneously and two adjustable Hi/Lo relay contacts deliver results to automated process control systems. With an extended conductivity measurement range of 0.000 uS/cm - 200.0 mS/cm in 6 ranges, the CON-3000 is suitable for full range applications. The NEMA 4x, IP65 enclosure can be wall, panel, or pipe-mounted for easy integration in most installations. The CX3000 can be easily programmed onsite with its push button interface. The unit can be password protected for secure installations.
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
An Iranian firm is willing to offer activated carbon from coconut shells. Areas of application Food processing, pharmaceuticals, etc Forms of transfer Technology licensing
An Indian firm is offering technology for manufacturing phosphate esters like tributyl phosphate. 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. Ethyl alcohol is widely used for making many organic chemicals. Areas of application Chemical and energy industries Forms of transfer Technology licensing
Furfuryl alcohol technology
Sodium hydrosulfite 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 Chemical industry Forms of transfer Technology licensing
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 services, technology licensing
Sodium silicate recovery from rice husk ash
Precipitated calcium carbonate
An Indian consulting company for the chemicals, minerals & food processing industries is offering precipitated calcium carbonate and turnkey projects for the same. Areas of application Plastics, paper, paints, rubber, inks Forms of transfer Consultancy, technical services
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 Leather industry, textiles, curriery industries, paper mills, etc Forms of transfer Turnkey
Chemical World | November 2012
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
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 â€“ 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 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 knowhow 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
An Indian company seeks to adopt new cost-effective technologies, which can reduce carbon emissions and earn carbon credits, for manufacturing lime. Areas of application Quick lime and hydrated lime Forms of transfer Others
An Indian firm is looking for new technology for manufacturing silica gel in which the wastewater discharge is minimum. Areas of application For various industries and most importantly breweries 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 Others
Quaternary ammonium chloride 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 Forms of transfer Technical know-how, consultancy
Small-scale environment-friendly 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 Textile and pharmaceutical industry Forms of transfer Others
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 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: firstname.lastname@example.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 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 World, Network18 Media & Investments Ltd, â€˜Aâ€™ Wing, Ruby House, J K Sawant Marg, Dadar (W), Mumbai 400 028 Tel: 022-3024 5000, 3003 4672, Fax: 022-3003 4499, Email: email@example.com
November 2012 | Chemical World
IN CONVERSATION WITH Mark Zyskowski
India is an integral part of Honeywell’s global growth strategy
Photo Courtesy: Honeywell Process Solutions
…says Mark Zyskowski, Vice President - Global Sales, Honeywell Process Solutions. During Honeywell Users Group conference in Australia, he announced that the company has evolved to become a business transformation provider. In conversation with Rakesh Rao, Zyskowski emphasises on this transition and analyses the impact of mega trends – globalisation, mobilisation, integration and collaboration – on the industry.
Chemical World | November 2012
Honeywell has moved from being just an automation company to become a business transformation company. What does that indicate? At Honeywell, we see that our impact on process industries goes well beyond standard control and measurement technology. This means we help customers change the way they operate, making them more flexible and productive. It also means that we change how they make decisions, the speed of those decisions, and even the place that the people need to be when making those decisions. Our objective is to engage with the customers beyond supplying just products and simple point solutions, and become a trusted advisor in helping them achieve their critical business goals.
How does Honeywell tap opportunities arising from mega trends? I see the importance and the impact of trends such as globalisation, mobilisation, integration and collaboration more than ever before, and happening at record speed. Honeywell is at the forefront in all these areas and helping its clients to react quickly and adapt to the new opportunities and global challenges. These trends contribute to the need for a new type of client-supplier relationship, namely a trusted advisor role. With these changes, Honeywell is helping customers to focus on supply chains to better react to real-time market supply and demand opportunities, and enable companies to improve daily make, buy, or trade decisions that can have significant profit impact. Another trend is around the changing world, which also means evolving workforces. Companies are now realising the need to leverage a truly global resource pool by leveraging and/ or developing local talent in emerging markets and closely linking that resource pool with expertise that exists elsewhere in the company. To support the sharing of information and expertise, as well as to enhance collaboration across functional groups, Honeywell has introduced collaboration tools such as Intuition
Executive. This platform enhances a company’s ability to redesign the work flow of where people need to be when they make decisions. So, in summary, Honeywell is not just enabling the mobilisation of data. It is also enabling the mobilisation of people.
How can automation increase efficiency and improve bottom line? Honeywell’s portfolio of products, services and solutions is especially important to our customers during today’s economic uncertainties. This is the time when the variability in the business – product demand, raw material costs, logistics, etc – is at the highest. During such times, customers want the right information at the right time to help make prudent and efficient business decisions. Honeywell believes efficient automation offers an economic way to achieve these objectives.
How receptive are Indian chemical manufacturers to new automation technologies? As India is gradually emerging and maturing in the manufacturing sector, adoption of new automation technology is becoming increasingly important for running a profitable and safe/reliable business or plant. Indian chemical industry comprises several small- and medium-sized manufacturers that still require a robust, reliable plant automation system to run their plants safely. Large chemical companies, however, are coming of age. There is an increased awareness on how modern plant automation can help them negotiate the uncertainties of the market; improve bottom line by employing process and business excellence initiatives; and ensure plant safety by deploying safer and more secure automation systems.
How do you see India as a market for Honeywell? Honeywell Process Solutions is one of Honeywell’s significant businesses committed to improving the business performance of industrial customers
Which was the toughest business decision taken by you? Quite frankly, it was my decision to join Honeywell way back in 2005. I had a successful career underway at my previous employer with a solid track record. Leaving that comfort zone and taking on a new challenge with a leading global company was difficult, but in the end it has worked out well for me.
Name a book that you like the most and why? To this day, one of the most impactful books that I have read is ‘The discipline of market leaders’. Although written over 20 years ago, this business book clearly helped me define business models that help create competitive advantage for a business. One of the key strategies outlined is ‘customer intimacy’, which is a key element of how Honeywell goes to market today.
through automation solutions that focus on enhancing safety, reliability and efficiency. It has a strong track record of success in Asia-Pacific, and India is an integral part of Honeywell’s global growth strategy. It is a critical manufacturing location, and most importantly a centre of engineering and R&D excellence for Honeywell. We are well-positioned to grow our business in India, and help drive the growth of the Indian economy with innovative technologies. We will continue to expand our footprint in Asia-Pacific region with regard to resources, manufacturing and R&D. The region plays a critical role in the global economy and Honeywell will maintain its focus by aggressively growing our capabilities across the region. Email: firstname.lastname@example.org
November 2012 | Chemical World
HEATING & COOLING EQUIPMENT EFFICIENT BOILERS Managing energy consumption, boosting productivity .............................................................................26 ABSORPTION CHILLERS A ‘cool’ transition from the conventional ..................................................................................................28 HEAT EXCHANGERS Right selection, a must for optimum performance ...................................................................................30 POLYURETHANE A hot solution to promote cooling ...........................................................................................................32
November 2012 | Chemical World
SPECIAL FOCUS Efficient boilers
recent study by the University of Minnesota revealed that each year, a typical boiler consumes fuel, which is several times its initial capital investment itself. To cite an example, an industrial boiler purchased for $ 75,000 uses more than $ 4,00,000 in fuel annually. Even a meagre one per cent increase in efficiency equals as high as $ 4,000 in fuel savings. Thus, improved boiler efficiency translates into substantial savings that can pay for a higher efficiency unit many times over.
system. The unburnt fuel is generally retained with the solid combustion residue and is found in the form of free carbon. The chemical energy of the fuel is released as heat through the oxidation process. “In the present day technology of gaseous fuel combustion, it is possible to completely curb this loss. The unburnt carbon can be significantly reduced by improving the design and operation of combustion equipment. The combustion of fuels improves by increasing the temperature of the fuel and air as well as by increasing time available for combustion. By providing adequate turbulence to the combustion air, it will allow fresh
is production of carbon monoxide. This leads to a certain amount of unreleased heat from the fuel. The total gaseous product of combustion is termed as ‘flue gas’. The flue gas without moisture is termed as ‘dry gas’. “The reduction of flue gas temperature to increase the efficiency would largely be a tradeoff between initial capital cost and revenue savings of fuel cost due to higher efficiency. Fuels containing sulphur should be dealt with carefully to avoid corrosion. Corrosion can be minimised by using special alloy steels for the construction of last stage heat recovery surfaces,” adds Raman.
Managing energy roductivity An indispensable part of industrial infrastructure, boilers contribute to a large fraction of energy consumption. In these days of sustainability doctrines, various strategies need to be adopted to make boilers energy efficient. “Boilers are equipment used for heating water or producing steam, an integral part of any process industry. Boiler thus performs an energy conversion action along with heat transfer duty. Because the thermal energy required for transfer to the incoming water is supplied by burning fuels, it is important to manage efficiency in these days of rising fuel costs,” says Dr Vilas G Gaikar, Bharat Petroleum Professor of Chemical Engineering, and Head, Department of Chemical Engineering, Institute of Chemical Technology (ICT), Mumbai.
Combating loss due to unburnt fuel The major loss in boiler efficiency is caused due to unburnt fuel and this directly reflects the efficiency of the combustion
Chemical World | November 2012
molecules of oxygen to continuously come into contact with solid fuel particles and thereby ensure complete combustion. In order to achieve these results, it is necessary to increase the air pre-heat and the heat loading in the furnace. The admission of combustion air at appropriate locations along the trajectory of the fuel particles would also enhance completeness of combustion,” says G V Raman, Managing Director, Avant Garde Engineers & Consultants Pvt Ltd. The fluidised bed combustion is an effective method of reducing unburnt fuel loss. Many advances have been achieved in the recent past, in this technology.
Partial combustion, no problem! Next comes loss due to partial combustion, as a result of which there
Targeting challenges of fuel moisture content Almost all the fuels contain moisture along with the combustibles. In addition, the combustion of fossil fuel releases water vapour as well. This moisture leaves the boiler at a high temperature along with the other products of combustion. “In almost all practical cases, this temperature is higher than 100˚C. Thus, this total quantity of moisture takes away its requirement of latent heat of vapourisation and the sensible heat of water and steam from the calorific value of the fuel. This represents the loss due to moisture in fuel,” adds Dr Gaikar. This loss can be combated by predrying the fuel with separate equipment. “An efficient model would be to utilise boiler exhaust flue gas itself for pre-
drying of fuels. This would be an attractive option for fuels with higher moisture content such as lignite and bagasse,” says Raman. In recent times, non-metallic air preheaters and feedwater heaters have been developed to reduce outgoing flue gas temperature to values below 100˚C, which can increase boiler efficiency considerably.
temperature. Generally, this would keep down the loss to a value less than 200 Kcal/sq m/hr. The skin temperature of the insulated surfaces is also governed by safety requirements. Wherever there is a possibility of workers moving close to the insulated surfaces, it should be ensured that the insulated surface skin temperature should not be higher than 60˚C,” adds Raman.
Challenges caused due to radiation
Maintenance is the key
Most of the boiler components work at high temperatures. The boiler surfaces lose heat continuously to the surrounding space. “A typical bagasse-fired boiler loses anywhere between 30-33 per cent of the input heat in various ways. The efficiency of the boiler would then be anywhere between 70 and 67 per cent,” says Raman. The solution to combat this energy loss is by modifying equipment design. “The general practice for insulation is to design the insulated skin temperature to be at least 20˚C above the ambient
The primary deliverable of the boiler operator is to achieve optimum operating efficiency of the equipment and being consistent with high reliability and low cost. Also, the efficiency of the steam generator largely depends on proper control of time, temperature, turbulence and oxygen. Usually, the primary cause, as high as an estimated 75 per cent of boiler failure is low water. “The main reason behind this is the assumption that boilers require little or no attention because of the redundant,
automatic controls they are equipped with. But without regular operation and maintenance controls, a series of automatic control failures can occur, preceding an explosion. The automatic feed device can fail, causing the low-water condition. The low-water fuel cutout may fail to sense the low-water condition and stop the fuel supply. The safety pop valve can fail to actuate in order to relieve the pressure build-up,” says Dr Gaikar. Although all these devices are automatic, they have a finite lifespan under the conditions in which they operate. Proper maintenance of boilers can prove to be an effective solution for improving safety and reliability while also curtailing the use of energy and water. Providing training and orientations can help technicians deliver safer conditions in critical issues surrounding boilers. Combating energy efficiency coupled with safety of personnel involved will together help boost productivity. Email: email@example.com
November 2012 | Chemical World
SPECIAL FOCUS Absorption chillers
bsorption chillers are rising in popularity in the process industry. Growth in this segment will be primarily driven due to rising energy prices,
growing environmental concerns, and increasing demand for low cost, high efficiency cooling systems. As per a report by GIA Inc, developing countries in Asia-Pacific are expected to drive future growth in the market, largely as a result of the rapid pace of industrialisation and
cooling technologies. â€œThe Montreal Protocol initiated for protecting the ozone layer and reducing global warming is a major step in this direction. The protocol mandated the phase out and ban of ozone depleting substances such as hydro chlorofluorocarbons (HCFCs) and chlorofluorocarbons (CFCs) among others. Thus, absorption chillers have grown considerably in terms of awareness and acceptance,â€? says Dr Terrence J Collins, Director, Institute for Green Science, Department of Chemistry, Carnegie Mellon University. The prime advantages of adopting absorption chillers can be summarised as low electrical power requirements, fewer moving parts, quieter operations, and the use of low Global Warming Potential (GWP) refrigerants.
Upcoming market: Asia-Pacific Environment-friendly and safe cooling systems are being demanded One of the most prominent by the process industry. Be it for cold chain logistics, automobiles, refrigeration, or commercial structures, absorption chillers will turn out to be the technology of choice, technologies gaining impetus globally is the absorption considering its various advantages.
TYPES OF CHILLERS Absorption chillers can be classified according to the form of heat input: o Direct-fired units: These units combust fuel (typically natural gas) in an integral burner o Indirect-fired units: These utilise steam or hot liquid, which is supplied from an external source, typically a prime mover or solar array o Bespoke machines: Fired by exhaust gases or a combination of heat sources, these machines can be coupled directly to a prime mover reducing space requirements
Chemical World | November 2012
surge in the number of large commercial structures, which in turn drives the need for effective & safe cooling systems. Another trend is that these segments are gradually turning to alternative sources of energy. The report states that the global market for absorption chillers is forecast to reach $ 924.2 million by 2017.
Creating the demand The demand for cooling systems has witnessed a steep rise globally. This is not just limited to comfort cooling purposes but has expanded largely to process cooling in industrial applications. With an intention to overcome energy- and environmentrelated issues caused by conventional cooling equipment, considerable efforts have been made to promote alternative
cooling technology that uses absorption chillers to provide cooling using natural solar and thermal sources of energy. In contrast to the European and American markets where centrifugal and positive displacement chillers occupy a dominant position, absorption chillers drive maximum demand in the Asian chiller markets, particularly in Japan, China and Korea, which account for a significant 75 per cent of the global market. The Indian market is showing a sharp rise as well. The Asia-Pacific region represents the largest and the fastest growing market with a projected CAGR of 4.4 per cent, as per GIA, Inc. â€œHigh level of R&D activity and the consequent innovations designed to enhance performance, while simultaneously reducing costs, will push this market forward. Simplistic fabrication
of absorption chillers with more compact, lightweight and efficient design are desired by the market,” says Dr Vilas G Gaikar, Bharat Petroleum Professor of Chemical Engineering, and Head, Department of Chemical Engineering, Institute of Chemical Technology (ICT), Mumbai. Besides, government initiatives are steadily encouraging the use of chillers; rising consumer awareness and gradual phasing out of traditional refrigerants are also pushing the adoption of absorption chillers.
Novel developments The conventional form of compressor air-conditioning chillers is powered by electricity. Absorption chillers, on the other hand, use high-temperature heat as the chief energy source. “When it comes to energy consumption, a small amount of electricity is needed in absorption systems when compared to compression cycle systems. This is because only the pumps in the system are operated by means of electricity,” says a spokesperson from Carrier Transicold India. However, the investment cost of the absorption chiller system is considerably higher than that of a compressor system. “Depending on the unit size, the capital cost of single-effect absorption chillers is roughly 20-50 per cent higher compared to an equivalent electric or engine-driven chiller,” adds Carrier Transicold India’s spokesperson. As a result, keeping cost efficiency in mind, absorption chillers are used mainly for large installations where electricity is limited or heat is plentiful. The most efficient model of modern absorption cycle chillers uses water as the refrigerant and a solution of lithium bromide (LiBr) as the absorbent. “The concentration of LiBr is characteristically around 64 per cent after the generator and approximately 60 per cent after the absorber,” notes the spokesperson from Carrier Transicold India. In conclusion, the simplest absorption system is a onestage system, which is equipped with a single absorber and generator. According to Carrier Transicold India’s spokesperson “One is benefitted by lower investment costs; however, the trade-off is the lower efficiency. The use of multistage absorbers or generators not only increases the system performance, but also the investment cost.” However, absorption chillers come with inherent challenges for which solutions need to be designed, so that a larger market accepts this equipment. “Absorption chillers have a high rate of heat rejection limited unit selection and support, large physical size and weight, and toxic ammonia, which is used as the absorbent,” states Dr Collins. Machines that are capable of simultaneous cooling and heating are also available in the market. Absorption chillers-heaters possess the capability to eliminate the need for separate boilers, thereby reducing the cost and space requirements. Email: firstname.lastname@example.org
November 2012 | Chemical World
SPECIAL FOCUS Heat exchangers
Right selection, a must for optimum performance Location Courtesy: HRS Process Systems Ltd’s Pune plant
Attach an ‘energy saving’ tag on any appliance or equipment, and the business will turn into a goldmine. Energy saving is rapidly emerging into a huge industry worldwide. This global trend towards reducing heat energy costs will continue to push the heat exchanger sector as one of the most popular ones.
Plate heat exchangers testing at HRS Process Systems’ Pune plant
s per market reports, the chemical industry is the largest beneficiary of heat exchangers. Apart from that, these are largely used in steel production, power generation, pulp & paper, pharmaceuticals and food & beverage
FACTS & FIGURES o The global heat exchanger market crossed $ 12.7 billion in 2012 o Asia-Pacific represented the fastest growing segment, exhibiting a CAGR of 4.8 per cent over the period 2000-2010 o The shell and tube heat exchangers market, the largest product segment, is projected to reach $ 3.5 billion by 2015 o Asia-Pacific is the fastest growing market in plate and frame heat exchangers, and is projected to grow by around 12 per cent in the next five years Source: Business & Markets Report, 2012
Chemical World | November 2012
processing industries. Dynamically emerging technologies and regulations have also helped the propulsion of heat exchangers in the industry. In these days, innovative heat exchangers that can withstand corrosive chemicals are rapidly gaining popularity.
Maximising efficiency A heat exchanger is an industrial equipment in which energy is efficiently transferred from one fluid to another across a solid surface. In order to optimise efficiency of heat exchangers, the surface area of the wall between the fluids can be maximised while simultaneously minimising the fluid flow resistance. Fins or corrugations are also designed in order to increase the surface area and induce turbulence. Proper selection of a heat exchanger variant aids in energy efficiency and can make heat recovery projects a reality. There is growing recognition of a need for profitability measurements. Reducing energy costs is still one of the best methods for improving profitability. “Today, production and plant managers worldwide are realising that heat recovery through the
use of industrial grade heat exchangers is a cost-effective investment that can address the challenges of the manufacturing industry. But while selecting a heat exchanger, many companies often do not get the optimum solution,” says Sachin Raverkar, AGM Sales, Liquid Processing, GEA Process Engineering India. Different types of heat exchangers include shell and tube, plate heat exchangers, adiabatic wheel heat exchangers, plate fin, pillow plate heat exchangers, fluid heat exchangers, waste heat recovery units, dynamic scraped surface, and phase-change heat exchangers. Highly industrialised users would necessitate the adoption of more rugged and powerful heat exchangers. Shell and tube heat exchanger happens to be the most widely used. These heat exchangers are considered to be more efficient, economical and convenient.
Making the right choice While making a choice, the primary question to be answered is, why are you looking for a heat exchanger? “Start with the targets and limits of the application intended and then describe the flow conditions into the heat exchanger. Collating accurate data is of utmost importance. The heat exchanger solution relies entirely on the accuracy of the design data provided for inlet conditions of hot and cold sides. This data will be applied to a model that can accurately
predict heat transfer performance,” says Craig Carswell, President and CEO, Lyton Total Thermal Solutions. The heat exchanger surface is normally designed to make the cold and hot flows turbulent. “This will subsequently increase the fluid friction through the exchanger. Also, increasing the turbulence will thereby improve the performance of the heat exchanger surface as well. However, it will affect the cost of the power expended to overcome the pressure drop. As a result, the design needs to balance the effectiveness of the heat exchanger with the ultimate cost of pressure drop,” adds Carswell. It is also equally necessary to consider the physical properties of the materials of construction used. “The design should allow for a balance of strength and yet not be too rigid, and it should be resistant to corrosion and even erosion for some applications. For instance, a heat exchanger made of plastic will not last long when applied
to a thermal oxidiser as a primary fume preheater,” explains Carswell. New materials are emerging as a promising way to increase a heat exchanger’s efficiency. “Replacing conventional aluminium tubes with copper, for instance, could help reduce the
Highly industrialised users would necessitate the adoption of more rugged and powerful heat exchangers. Shell and tube heat exchanger happens to be the most widely used. overall cost of the heat exchanger without significantly affecting its thermodynamic performance. Also, polymer substrates or even polymer-coated metal substrates could be used in many heat transfer applications,” says Carswell.
Tried and tested Shell and tube heat exchangers are generally used for industrial operations involving high pressure and chemical exposures. Chemical plants and oil refineries are known to be popular end-users of this kind of heat exchangers. However, several factors like diameter, thickness and length are taken into consideration when choosing the kind of tubing used. Smaller diameter tubes are more compact, which allows for the fluid in the tubes to be easily heated or cooled. This kind of tube, however, is harder to clean and prone to dirt accumulation. “Bigger tube diameters are preferred as they wear out to a comparatively lesser extent. Also, tubes that are thicker are preferred, as they are more resistant to extreme temperature changes,” summarises Carswell. Once installed, the heat exchanger will be involved in recovering energy ideally for 15 to 20 years; so time spent reviewing the design procedure is important. Email: email@example.com
November 2012 | Chemical World
SPECIAL FOCUS Polyurethane
Council. This may translate into more ﬂoor space for the same total price.
he time to invest in polyurethanes is now. Tech Sci Research quotes that the cold chain market in India will cross ` 6,400 crore by 2017. Besides, the appliance industry (ACs, refrigerators) and automobile industry are seeing healthy double-digit growth. And an integral part of these sectors is polyurethane. Insulation and cooling are poised to drive the growth of polyurethanes in India. In these days where emphasis on sustainability and energy efficiency is high, and global warming is a universal threat, investment opportunities
Change is here! According to a conservative estimate by the Chairman of the Indian Polyurethane Association (IPUA), India will consume 1 kg of PU per capita by 2020. The current per capita PU consumption in India is about 200 gm. But how practical is the estimation to add an additional 800 gm per capita consumption in the present scenario? Industry experts opine that it is quite possible and that the foreseeable future is optimistic towards the growth of PU. “In India, we see that most launches of ACs and
the term. This includes the fitment of air conditioners in the automobiles being manufactured. So how can a norm in an EU nation impact the auto industry in India? An insane amount of investments in the auto sector in India has resulted in the country becoming a hub for automobile production and export. “We are seeing a lot of investments in this industry and a large amount of exports to the EU nations is being witnessed. Recently, EU has come up with a new MAC directive for car ACs (mobile air conditioners). Refrigerants that are best placed to serve this new directive and comply with these EU norms will be more in demand. We expect Indian car
A solution to promote COOLING What do unrelated products such as cars and ice creams have in common? The answer lies in the product called polyurethane (PU). This polymer has been uplifting the cooling technology and providing the muchneeded boost to the automobile, appliance, cold chain, and thereby the retail sector in India.
in the wonder polymer PU is immense. Innovative material design and technology advancements have resulted in high quality PU insulation products that reduce energy loss. Energy efficiency impacts more than just operating costs. Highly efficient walls and roofs may allow heating and cooling equipment to be downsized by as much as 35 per cent, as per American Chemistry
refrigerators are happening on the energyefficiency positioning. This means that the end-consumer is also becoming aware,” says Paul Sanders, Managing Director (Europe, Middle East, Africa and India), Honeywell Fluorine Products. Moreover, norms are driving the automobile industry worldwide towards being eco-friendly in the real sense of
WHAT IS POLYURETHANE FOAM? Polyurethane foam is a thermosetting insulation, providing structural performance and ﬁre resistance. Polyurethane products have a strong yet lightweight structure, and are dimensionally stable, moisture resistant and durable. This combination of properties allows manufacturers to design polyurethane thermal insulating products for many diverse applications and allows it to be attached to a wide range of substrates. In addition, when combined with the proper materials, they can perform as external air barriers, helping prevent the inﬁltration of outside air and the escape of indoor air. Courtesy: American Chemistry Council
Chemical World | November 2012
manufacturers to react positively to such products,” adds Sanders.
Fuelling cold chain logistics “Today, an increasing number of emerging economies in Asia are seeking ways to keep food safe by maintaining a cold chain all the way from farm to fridge, and PU provides an important part of the solution,” says Dr Melanie Maas-Brunner, Senior Vice President, Asia-Pacific, BASF Polyurethanes. And with investments rising in food processing, cold chain logistics too is growing exponentially. “Fresh produce travels quite a distance before it finally reaches the consumer. Therefore, it must be transported in properly-chilled facilities throughout its journey to stay fresh and retain its quality. The most critical aspect
for manufacturers and consumers alike is a refrigeration system that is both efficient and conserves resources. BASF’s three grades of polyurethane systems are designed to work effectively throughout all stages of the cold chain to deliver the perfect insulation and cut expensive waste,” adds Maas-Brunner. According to the findings from University of Southern California, if all of the storage facilities, freezer chests and transport vehicles were to be insulated with polyurethane rigid foam having an optimised insulating thickness, then 16 times more energy could be saved than what is needed for the production of the insulating material. At the same time, modern insulation made of PU not only improves the energy balance but also reduces CO2 emissions.
Montreal Protocol calling the shots The Montreal Protocol on Substances that Deplete the Ozone Layer is an international
treaty designed to protect the ozone layer by phasing out the production of numerous substances believed to be responsible for ozone depletion. Its subsequent amendments create a schedule to phase out the uses of ozone depletion substances (ODS) by substance classes (CFCs, HCFCs, etc). Prior to the implementation of the Montreal Protocol, CFC-11 was the primary blowing agent used in PU foams. Since the phase out of CFC-11, HCFC-141b has become the blowing agent of choice in rigid polyurethane foam applications because it has desirable physical properties. “India, as a part of Article V countries of Montreal Protocol on Substances That Deplete the Ozone Layer, is working towards the phasing out of HCFC141b and R22 from 2013 onwards. The transition from HCFCs to environmentfriendly alternatives is of particular significance since the country aims at not only phasing out ozone depleting HCFCs, but also significantly improving the energy-
Global demand for polyurethane 0.9% 6.7%
18.4% 53.5% 20.4%
Asia-Pacific North America Europe South & Central America Middle East & Africa Courtesy: GBI Research
efficiency of domestic appliances over the next two to three years,” explained Sanders. So along with PU, it is necessary to equally invest in research towards alternative liquid blowing agents. Email: firstname.lastname@example.org
November 2012 | Chemical World
FACILITY VISIT Novel Spent Acid Management
pent sulfuric acid is generated in chemical companies involved in the manufacture of dyes, dye intermediates and other chemicals, where sulfuric acid or oleum is used as raw materials. The concentration of sulfuric acid in the spent acid is normally in the range of 10-30 per cent. The individual companies find it difficult to store, handle or treat it effectively. This led to the establishment of NSA Management, a facility for by-product recovery and industrial waste exchange on no-profit, no-loss basis.
Acid being unloaded in acid collection tanks
Adding value to waste through recycling technologies With growing environmental concerns, industries are looking for novel concepts that can help them in reducing carbon footprint. For providing a solution to the chemical companies generating large amount of spent sulfuric acid, the one-of-its-kind large-scale project – Novel Spent Acid Management (NSA Management) – has been set up at Vatva in Ahmedabad, Gujarat, which aims at reusing, recycling, and recovering by-product from spent acid generated during manufacturing of dyes, dye intermediates and other chemicals. NSA Management is a company promoted under Section 25 of Company’s Act. It has provided a common platform for chemical companies to ensure that the spent acid is sold only to authorised and genuine end-users, and also ensure possibility of segregation of gypsum, which can be sold to cement industry. The remaining effluent
undergoes biological treatment, thereby reducing the organic load on Common Effluent Treatment Plant (CETP). It is one of the most important and necessary infrastructure to companies, especially in the small and medium sectors. J P Patel, General Manager, NSA Management, says, “It is a community
project meant for chemical companies in and around Ahmedabad, and covers almost whole of Gujarat. The project was commissioned in 2006 and operations started at the facility in 2009. The centralised facility caters to about 200 companies in Vatva, Naroda and Odhav as well as nearby industrial estates such as Sanand and Chhatral. The members can simply send their effluent in the form of spent acid to us for treatment, and focus on their production.”
The novel procedure
Aeration tank for secondary treatment
Chemical World | November 2012
The facility is spread over an area of 44,500 sq mt and has the capacity of handling 1.5 million litre of waste per day. The facility has all necessary infrastructure required for the treatment of spent acid. Patel explains, “First, the companies become the member by paying membership fees, and thus become eligible for sending their effluents. The spent acid is transported in
Novel Spent Acid Management
tankers from the companies to the facility. Effluent sample is drawn and analysed. The acid from tankers is unloaded in different collection tanks depending on the chemical composition, colour, quality and other characteristics of spent acid.” There are six collection tanks, which are acid-proof and brick lined tanks. He adds, “The concentrated acid is sent to companies, which need it for various processes. Whatever is treatable acid is sent to neutralisation tank or chambers through acid handling pumps for treatment. On the other hand, lime slurry is prepared as this also needs to be pumped into the neutralisation tank so as to neutralise the acid. Earlier, hydrated lime, which was a costly chemical, was used for lime slurry preparation, but now calcium carbonate is used. This has reduced the cost.” During the neutralisation process, a huge amount of sludge is formed. The thick slurry is sent to filter presses. Here the litchete and solid cake gets separated. The cake, which is obtained during this process, is gypsum. It is stored in gypsum yard and dried. It is then collected by the cement manufacturing companies. Almost 150-200 tonne of gypsum is obtained per day. The litchete generated from the filter presses is collected in a separate area and
then transported to the clariflocculator where chemical dosing is done, so that the suspended impurities become heavier and settle at the bottom of the tank. This is then removed easily. The liquid is then sent to the aeration tank, which reduces the Biochemical Oxygen Demand (BOD) & Chemical Oxygen Demand (COD) levels and some more impurities are removed. The aeration tank has the capacity of treating 85 lakh litre of water per day. This is the secondary and the final treatment process followed by the company. From here, the acid is sent to further tertiary treatment outside the facility. The entire operation involving transportation of spent acid from member industrial units, storage, handling, treatment, handling of gypsum and sludge is carried out in strict compliance with the guidelines and requirements specified by Central Pollution Control Board, Gujarat Pollution Control Board and Ministry of Environment and Forests (MoEF).
Envisioning growth The facility generates absolutely no wastage, as the by-product gypsum is used by cement industry for various applications. Also, many steps are taken for water conservation. Patel avers, “We have reduced the usage of water drastically. For example,
A NOBLE INITIATIVE NSA Management is established to perform a number of functions that include: o Segregation and collection of spent acid received at site in different tanks, depending on the concentration of sulfuric acid and other properties o Supply the colourless and concentrated spent acid directly to the actual users to utilise it as a raw material in the process or as neutralising agent in treatment of wastewater o Supply a part of spent acid to manufacturers of ferrous sulfate, alum, single super phosphate etc o To neutralise relatively dilute and colourless spent acid by using hydrated lime for the production of gypsum, which is in turn supplied to the cement manufacturing plants o Neutralise spent acid having colour and other contaminants with hydrated lime and dispose of the resulting sludge into secured landfill facility o Treat the wastewater generated in the Effluent Treatment Plant (ETP) consisting of primary & secondary treatment facilities and send the effluent after treatment to CETP of Green Environment Services Co-operative Society Ltd (GESCSL) for further treatment and joint disposal
This project is and will be a lifeline for the chemical industry. Earlier, we had to go to companies and explain this concept. But now, they are coming to us and becoming a member of this project. J P Patel General Manager
in lime slurry preparation, lot of fresh water was used earlier. We reduced this to substantial levels. Further, the treated water is reused for cleaning of tanks etc. Keeping in mind the energy conversation issue, the company has reduced its energy cost from almost ` 11 lakh to ` 8 lakh per month.” Focussing on its vision statement, Green Chemistry and Green Environment in Gujarat, NSA Management aims at starting new projects in this direction. Patel notes, “Keeping in mind the growing awareness about environmental issues among chemical companies, we will be going for additional treatment facilities. We plan to increase the existing 7,000 sq mt area of gypsum yard to 10,000 sq mt area. Besides, we are going for additional neutralisation chambers so as to meet the requirements of more companies. We plan to start hydrochloric acid treatment at the facility in addition to treatment of spent sulfuric acid. We are also considering starting brick manufacturing, as gypsum obtained in large quantities can be used for the same. The facility currently has 400 metric tonne (MT) neutralisation capacity, which will be expanded to 800 MT in the coming years.” Last but not the least, commenting about the future prospects, Patel says, “This project is and will be a lifeline for the chemical industry. Earlier, we had to go to companies and explain this concept. But now, they are coming to us and becoming a member of this project. Further, chemical companies not only from Gujarat, but also outside the state, are showing interest in us. Thus, awareness is increasing, and this is a positive sign for the growth of the chemical industry.” Photo: Nikhil Patel Email: email@example.com
November 2012 | Chemical World
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INSIGHT & OUTLOOK
CSR INITIATIVES BY CHEMICAL COMPANIES CORPORATE SOCIAL RESPONSIBILITY Volunteering to lead from the front....................................................................................................... 38 HEALTHCARE INITIATIVES In service for a better cause .................................................................................................................. 40 ROUNDTABLE Are there effective ways to implement CSR? ........................................................................................ 43 HSE STRATEGY A proactive approach to safety ............................................................................................................... 44 LUBRICANT INDUSTRY Embracing safety measures to tackle any eventuality ............................................................................ 46 PUMPS FOR O&G INDUSTRY Advanced pumping systems redefining growth ..................................................................................... 48 INDUSTRIAL PAINTS On a fast lane to fortune with high demand from automotives ........................................................... 50
November 2012 | Chemical World
INSIGHT & OUTLOOK Corporate social responsibility
Volunteering to lead from the front
Chemical manufacturers in India have undertaken several path-breaking steps under Corporate Social Responsibility (CSR) programme to make a meaningful difference to society. The initiatives encompass right from water management, health and education to recycling waste. The results of such initiatives have tremendous effect on society. Prasenjit Chakraborty
here has been a significant transformation in the way CSR is being perceived throughout the world. ‘Responsible Care’ is a social initiative adopted by 90 per cent of the chemical manufacturers globally. “The India chapter of the chemical manufacturers has been encouraging alignment with these global norms, indicating that CSR is undergoing a paradigm shift from simple philanthropy towards initiatives focussed on the Millennium Development Goals, thus resulting in sustainable solutions at the grass roots level,” points out Sudhir Singh Dungarpur, Head & Partner Development Sector Practice, KPMG, India. CSR activities could be categorised into community development initiatives on health, education, women empowerment, financial inclusion, and environmental
Chemical World | November 2012
issues. There has been a transformation in the outlook towards CSR, with companies becoming more open, flexible, transparent, responsible and accountable towards these initiatives. “Besides advising our clients in this sector on CSR strategies, we have also assisted them with developing systems for reporting, measurement and monitoring these initiatives on a regular basis,” says Dungarpur. There are different areas of CSR such as education, farming, sustainability, self-employment initiative for women, etc.
Imparting education Education seems to be the most preferred area for companies. Naturally, several companies have taken initiatives in this direction. For instance, in India, LANXESS has carried out several projects in the area of education and skills training. These initiatives have been undertaken in schools and training institutes near its sites in Jhagadia and
Nagda located in Gujarat and Madhya Pradesh, respectively. “As a part of child welfare and education programme, we have supported the girls’ education initiative by the Government of Gujarat, namely Kanya Kelavani Nidhi,” says Dr Joerg Strassburger, Country Representative and Managing Director, LANXESS India Pvt Ltd. Similarly in Nagda, LANXESS supports selfemployment at Shaskiya Prathmik Vidyalaya. In order to support girl students, sewing machines, embroidery machines and peripherals such as ceiling fans, water purifiers, etc, were provided to them so that they are trained in tailoring along with their academic curriculum. Similarly, Dow Corning worked with the Dhoksangvi School (near Pune) to provide them with a science laboratory and a library, which provide the senior students with better and more convenient learning opportunities. “Earlier, a mobile science laboratory used to visit the school once a year and they did not have a library at all,” points out David Longo, Site Manager, Pune Manufacturing Facility, Dow Corning. It also conducts regular science days at its plant to create awareness about silicones and their benefits in everyday lives. Students also participate in sessions on career development, personal development, safety and hygiene. In order to promote a better learning atmosphere, Akzo Nobel has helped with the construction of a government school classroom in Cholappanahalli, a small village about two kilometre from its factory in Bengaluru.
Farming arena The approach of CSR varies from company to company; however, the goal is same – social development and community welfare. For instance, integrated water management is the key programme of Tata Chemicals Society for Rural Development (TCSRD) in the Mithapur region of Gujarat as nonavailability of quality water is one of the biggest concerns of this droughtprone region. The initiative immensely
Corporate social responsibility
benefitted the farming community of this region. “This programme has helped in creating 246 million cubic foot capacity of water in the parched area of Mithapur and has provided critical irrigation facilities covering 6,895 acre of land. About 236 medium water harvesting structures such as check dams have been built for better percolation and water harvesting. Moreover, 2,165 small water harvesting structures such as farm ponds, farm bunds have been deepened and salinity pushed back by increasing the underground water buffer,” says Alka Talwar, Head – Community Development, Tata Chemicals Ltd. The programme has helped in improving the production by 40 per cent and achieving a direct economic gain by Rs 240-270 lakh per year. TCSRD’s Livelihood Development Programme seeks to strengthen incomegenerating capacity of marginal farmers who are not adequately covered by the ‘Natural Resource Management Program’. It focusses on micro-enterprise development, aimed at building capacities through extensive training, helping identify enterprise opportunities and supporting these activities through micro-finance and marketing. The main vehicles driving this component are the formulation of self-help groups in villages; the Rural Entrepreneurship Development Programme; skill-building through Vocational Training Programme; Uday Foundation (rural BPO) and promotion of rural handicraft (Okhai). This programme has spurred the selfhelp group members into utilising their savings for investing in an enterprise.
As a part of child welfare and education programme, we have supported the girls’ education initiative by the Government of Gujarat, namely Kanya Kelavani Nidhi. Dr Joerg Strassburger Country Representative and Managing Director, LANXESS India Pvt Ltd
It has helped in increasing individual savings leading to financial security. “Collaboration with organisations such as Dalit Shakti Kendra, NABARD, and Gram Technology has further strengthened this programme. So far, 5,521 people from 62 villages have undergone skill development training programme,” says Talwar. As a responsible corporate citizen, Akzo Nobel is also not far behind. It works in the interiors of Maharashtra and helps below-poverty-line farmers towards development of barren land. “We are associated with the Department of Botany (RJ College) so that we could assist the farmers in planting fruit-bearing trees and also help them with inter-farming techniques. This project won an award for being the best community practices project, within Akzo Nobel, globally,” says Asesh Sarkar, General Manager, RD&I, Decorative Paints, Akzo Nobel India. Plans are also afoot to go a step further; it is working on a water harvesting project on the same land.
Sustainability initiative For chemical companies, sustainability is one of the prime focus areas. Keeping this in mind, in 2011, LANXESS celebrated ‘World Environment Day’ with Stree Mukti Sanghatna (SMS) Women’s Liberation Organisation. SMS is an NGO that works for the welfare of women rag pickers and offers professional services for office waste management by holding a ‘best from waste’ paper competition where the SMS team judged and selected winners. LANXESS India now collaborates with them for recycling its used paper in support of the cause of zero waste. SMS converts this waste into branded stationery for internal use. Similarly, TCSRD’s Environment Conservation and Care programme encompasses renewable energy and bio-diversity reserve plantation project. Restoration and conservation of coastal ecosystems such as coral reef restoration, mangrove plantation, and protection of endangered species such as whale shark,
Collaboration with organisations such as Dalit Shakti Kendra, NABARD, and Gram Technology has further strengthened TCSRD’s Livelihood Development Programme. Alka Talwar Head – Community Development, Tata Chemicals Ltd
Asiatic lion have been undertaken in partnership with institutions of excellence – Wild Life Trust of India (WTI), and International Union for Conservation of Nature (IUCN). Under this initiative, 275 whale sharks have been rescued till now. Eco-clubs have also been formed to create awareness among the community members on environment conservation.
Going proactive According to Dungarpur, best practices in CSR were evolved internationally in the early 1990s under the Kyoto and Basel conventions, and these were proactively adopted by companies in Europe. Many of these practices have been formalised under the ‘Responsible Care’ industry initiative promoted by the International Council of Chemical Associations. “These include bans on production of various chemicals deemed harmful to the environment. Not all these bans are enforced in India, due to which many Indian firms have been generally reactive rather than proactive in their adoption of sustainability and CSR initiatives,” he points out. Larger Indian companies have responded to evolving standards being enforced by their global clients. The Registration, Evaluation, Authorisation and Restriction of Chemicals (REACH) regulations of 2006 require buyers of chemicals in Europe to be able to trace inputs back along their supply chain to the original producer. Those Indian firms that are part of such supply chains have rapidly developed wide-ranging CSR responses. It is time for others to follow suit. Email: email@example.com
November 2012 | Chemical World
INSIGHT & OUTLOOK Healthcare initiatives
In service for a better cause
Courtesy: Tata Chemicals Ltd
Healthcare is one of the top priority areas before chemical manufacturers for their Corporate Social Responsibility (CSR) initiatives. Many companies are taking steps to provide better infrastructure and services in healthcare, but there is a need to have a closer interaction with the community to have profound and lasting effect.
‘Parivar Kalyan Kendra on wheel’ initiative of Tata Chemicals
ccording to Assocham Eco Pulse (AEP) study on ‘Corporate Social Responsibility by Indian Inc in Q1 2010-11’, healthcare was the fourth most popular area for companies for their CSR initiatives, with community welfare, education, and environment occupying the first three positions. Many chemical manufacturers are taking active initiatives to provide better healthcare services, especially in the rural areas. For example, Tata Chemicals Society for Rural Development (TCSRD), the social arm of Tata Chemicals Ltd (TCL), in collaboration with Population Foundation of India (PFI), has initiated Intensive Family Welfare Project
Chemical World | November 2012
(IFWP) in 84 villages of Rajpura block and 96 villages of Gunnour block of Uttar Pradesh’s Badaun district, which has been ranked among the 90 most backward districts of the country by the Government of India (GoI). “The project IFWP was re-named as Swasth Aagan project from 2007 onwards. This project was initiated to bring about a positive impact and move towards sustained interventions. It laid emphasis on promoting institutional deliveries; strengthening Village Health and Sanitation Committees (VHSCs) and Parivar Kalyan Kendra (PKK); improving preventive healthcare, especially antenatal and post-natal services. The project focussed on newborn care, management of communicable diseases in children and improving health of pregnant women and
adolescent girls,” says Alka Talwar, Head – Community Development, TCL. TCSRD, along with creating awareness about various government medical care services and its schemes, has helped in building processes and linkages between the community and relevant institutions with the aim to bring about sustained improvement in all the Reproductive and Child Health (RCH) indicators such as fertility rate, Maternal Mortality Rate (MMR), Infant Mortality Rate (IMR). Talwar notes, “Overall, the project helped in bringing about positive impact with 80 per cent coverage in routine immunisation in the targeted area as against 7.8 per cent. Although the dai’s were given training in safe delivery practices, and there seemed to be fewer deaths, the real effect would be known in the coming years.” According to Assocham, as part of their CSR activities, companies offer mobile medical services with medical help along with organising regular medical camps to eradicate diseases, creating awareness on preventive healthcare among others. Ruby Thapar, Director - Public Affairs, Dow Chemical International Pvt Ltd, says, “At regular intervals, Dow India’s Kalwa plant conducts basic health check-ups and hygiene workshops for the communities around the plant.”
Prevention is better than cure Understanding the importance of sanitation in disease prevention, many chemical manufacturers are educating villagers about hygiene and cleanliness. As part of its community initiatives in January this year, Dow India’s Chennai Plant donated 100 dustbins to Pondur, a neighbouring village, to help provide a clean and hygienic environment for the locals. Thapar elaborates, “This initiative encouraged villagers to use the dustbins placed at the corner of each street for disposal of their household waste. The village authorities, however, faced another challenge – the need to identify a mechanised and cost-effective method of disposing the garbage from
these dustbins to the designated isolated location. Dow stepped in and helped by donating a customised, mechanised trolley to help solve the issue.” Similarly, Dow’s India Engineering Center in Chennai has renovated the toilets at a neighbourhood matriculation school, which was facing a shortage in attendance (especially from girl students),
Courtesy: Dow India
Jaipur foot is an ideal example to show how co-operation between a chemical manufacturer and other stakeholders can solve some of the critical challenges faced by the society. The Jaipur foot was originally an artificial limb, handmade from vulcanised rubber. A skilled workforce laboured for hours on end to make each individual foot. In 2005, Dow India partnered with the NGO Bhagwan Mahaveer Viklang Sahayata, vehicle interiors manufacturer Pinnacle Industries and the Indian Space Research Organisation to develop a new version of the Jaipur foot. Thapar says, “The new foot, thus designed, is more durable and 20 per cent lighter. The user has greater mobility with increased comfort and flexibility, in addition to the limb being cosmetically close to a natural human limb. Costs have been cut by 25 per cent. Where one old limb took an hour to produce, eight of the new model can now be made in the same time, using Dow technology and expertise.” Dow India is currently working towards further bettering the prosthetic Jaipur foot in collaboration with global universities.
Chemical World | November 2012
due to the lack of hygienic toilets. Chemical manufacturers are using their knowledge about chemistry to solve challenges faced by community. Thapar says, “Extending its global expertise and innovations in water solutions, Dow India has designed and developed a solution that aims to provide safe drinking water among 1,577 families in Tamil Nadu through the installation of Reverse Osmosis (RO) plants.” Dow India has incorporated, in 2010, this project in Tamil Nadu called ‘Provision of safe drinking water to coastal villages’, in association with Habitat for Humanity India. The aim of this ongoing project is to provide safe drinking water for community members in three villages of Eraviputhenthurai in Kanyakumari district and Thangamalpuram and Periyasamipuram in Thoothukudi districts of Tamil Nadu, through installation of three RO water treatment facilities of appropriate capacity. “The plants, designed by Dow India and built by a third party, function on FILMTEC – the RO and nanofiltration technology by Dow India,” Thapar adds.
Continuing the good work Showing commitment to the community services, many corporates continue to do their work in spite of many challenges. For example, TCI is still continuing with the project even though the partnership with PFI ended. “We will continue to improve the reach and the access to quality Reproductive Health (RH)/Family Planning (FP), by way of community-based mechanism. Apart from strengthening the capacity of the ASHA workers, the government health workers, and different committees such as Village Health and Sanitation Committees, we would continue to strengthen Parivar Kalyan Kendra in order to make the Swasth Aagan project more sustainable,” states Talwar. Chemical manufacturers are investing in the areas where they are working currently – in terms of technology, employee volunteerism and monetary contribution – to address some of
Companies today are taking an active interest in working closely with the communities where they are based. This is an important step in educating the people about the organisation (based in their habitat) and its work, in collaboration to find solutions to common problems and build more sustainable communities. Ruby Thapar Director - Public Affairs, Dow Chemical International Pvt Ltd
the everyday challenges better. “Our expansion will be more in terms of doing better what we already are doing well, instead of enlarging the bouquet of activities. Dow India places a high value on the success of the communities in which it operates in, listening and striving not just to be a good neighbour, but a global corporate citizen. Our promise is our most vital product and through authentic relationships we are building stronger, better, more sustainable communities in all the places we do business,” says Thapar. Even though chemical companies are realising the importance of CSR, experts feel that there is a need for greater engagement with community. “Yes, engagement with the community and other stakeholders is core to our organisation and for other chemical companies in India as this is the first step towards sustainable business practices,” opines Talwar. Interacting with community will also help companies achieve their sustainability goals in the long run. Thapar concludes, “I think companies today are taking an active interest in working closely with the communities where they are based. This, according to me, is an important step in educating the people about the organisation (based in their habitat) and its work, in collaboration to find solutions to common problems and build more sustainable communities.” Email: firstname.lastname@example.org
Roundtable INSIGHT & OUTLOOK
Are there effective ways to implement CSR? Today, reputed companies in the chemical industry are carrying out Corporate Social Responsibility (CSR) activities, which aim at serving a particular community. The benefits of such activities are more effective and successful when there is a clear cut strategy and understanding of the real needs of people in a particular area. Prasenjit Chakraborty interacts with people associated with CSR activities to gain further insights.
David Longo Site Manager, Pune Manufacturing Facility, Dow Corning
Asesh Sarkar General Manager, RD&I, Decorative Paints, Akzo Nobel India
Sudhir Singh Dungarpur Head & Partner - Development Sector Practice, KPMG India
In our current business, we are extremely focussed on whatever we are doing. But we often realise that to serve the community around us, we need to go beyond what we are doing and engage with various organisations through CSR services and advance their skills. Further, through our volunteering and Citizen Service Corps programmes, we are looking for opportunities to help and also understand if solutions from Dow Corning can be extended to under-served markets. In my opinion, it would be pertinent to understand the needs of the communities and society where we operate and plan activities accordingly. By doing so, we would work not just as an outside entity helping a closed group, but by engagement with the communities, the activities would be more effective and encourage good feedback for further understanding.
There are many ways to do CSR effectively in India. We are not experts to be able to comment on that. We are merely committed employees in an organisation, which has a deep sense of belief and dedication in working for causes related to education and empowerment. At Akzo Nobel India, our community programme aimed at productively contributing to the welfare of society is designed in a way that the activities undertaken imbibe a sense of ownership within the employees and help develop leadership qualities. This not only helps promote entrepreneurial thinking, confidence and courage to develop new initiatives, but also increases employee integrity and responsibility. One of the critical parameters before developing any community programme in India is to assess the need of the community.
The hallmark of a good CSR programme has always been solid reporting backed by data interwoven with sustainable solutions. These are generally achieved by conducting targeted programmes aligned towards a long-term value-creating CSR implementation strategy. In todayâ€™s CSR environment, transparency and accountability also hold the key towards sustainable development. KPMG has advised its industrial clients on the development of impact mitigation strategies as well as on stand-alone community interventions. In both cases, we recommend that clients select a geographical area or thematic focus, which is relevant to their business, and where they can apply their own technical expertise. We also recommend that they carefully select performance metrics for their initiatives and conduct a baseline survey of the current situation, so that they can assess their progress in the near future.
EDITORIAL TAKE One of the most important parameters to be considered before undertaking any community programme is to assess the need of the community. After assessing the need, it is imperative to chalk out a strategy that will be most effective in terms of providing maximum benefits to a particular community.
November 2012 | Chemical World
INSIGHT & OUTLOOK HSE strategy
A proactive approach to safety Given the gigantic risks to lives, property and environment, Health, Safety and Environment (HSE) has evolved over the years into a high priority area where chemical plants are concerned. HSE attaches importance to reducing risk to people, assets and the environment through appropriate measures and considerations. B S Murali
he chemical plant is a complex construction involving huge investments and with the potential to impact the lives of thousands of people involved in some way or another with it. The risk inherent in a chemical plant is continuous and permanent, and starts with engineering design and extends through its construction, set up, commissioning, test runs, operation, shut down and even closure. By virtue of their extremely volatile and hazardous nature, chemicals that form the feedstock and products in chemical plants make these plants a virtual time bomb, waiting to explode, if proper precautions are not taken at every stage. A look at some of the factors/ conditions/elements at work in a chemical plant will substantiate this. Chemical plants are characterised by conditions such as complex and volatile chemicals & chemical processes, critical equipment working at high temperatures, remote sites with generally minimal medical access, deep excavations, confined operating
and working spaces, heavy construction equipment and materials, computerised systems and diversely-skilled workforce. In such circumstances, where risks loom large, be it in terms of lives or assets, HSE has become a high priority area in chemical plants.
Safe chemical plant: A myth or reality To say a chemical plant is absolutely safe and beyond accident, mishap or disaster is
ROLE OF HSE IN CHEMICAL PLANTS HSE practices involve the application of formal, structured risk assessments, risk management, with a view to effectively reduce risks to people, asset and environment. The considerations of HSE can be briefly summarised as follows: o Identifying practicable risk reduction measures and implementation o Using appropriate standards, codes, current good practices, etc and justification of any deviations o Ensuring that safety principles meet legal requirements o Defining effective change control procedures o Providing information with a view to enable safe operation, maintenance and repair o Aiming at influencing the development of appropriate codes, standards or guidance through the provision of operational intelligence (from inspection and investigation) and expert advice
Chemical World | November 2012
an untruth. Chemical plant manufacturers know only too well the risks that are associated with their facilities, and consequently opt for heavy insurances on their chemical complexes. The list of accidents in chemical complexes is long, and so it is not out of place to see every nook and corner of a plant site emblazoned with safety messages. Despite the best safety measures, the chemical plant remains one of the most volatile and potentially hazardous locations on earth, calling for stringent safety measures and round-the-clock safety surveillance. To relax safety measures can be fatal and good safety practices involve logging of safety hours. Justifiably, safety milestones are celebrated at sites. The ‘safe set-up’ of a chemical plant is addressed by ‘foolproof design’ in the engineering stage of the plant. Accurate assumptions and calculations during the engineering phase ensure reduction of risks to the lowest practicable level by application of principles of inherently safer design. Today, HSE experts join process and design teams for initial project meetings. Proven technologies and competent consultancies are sought out,
for an unproven chemical process or an incompetent engineering consultant without prior implementation experience of a project can result in heavy losses. Inherent at the engineering phase is the application of national/international design codes and standards, as well as the conduct of a Hazard and Operability (HAZOP) study, where among other aspects, potentially hazardous areas are identified, classified and evaluated for safety standards. Areas such as chemical storage locations and plant operation areas are earmarked as high risk areas, and generally have fire-fighting stations and firefighting equipment at hand, to take care of emergencies. Once the engineering drawings have been released for construction, the aspect of HSE assumes increasingly important proportions. Site work involves the appointment of contractors who will be in charge of handling and erection of critical equipment at the site. It is not uncommon to have many contractors with their respective teams working on a single site. In light of the risks involved, it is imperative that contractors’ safety records are thoroughly examined before their appointment – this is one area where cost considerations may have to be set aside to ensure that the most experienced and safe contractors are selected. It is an accepted practice for a meeting to be called, of all contractors, wherein HSE requirements are clearly conveyed. Today, contracts involving contractors engaged in construction of chemical plants come loaded with safety clauses. Before mobilising manpower to site, contractors need to submit and have their site HSE plan approved.
Role of the safety officer A decade ago, the presence of a safety officer was considered a luxury. Not any more. Today, it is not uncommon to have more than one safety officer posted to site, and the number of safety officers is commensurate with the criticality and size of the project on hand. In a smoothly running chemical plant, the safety officer may seem slightly out of place. But
construction engineers and site operating personnel know only too well the efforts of the safety officers in ensuring smooth state of affairs. The safety officer’s work at a chemical plant or facility starts at an early stage of a project, concurrent with the engineering phase when hazard identification and risk assessments are carried out. The findings and recommendations of the safety officer are required to be conveyed to all concerned. The role of safety officers is a proactive one – they have access to the senior management as well as to all areas of the plant site. It continues unabated through the set up and operation of the chemical plant.
Safety measures The need for safety has resulted in organisations adopting intense and rigorous safety practices that are followed at chemical complexes. Mobile devices, for example, cannot be carried into a chemical complex; it is mandatory for them to be deposited outside at the security post, before entering. Some of the safety measures are mentioned below. Work permit system for all jobs such as hot work, working at height, confined space entry, excavation etc is mandatory. Site-specific safety induction training programmes, held prior to all employees starting work at site, are a must. Jobspecific work such as grinding, fire-related and suspension-inherent activities should be performed using Personal Protective Equipment (PPE) such as goggles, face shields, safety helmets, shoes, and full body safety harness. Heavy construction equipment such as cranes, loaders etc must be fitted with reverse alarm/back-up alarms. Inspection of all heavy and critical equipment is essential. The safety teams should comprise representatives from all entities – customers, consultants, contractors. There should be weekly and monthly safety meetings; daily safety inspections, highlighting of safety hazards, immediate implementation of control measures in event of safety lapse with the involvement of all concerned. Logging, reporting, review and recording
of safety lapses/safety-compromised incidents with full investigation should be practised and findings to be reported and discussed at safety and other project review meetings. There is need for safety warning signs throughout the site; provision of daily safety tool box; and emergency mock safety drills once in every six months and if required, at more frequent intervals. Programmes promoting safety need to be organised on nominated safety days – National Safety Day/Week, Fire Safety Week and World Environment Day – for the entire site team with active participation of the top management. Other measures include safety audits and periodic safety meetings with senior management in attendance; and provision of first-aid, medical, trained medicos and ambulance on hand 24/7.
All for one cause Safety is all about teamwork. The best safety policies and practices, HSE teams and safety officers ultimately will be able to achieve next to nothing, if they are not supported by the entire workforce. HSE certifications today make it mandatory for all the employees of an organisation to be oriented in HSE matters. Safety is also about being proactive. It is not the responsibility of the HSE team or safety officer alone. Any potentially hazardous situation or safety breach needs to be brought to the attention of the safety officer immediately, just as any incident needs immediate pooling of efforts, in the interests of all concerned. Indeed, the adage ‘Safety first and last’ is not out of place, where a chemical facility is concerned. B S Murali is the Deputy GM – HSE (Quality Assurance) at Uhde India Pvt Ltd. He is Bachelor (Mechanical Engg) with additional Post Diploma in Industrial Safety from Regional Labour Institute (RLI), Chennai. He has an experience of around 20 years in HSE in various industry sectors in India and Gulf countries. For details, contact Sushil Sorte on email: email@example.com
November 2012 | Chemical World
INSIGHT & OUTLOOK Lubricant industry
Embracing safety measures to tackle FLAMMABILITY any eventuality
may even continue working. However, in every case in which a person suffers this type of injury, he should stop work and get immediate medical treatment. In case of a grease gun accident, seek immediate medical Workplace accidents and safety-related issues treatment. can be prevented and controlled to a large Identify the extent. Post-accident investigations HEALTH INSTABILITY grease or reveal that many of these mishaps could oil involved have been avoided if personnel had better in the accident. awareness about workplace hazards and Contact the supplier applicable critical safety guidelines. or the manufacturer SPECIAL to obtain the productâ€™s Naveen Shukla 621-1,034 kPa (90Material Safety Data Sheet 150 psi) air pressure. (MSDS) about possible toxicity, nderstanding basic safety Most modern industrial if a physician or hospital needs more precautions is important hydraulic systems operate in information. for any employee working the range of 13,790-34,475 kPa Mechanical hazards in an industrial plant. (2,000-5,000 psi). A stream of oil ejected These types of hazards are common in Below are a series of guidelines that from a nozzle or leak under pressure of chemical industry and precautions such can help lubrication specialists recognise this magnitude has a velocity comparable as those mentioned below need to be the potential hazards associated with to the muzzle velocity of a rifle bullet. taken to avert them. handling, storing, and using petroleum The most common sites of injury Handling drums: A typical products. are the fingers or hand. However, any 55-gallon drum of oil or grease weighs part of the body can be involved. With High-pressure injection hazards nearly 450 pounds (204 kg). If a drum grease guns particularly, accidents usually High-pressure injection injuries, also is dropped, it may bounce out of control occur when the injured person wipes the known as grease gun injuries, are caused or burst at a seam, creating a spill and/or tip of the nozzle with his finger or the by the accidental injection of a foreign fire hazard. Two people should overturn nozzle slips off the grease fitting while material, such as grease, oil, or solvent or upend a drum to prevent muscle being held in place. Grease may also be under pressure, through the skin and into strains and other injuries. When rolling injected into the body from a leak in the the underlying tissue. This is analogous a drum, always keep its motion in check; grease line. In hydraulic system accidents, to medical techniques used to administer never allow it to free roll. When hoisting a leak in a hydraulic line can emit a highimmunisation shots without a needle. A a drum, use a drum sling that hooks velocity stream of oil and cause injury if it grease gun injury can cause serious delayed over the ends of the drum. Do not use strikes a person. Workers are commonly soft tissue damage and should be treated as air pressure to empty a drum as it may injured when they try to stop the leak by a surgical emergency. Any person who has burst open. covering it with their hand or finger. suffered an injury of this sort should seek Oil and grease spills: Oil or grease Chemical irritation is not a major immediate medical attention, regardless of spilled on floors, catwalks, and ladders problem with most petroleum products the appearance of the wound or its size. can present fall and fire hazards. Wipe because hydraulic oils and greases are Accidents involving injection injuries can up lubricant spills immediately or use generally non-irritating with low toxicity. occur when using any type of pressurised absorbent drying pads or granules. It However, the resulting bacterial infection equipment. Two common cases in which is essential to repair or report sources can be a problem because of the damaged petroleum products may be involved are of lubricant leaks. In the oil house or tissue and circulation in the wound, even accidents with pressurised grease guns or storage area, replace leaky dispensing if the foreign material is removed through with hydraulic systems. devices, keep drip pails in place, and wipe surgery. One of the dangers from this type Pressurised grease guns are commonly up any spills. of injury is that it is not recognised quickly used in service stations, garages and Application to machines: Do not by the injured person as being serious. industrial plants. Typically, most service apply lubricants to machines in operation Often the initial wound may be minor and stations have grease guns operating at unless the machine is equipped with essentially painless. The injured person
Chemical World | November 2012
central lubrication systems or the fittings and oil caps are piped out to a safe place. Do not reach over, under, through or past moving parts of machinery. For machinery requiring lubrication during operation, refer to OEM recommendations for safety procedures. Machine guards: Guards on belt or chain drives, open gears, couplings, etc, should be removed only after the machine is shut down and properly locked & tagged out of service. Replace guards promptly after lubrication work is done and report damaged guards or places where guards are needed. Ladders and work lifts: A ladder should be of suitable material; for example, a metal ladder or lift should not be used where there is possible contact with electrical wiring or equipment. Use ladders of the proper length; do not overextend extension ladders. The ladder or lift should be inspected to be sure that the safety feet, rungs and slide rails are in good condition and free of oil & grease. Safe clothing: Follow plant rules for the proper kind of safety shoes, hats, goggles, glasses, gloves, or special clothing. Do not wear loose or torn clothing that can be caught in moving parts of a machine. Wear long sleeves in the vicinity of hot surfaces. Hand tools: Take special care when using hand tools. Use the right tool for the job; do not improvise or change its configuration for a purpose for which it was not intended. High-pressure grease guns can develop several thousand pounds of pressure and a grease jet from a grease gun can pierce the skin. Hazards to the skin: The skin may be sensitive to prolonged exposure to petroleum products such as cutting fluids, solvents and rust preventatives. Irritation, itching, or skin rashes (dermatitis) may develop. To prevent trouble or escalation, wear rubber gloves whenever possible. Wash hands and affected skin areas frequently with mild soap and warm water.
Fire hazards Most petroleum products will burn. Lube oils and greases have relatively high flash
BASIC RULES TO BE OBSERVED TO AVOID GREASE GUN INJURIES DONâ€™Ts o o o o
One should not: Play around with or use a grease gun for practical jokes Touch the end of a grease gun Use any part of the body to test a grease gun for grease flow Use any part of the body to stop a leak in a hydraulic line
points, but solvents, kerosene, diesel fuel, and gasoline have much lower flash points and will burn readily. Do not use gasoline for cleaning and do not smoke around any petroleum product. In the event of a fire, sound the alarm. Do not let the fire cut off your escape route. Stay upwind and do not breathe any more smoke than is necessary, since smoke from certain petroleum fires can be dangerous. Firefighting should only be performed by designated and trained individuals. For extinguishing agent, dry chemical, foam and carbon dioxide (CO2) are recommended. Water can also be used, but be cautious of using a solid stream of water as it can disperse across the affected area and will conduct electricity if sprayed directly on a live electrical panel. Use of water sprays should be left to trained firefighting personnel. Oily rags: Keep oily rags in a labelled, closed, oily waste can. Rags soaked with paint or linseed oil should not be kept in a closed container, but instead should be hung up to dry and then disposed of according to plant practices and governmental regulations. Handling solvents: Many solvents emit enough vapour to form flammable mixtures with air. Any spark, even from static electricity, can cause a fire. Before opening or dispensing solvents or fuels, make sure the containers are grounded, either with ground wires, metal to metal contact between containers or
DOâ€™s One needs to: o Routinely check all hoses for wear and possible weak spots o Handle a grease gun with respect for its power o Take special care when starting up a new hydraulic system to be sure that every part of the system can withstand the operating pressure
direct contact with the ground. Handle solvents in well-ventilated areas and keep containers closed when not in use.
Hazards to lungs Dangerous vapours, mists, or dusts can form in plant working areas and prolonged exposure can be hazardous. If overexposed, get out of the area and get first aid. Do not enter any large confined spaces such as empty tanks, vats, kettles, etc, alone and without checking for oxygen deficiency with approved measuring devices. Regardless of toxicity levels, approved respiratory devices are recommended for use in these areas. Always use the two-man rule when working in these spaces and talk to each other frequently. If entering into a confined space wear approved ropes/harnesses, especially in dark areas. Last but not the least, consult your local and state officials for published Lower Explosive Limits (LEL) and Permissible Exposure Limits (PEL). All these measures, if undertaken in the right manner and at the right time, will go a long way in preventing as well as controlling hazards associated with handling of petroleum products. Naveen Shukla is the Field Engineering S uppor t Manager, APAC, at ExxonMobil Lubricants & Specialties. For details, contact Vineet Recriwal on email: firstname.lastname@example.org
November 2012 | Chemical World
INSIGHT & OUTLOOK Pumps for O&G industry
Advanced pumping systems redefining growth
identify oil deposits below the earth’s surface. This technology combined with innovative drilling and enhanced recovery procedures such as hydraulic fracturing have led many to believe that India is on the verge of a golden era in oil & gas exploration and production,” says Mukul Gupta, Managing Director, Chemtreat India.
Enhanced oil recovery
India’s oil refining capacity is forecast to rise by more than 43 per cent. A prominent partner in this growth has been the technological advancements in specialised pumping systems for the oil & gas (O&G) industry, especially for the nitty-gritties of subsea operations involving exploration and production.
il secretar y G C Chatur vedi recently announced that the refining capacity in India will rise by more than 43 per cent to 310 million tonne per year by March 2017 from current 216 million tonne. He added that additional global refinery capacity planned up to 2017 is about 6.1 million barrels per day or about
Chemical World | November 2012
305 million tonne per annum, and half of this incremental capacity addition will be in the Asia-Pacific region with around 12 per cent contribution from West Asia. In such a situation, the exploration and production technologies acquire eminence. Pumping systems play an important role to support this growth. “Centrifugal pump technology plays a critical role in many O&G applications. Significant advancements have occurred in this technology, which is used to
A major usage of pumping systems in the O&G industry comes by way of enhanced oil recovery (EOR) strategies, in these days of depleting resources. In recent years, various innovative EOR techniques that seek to maximise total reservoir recovery have gained renewed interest and attention. “Raising the recovery factor above 40 per cent is a challenge. EOR, sometimes called tertiary recovery, is an important part of improving total production. More often, asset managers consider various EOR methods as part of the initial field development plan,” observes Gupta. Yet, questions remain with respect to the technical and economic viability. With a range of technologies for EOR, a way forward can be developed that reduces uncertainty at each step. “Although a number of operators are investing heavily in this recovery method, the potential of EOR solutions has not been fully realised. It is imperative that the industry implement EOR projects now, in a fully integrated fashion, from studies to incorporating operational readiness, and project execution – with a greater sense of urgency, and pumping systems can be thus designed to efficiently propel the same,” says Gupta. At the end of 2009, the global market for EOR was estimated at $ 62.5 billion (for barrels of crude oil), having grown rapidly from $ 3.1 billion in 2005. Although technical challenges and costs have often dissuaded many oil companies from adopting EOR methods, it has quickly become more feasible and is expected to continue to grow rapidly, as per a report by Senergy.
Pumps for O&G industry
Rise in non-conventional energy sources Apart from the widespread usage in the traditional oil & gas E&P operations, the industry has seen a sudden surge in non-conventional energy sources. And because exploration of these sources is tougher, the pumping industry has a lot of opportunity in that sector. Under the International Energy Agency’s scenario, global natural gas demand from until 2035 will grow 2 per cent each year. At this rate, demand for natural gas would surpass those of coal by 2030 and approach the demand level of oil by 2035. Additionally, 40 per cent of the increase in global natural gas production up to 2035 would come from unconventional production processes, such as the hydraulic fracturing of shale beds or exploiting deposits of coalbed methane gas. “Having the sixth-largest proven coal reserves and being the third-largest coal producer in the world, India holds significant prospects and resources for commercial recovery of CBM. This resource has been estimated to be more than 300 trillion cubic feet. Gas demand in India far exceeds supply. As an alternative to LPG, diesel and petrol, CBM has immense commercial prospects and is clearly emerging as one of the most viable and cleaner routes to India’s energy security,” opines B Akala, Director, CBM Solutions India, and former CMD of Central Coalfields Ltd and Central Mine Planning & Design Institute Ltd (a subsidiary of Coal India Ltd).
As exploration moves to more challenging scenarios when it comes to non-conventional energy sources, intelligent pumping systems can contribute significantly to the reduction of operating costs and monitoring of equipment in remote applications. Mukul Gupta Managing Director, Chemtreat India
Worldwide, CBM is becoming an important source of energy. In recent decades, CBM has become a cheap and reliable source of energy in the US, Canada and Australia. China and India are following the footsteps. “With more shale gas discoveries pouring in, this sector is expected to call the shots. Production costs of CBM, being produced from comparatively shallow depths, are far lesser than natural gas that is normally produced from much deeper reservoirs, both on- and off-shore. The economics will play a dominant role in CBM production. CBM being a low pressure gas, the production from wells is steady and prolonged for years. Some wells are reported to be producing even for more than 20 years,” adds Akala. The O&G sector is promising and is expected to be one of the early adopters of intelligent pumping solutions. “As exploration moves to more challenging scenarios when it comes to non-conventional energy sources, intelligent pumping systems can contribute significantly to the reduction of operating costs and monitoring of equipment in remote applications. The discovery of new reserves, increased demand for non-conventional energy products in key growth markets (Asia, Middle East, BRIC) and continued investment in subsea exploration are leading to high demand for pumping systems in India also,” adds Gupta. Environmental compliance and energy efficiency are expected to be top priorities in this end-user space, facilitating adoption of advanced pump technologies.
Hydraulic fracturing market Hydraulic fracturing is the propagation of fractures through layers of rock using pressurised fracturing fluid. This technique is primarily used in the extraction of resources from low permeability reservoirs such as shale gas, tight gas, CBM, and unconventional liquids, which are difficult to recover through regular drilling procedures. In view of the rising demand from the
As a process, fracturing takes up a large percentage of the total water required in well drilling, at roughly 89 per cent. This presents a good opportunity for players to capitalise on. B Akala Director, CBM Solutions India
O&G industry, the global hydraulic fracturing market generated revenues of $ 31 billion in 2011, registering a 63 per cent rise from $ 19 billion in 2010, and is projected to rise a further 19 per cent to $ 37 billion in 2012, as per a recent report published by Business & Markets. “The major drivers for hydraulic fracturing market are the fact that the advancement in technology increases production rate and adds to recoverable reserves; provides access to an energy strategy shift through natural gas and energy security by domestic supply,” says Gupta. However, this technology is facing public opposition due to potential environmental hazards caused by fracturing. “ Water usage, water contamination, and seismic activity are the most important concerns related to hydraulic fracturing. Because of this, the growth of hydraulic fracturing is somewhat declining. In fact, some companies have even banned the use of hydraulic fracturing. This presents an opportunity to oilfield service companies to use ‘waterless’ hydraulic fracturing or foam fracturing,” adds Akala. Foam fracturing pumping system offers properties such as high viscosity and low liquid content. “This alternative utilises lesser amount of water than traditional fracturing. As a process, fracturing takes up a large percentage of the total water required in well drilling, at roughly 89 per cent. This presents a good opportunity for players to capitalise on,” sums up Akala. Email: email@example.com
November 2012 | Chemical World
INSIGHT & OUTLOOK Industrial paints
On a fast lane to fortune with high demand from automotives Encouraging growth of the automotive sector in India is offering tremendous opportunities to the automotive paint manufacturers to leverage upon. Today, this paint segment constitutes the largest share in the total industrial paint industry in the country. In fact, both the industries (auto and paints) are aiding each other’s growth. This is because, apart from all important features, the colour of a car or any vehicle is a deciding factor in the buying decision. Hence, automotive paint manufacturers can expect new business vibrance.
olour is one of the most basic means of human expression and is applicable for every aspect of life. It is colour that draws the attention of a consumer when it comes to buying something. Same is the case while selecting a car or two-wheeler. In this context, significant growth of the automotive sector in
THE MARKET DYNAMICS o Increase in car sales driving the demand for automotive paints o Colours influence the sale of a car o ‘3 wet coat’ technology gaining momentum in India o Kansai Nerolac emerged as a prominent player o Metallic shades are popular in India
Chemical World | November 2012
India is opening up new avenues for the automotive paint segment. For example, automotive paints use chemicals to ensure specific properties like mar resistance and lustre. Let’s have a look at the growth of automotive sector in India and what it signifies for the automotive paint industry.
Automotive industry accelerating growth Indian automobile industry is highly driven by demand for new models and variants in domestic and international markets. Rise in disposable income, favourable demographics and supportive business environment are certain factors that are attracting automobile giants from all over the world to the Indian landscape. Even domestic manufacturers are executing changes in their production patterns to meet the international standards and deliver the best quality in their offerings. “Establishment of global and Indian auto majors is providing a
thrust to domestic sales and exports of four- and two-wheeler segments. Also the upgradation of intra-city and inter-city highways has resulted in improvement in vehicle sales. Easy availability of auto loans and good schemes are accelerating the industry’s growth. Naturally, paint consumption has increased with growing market demand, particularly in twowheeler and farm equipment segment. New shades of colours are developed considering customer choice, demand etc,” points out Tej Dialani, Head, Sales – Coatings & Tinting Systems, India Sub Region, BU Pigments, Clariant Chemicals (India) Ltd. Besides, hybrid and electronic vehicles are new developments on the automobile canvas and India is one of the key markets. Price-sensitive Indian customers are showing positive outlook towards green technologies and are migrating towards new vehicle technologies. Thus, global and Indian manufacturers are focussing their efforts on developing
innovative products, technologies and supply chains. According to the recent data released by the Society of Indian Automobile Manufacturers (SIAM), the cumulative production for April-June 2012 registered a growth of 7.65 per cent over April-June 2011, manufacturing 1,700,675 vehicles in June 2012. While passenger vehicle segment grew at 9.71 per cent during April-June 2012, overall commercial vehicle segment registered an expansion of 6.06 per cent year-on-year. All these are facilitating the growth of automotive paints segment.
Painting the future Demand for coatings in India has been estimated at 2,205,000 tonne in 2011. Decorative coatings account for nearly 78 per cent of the market in terms of volume and about 70 per cent in value, while automotive coatings, both OEMs and refinish segment, dominate the industrial segment, followed by high-performance protective coatings and powder coatings. The healthy growth of the automotive industry is creating good demand for OEM coatings and vehicle refinishes in the long term. The refinish segment is enjoying growth in each of the premium, medium and economy sub-segments as a result of rising car ownership across all classes. However, as car ownership is likely to increase at the low end in the future, the highest growth is to be expected in the economy area. “New technology like ‘3 wet coat’ is being used at some automotive paint shops,” says
Dialani. Today, the automobile segment generates more than two-third of the demand for industrial paints, and hence has emerged as the growth driver for industrial paints. According to the US-based PPG Industries, one of the world’s leading manufacturers of transportation coatings, white has been ranked as the most popular vehicle colour in the world. Approximately 21 per cent of 2011 model-year cars around the world have been white. Silver and black were tied for second-most popular at 20 per cent. “In India, colourful cars are preferred as compared to other parts of world. Metallic shades are more popular than solid colours,” opines Dialani.
If things go in the right direction, automotive industry will offer more opportunities for the industrial paint segment in terms of innovative colours, shades, and other features. A closer look reveals that a car despite having all important features may not sell in the market if the selection of colour is not proper. This speaks volumes about the role automotive paint industry plays for the growth of car segment. Dialani rightly points out, “In today’s times, customers also visit the website, showrooms along
A COLOURFUL PICTURE The preferences of colours vary from country to country and region to region. The US-based PPG Industries data shows that in North America, white ranked first in preference (20 per cent) followed by silver (19 per cent), black (18 per cent) and gray (15 per cent). Red and blue were tied for fifth (9 per cent), natural shades of brown, tan, gold, orange and yellow were sixth (7 per cent), green was seventh (2 per cent); and other/niche colours were less preferred (1 per cent). In Europe, black is the most popular colour (26 per cent), followed by white (19 per cent), silver (16 per cent), gray (15 per cent), blue (9 per cent), red (7 per cent), naturals (5 per cent), green (2 per cent) and other/niche colours (1 per cent). When it comes to the Asia-Pacific region, silver (25 per cent) is the most popular colour, followed by white (23 per cent), black (17 per cent), gray (8 per cent), red (10 per cent), blue (7 per cent), naturals (7 per cent), green (2 per cent) and other/ niche colours (1 per cent). Courtesy: PPG Industries
In India, colourful cars are preferred as compared to other parts of world. Contribution of automotive paints in the total industrial paint industry is expected to increase at a rapid pace, with new models that are expected to be launched in next two years. Tej Dialani Head, Sales – Coatings & Tinting Systems, India Sub Region, BU Pigments, Clariant Chemicals (India) Ltd
with family to select car/vehicle, and in many cases colour precedes over all other features. Paint manufacturers have separate colour designer department to develop innovative shades as per latest market trends.” While elaborating about the need to stay above the competition, he says that so far there is fair competition among the branded paint players. “Kansai Nerolac is currently the market leader with 60-65 per cent marketshare. PPG and BASF are among other top players in India,” he says. Today, Kansai Nerolac, through its various strategic collaborations, offers a total painting system to auto makers in India with a range of products, starting from pretreatment chemicals, electro deposition primers, intermediate coats/ primer surfacers, solid & metallic top coats, clear coats & touch-up paints. No wonder, the products are approved by most global auto majors. If things go in the right direction, automotive industry will offer more opportunities for the industrial paint segment in terms of innovative colours, shades, and other features such as protection from sunlight etc. And this will further help the automotive paint segment to consolidate its position in the total industrial paint sector. “Contribution of automotive paints in the total industrial paint industry is expected to increase at a rapid pace, with new models that are expected to be launched in next two years,” concludes Dialani. Email: firstname.lastname@example.org
November 2012 | Chemical World
AUTOMATION TRENDS Smart technologies
s per a Frost & Sullivan study, smart technologies will have profound impact on the future of industrial automation. Based on a survey of several hundred companies conducted in December 2011, Frost & Sullivan believes that factories of the future are likely to leverage ‘megatrends’ like cloud computing, cyber security and mobile communication technologies. Similarly, according to the recent findings of IMS Research, global industrial automation market is expected to surpass $ 200 billion by 2015. A lot of it, however, will depend on the kind of technologies and processes that automation industry will adapt to, going forward. But the
be clustered in a single centre quite far away o Wireless continues to be an emerging trend in the industry. The focus is increasingly shifting towards solutions that are difficult in the wired world such as mobile operations o One can also see a trend towards ensuring cyber security with technologies deployed with wireless standards like ISA 100 to be ported back to wired networks to assure individual authentication and encrypted communication, making it difficult for a cyber attack to be carried out Driven by the need for greater productivity and efficiency, organisations are adopting smart technologies to provide effective interaction between the factory floor and
industries are seeing an immediate increase in workforce productivity, improved data integrity, less equipment downtime, better asset management, and ultimately – increased profits through lower maintenance and operating costs. “Field operators are at the frontline of operational excellence – the ears and eyes in the field. Operators’ scope-ofwork at today’s plants is constantly expanding and calls for tools that allow them to meet new responsibilities. With the availability of mobile solutions, field operators are now empowered to take decisions immediately with availability of information at their finger tips anytime anywhere within the plant. Field operators can also use the mobile devices to capture the data during field
Companies are adopting technologies that can provide control over supply chain that is spread across the world. Lack of skilled manpower, along with uncertain global economy, means companies have to utilise their mobile workforce optimally by incorporating smart technologies such as cloud computing, virtualisation, wireless, etc. growth of industrial automation clearly lies in some of the trends that are expected to change the face of the industry. According to Mark Zyskowski, Vice President - Global Sales, Honeywell Process Solutions, some of these technologies and trends are: o Virtualisation can provide immense benefits in process control and help deal with major issues such as lifecycle cost and equipment churn. This technology reduces amount of equipment required and allows remaining equipment to run for longer time o Remote collaboration is an effective means to address the shortage of process control skills in remote locations. Process control systems will move more towards remote collaboration centres where skills can
Chemical World | November 2012
the enterprise across all end-users, enabling end-users to gain a competitive edge in the global market. “In this wireless and collaborative environment, there has to be integration, particularly between process control systems and advanced applications. Manufacturing Execution Systems (MES) and advanced control applications will increasingly become part of the process control system, allowing for operations staff to place greater emphasis on improving the business versus controlling the process,” says Zyskowski.
Aiding mobile workforce Mobile applications are gaining popularity as industries are looking at ways to implement new processes and leverage technology to improve bottom line. Through mobile applications,
rounds and provides further operational guidance,” adds Zyskowski. One of the basic key elements for mobility solutions is having an industrial wireless infrastructure backbone in place. Hence, automation solution providers are looking to offer comprehensive mobility solution right from providing wireless infrastructure to mobile devices for a range of applications such as enterprise asset management, safety and availability of real-time data. With the pressure to do more with less and the need to also protect people, plant and assets, in future, chemical manufacturers will increasingly rely on automation solution providers to improve business performance with solutions that increase safety, reliability, efficiency and sustainability. Email: email@example.com
ENERGY MANAGEMENT Case Study â€“ Reliance Industries Ltd
Enhancing energy savings through process simulation Gas absorbers are extensively used in the chemical process industry to separate components through absorption by contact with a liquid, in which one of the components is soluble. The solute is transferred between the gas and liquid phases. Here we look at the application of process simulation to optimise ethylene oxide (EO) absorber operations while improving energy efficiency at the ethylene oxide and ethylene glycol plant of Reliance Industries Ltd. Ethylene oxide absorber and stripper process Stripped EO
EO absorber overhead gas to reactor (recycle) Lean absorbent
Reactor outlet gas to EO absorber
Steam input Rich absorbent to EO stripper
Simulation study Courtesy: AspenTech Inc
Dipak Mehta, Viral Desai, Jignesh P Patel and Sunil Patil
thylene Oxide (EO) is produced by silver-catalysed, vapour-phase partial oxidation of ethylene by molecular oxygen. The EO content in the hot gaseous reactor effluent is quite low. It is recovered from the effluent gas by absorbing with lean absorbent, producing a dilute EO solution (rich absorbent). This rich absorbent is stripped in an EO stripper to produce an EO rich steam. The EO absorber was modelled using the Aspen Plus process simulator from AspenTechnology Inc. The steps followed for developing the simulation model started with the selection of property methods, input of tray details, and finally tuning the model to match operating data. Sensitivity analysis was performed to understand the effect of certain variables, such as lean
Chemical World | November 2012
the cycle gas. The cooled cycle gas enters the EO absorber from the bottom and is counter-currently contacted with lean absorbent from the top, which absorbs the EO. The rich absorbent with EO from the bottom of EO absorber then flows to the EO stripper for recovery of EO. The concentration of EO in the absorber top recycle gas product is maintained by adjusting the lean absorbent flow. It is important to maintain this concentration below a certain high limit to avoid process problems downstream.
absorbent temperature and flow, without compromising the top and bottom product specifications. Beyond energy savings, the same simulation model was also utilised to evaluate the potential for flooding at increased throughput in the column. The tray ratings were done by specifying the existing geometry of the trays, and the flooding tendency was then evaluated for both the current operating conditions and for the reduced absorbing liquid flow case.
The process In the Ethylene Oxide and Ethylene Glycol (EOEG) plant, ethylene undergoes vapour phase oxidation over a silver-base catalyst in the presence of oxygen to form EO, which is recovered from the reactor effluent cycle gas in an EO absorber. EO is further processed to produce pure EO and mono Ethylene Glycol (EG). The purpose of the EO absorber is to separate EO from
The main objective of the simulation modelling study was to evaluate the energy reduction potential in the EO absorber without any capital investment, and to check the EO absorber column performance for operating at higher loads (throughput). The methodology followed involved: o Selecting property method and developing the simulation model o Validating property method and simulation model based on Process Flow Diagram (PFD) design data o Finetuning the simulation model based on current operating parameters o Modelling sensitivity analysis with respect to lean absorbent flow and temperature o Conducting plant trials to implement the modelling study recommendations o Analysis and conclusions, including benefits Aspen Plus is the simulation software used for steady state simulation. For the purpose of this optimisation study, the Radfrac rigorous column model was selected.
Case Study – Reliance Industries Ltd
The SR-Polar Equation of State (EOS) was picked as the property prediction method. It was first validated by comparing the predicted model results with the actual PFD data provided by the licensor. It was further validated for the entire operating range of the project with operating data and proved to be the best method for this simulation model. Initially, the PFD data was used for feed composition, and the model predictions were compared to the stream compositions for the top and bottom products from the design case material balance. Later, the actual feed compositions were taken from the online analyser and the model predictions were again evaluated. The model was then finetuned by adjusting the Absorber Murphree tray efficiencies to match the following parameters with actual plant data – temperature profile along the column and top & bottom products composition. Once the model was tuned, it was used for sensitivity analysis with respect to change in lean absorbent flow and lean absorbent temperature. The objective of the sensitivity analysis was to gain insights to optimise operations without compromising the EO absorber performance. It was concluded from the simulation study and sensitivity analysis that it is possible to reduce the lean absorbent flow by 8 per cent without compromising product quality. This recommendation was
implemented in a step-wise reduction of the lean absorbent flow in the operating plant, as described later. The sensitivity analysis with respect to lean absorbent temperature was done to understand the impact of summer conditions, which essentially change cooling water supply temperature and can have an effect on the cooler in the lean absorbent circuit. Any change in lean absorbent temperature may impact absorption of pure EO from the cycle gas. This check was also necessary since the goal was to reduce lean absorbent flow, which could result in a change in lean absorbent temperature and thereby affect absorption. From the study, it was concluded that a variation up to +2˚C in lean absorbent temperature was insignificant in terms of absorber performance. Beyond energy savings, the same simulation model was also used to evaluate the potential for flooding at increased throughputs in the column.It was concluded from the simulation hydraulics study that the column was operating near the flooding limits and that reduction of lean absorbent cycle water flow will reduce tray flooding and increase the efficiency of the EO absorber.
Plant trial plan and the results The lean absorbent flow to the absorber was reduced in a series of six incremental
OPTIMISED OPERATING WINDOW Based on the results of the simulation study, a trial plan was formulated for a step-wise reduction of lean absorbent flow with continuous monitoring of absorber performance using the online analyser and analytical methods for analysis. The following benefits were projected: o A reduction in lean absorbent flow to the EO absorber will reduce the downstream load, leading to better performance of the EO stripping column and lower stream consumption for stripping EO from rich absorbent o A reduction in lean absorbent flow to the EO absorber will reduce the load on the lean absorbent water cooler, leading to a lower lean absorbent supply temperature and improved EO absorption efficiency in the EO absorber o A reduction in lean absorbent flow to the EO absorber will lower the pressure drop across the absorber, thereby improving EO absorption efficiency in the EO absorber o This trial will also identify any system bottlenecks in terms of lean absorbent flow and temperature during high plant load operation o The reduction in lean absorbent flow will also directly benefit energy consumption for pumping
steps over a six-day period. After each reduction, the unit was allowed to achieve stable performance and the key operating parameters and compositions were measured. The plant trials validated the findings of the simulation study in all respects. The projected benefits described earlier were all achieved in actual operations. Specifically, the unit was able to achieve the desired 8 per cent reduction in lean absorbent flow without compromising throughput, recovery or concentrations.
Conclusion The simulation model predictions were highly accurate and close to reality. The reduction in EO rich absorbent flow proved to be even more beneficial in stripping EO - substantially reducing the amount of energy required to strip out EO in the EO stripper column. The EO recovery process was therefore successfully optimised. The EO absorber lean absorbent flow was reduced by 8 per cent without compromising product quality, with a corresponding reduction of pumping energy of 39 kW and a 1,000 kg/hr reduction of low pressure steam (3.0 barg) in the EO stripper reboiler. This translates into significant energy savings, resulting in annual economic benefits of ` 9.5 million ($ 2,00,000) without any capital investment. This study strongly underscores the value of using process simulation technology to optimise operations and drive new levels of energy efficiency. Dipak Mehta is Vice President - Central Technical Services (CTS), at Reliance Industries Ltd (RIL), Dahej Manufacturing Division (DMD). He has more than 30 years of experience in the process industries. Viral Desai is General Manager, CTS at RIL-DMD. Jignesh Patel is CTS Lead Manager at RILDMD. Sunil Patil is Principal Business Consultant at AspenTech Inc. For details, contact Alroy Kenny on email: firstname.lastname@example.org
November 2012 | Chemical World
POLICIES & REGULATIONS Companies Bill, 2011
he Union Cabinet recently approved certain amendments to the Companies Bill, 2011, based on the recommendations of the Parliamentary Standing Committee on Finance, and interministerial discussions. It may be noted that in the previous draft of Companies Bill presented in 2009 (which was withdrawn), the CSR clause was voluntary, but companies were mandated to disclose their CSR spending to shareholders. The qualifying criterion that would make CSR spending mandatory as per the Companies Bill, 2011, is that companies should have a minimum net worth of ` 500 crore or turnover of ` 1,000 crore or a net profit of ` 5 crore during any financial year. Such companies are required to constitute a CSR Committee of the Board comprising at least three directors, of which one shall be an independent director. This Committee will formulate the CSR policy, including the activities to be undertaken and the related spending. The Board shall disclose the content of policy in its report and on the website. The modified Bill further states that the Board shall endeavour to ensure that at least two per cent of average net profits of the company during three preceding financial years shall be spent on such policy every year. If the company fails to do so, the Board shall give reasons for not undertaking such spending. The question arising about making CSR mandatory is what difference it will make. Says Asesh Sarkar, General Manager, RD&I, Decorative Paints, Akzo Nobel India, “We believe CSR should be voluntary. It should be self-driven through other
Chemical World | November 2012
policies to render community benefit, and a social responsibility rather than being made compulsory.”
Many believe that making CSR mandatory under the Companies Bill, 2011, is not going to make a significant difference. Rather, a strategic approach is the need of the hour, whereby CSR initiatives have to be aligned with a company’s core competencies to benefit people and society at large. Confronting issues There are many issues associated with industrial policy. For CSR, there has to be clear guidelines. Many-a-time, big industrial project starts with displacement of people. As the livelihoods of people are threatened in the process of setting up the industry, it is obligatory that the promoters take care of the rehabilitation and resettlement (R&R) of the affected
people. It has been seen that some companies include the spending on R&R as CSR activities. Given such practices, CSR works as a cover-up for some of the uglier aspects of industrialisation. Many believe that there is a need to align CSR with the broader objectives of industrial policy. Treating CSR in isolation serves limited purpose. There is also a need to distinguish between the CSR approach of manufacturing units and service-oriented industries. “Whether or not CSR is mandatory, it often makes good business sense, and there are aspects of the proposed Bill that offer helpful guidelines. One example is the push towards high transparency and verifiable outcomes. This requires companies to apply a similar rigor to their CSR activities as to their regular operations,” explains Sudhir Singh Dungarpur, Head & Partner Development Sector Practice, KPMG, India. The advantage – apart from higher impacts and better sustainability – is that shareholders, investors, regulators and the general public will be able to see for themselves the good that the programme is doing. Today, CSR activities are being carried out in different ways. In many cases, companies do not even understand the outcome of such philanthropy. The real issue is not how much a company spends on CSR initiatives but the manner in which the amount is spent and how it benefits people and society. It has to be more of a strategic approach, whereby the CSR initiatives are aligned with their core competencies. Once this approach is adopted, it would help society and people. “If CSR is considered a part of business strategy, it may not be necessary to mandate it,” concludes Alka Talwar, Head – Community Development, Tata Chemicals Ltd. Email: prasenjit.chakraborty@ network18publishing.com
STRATEGY Dyes and dye intermediates
yes are colouring pigments that find application in a variety of industries. The dyestuff sector is one of the important segments of the chemical industry in the country, having forward and backward linkages with various sectors such as textiles, leather, paper, plastics, printing inks, etc. However, its highest consumption is in the textile segment. The origin of the Indian dyestuff industry can be traced to the 50s when most dyes and intermediates were imported in the country. Thereafter, gradually dyestuff manufacturing picked up in the country and in the early 80s, this industry started to export in good quantity.
At present, the Indian dyestuff industry is faring well. However, one thing that can strongly impact the growth of the industry is stringent environmental regulations. Bhupendra C Patel, Managing Director, Jemby Chem Ltd, notes, â€œEarlier, the dyes and dyestuff manufacturing industry was mainly concentrated in European and American countries. Later due to environmental problems and other factors, the industry started shifting its base to India & China and thus, many small-scale units surfaced. Moreover, since the cost was higher as compared to products manufactured in Europe and America, countries preferred to buy from India and hence the export business flourished.â€?
Charting new success plan amid challenging market conditions The rising environmental concerns are raising alarm among chemical manufacturers, and the dyestuff industry is not far from this. Over the years, due to imposition of stringent environmental regulations, the manufacturers of dyes and dyes intermediates all over the world have changed their strategies, be it production or marketing, thereby leading to new opportunities.
Chemical World | November 2012
The organised sector dominates with 65 per cent share of the total market, while the unorganised sector controls the remaining 35 per cent of the market. However, owing to stringent environmental regulations and awareness among customers, the cost of operations for small, unorganised players is likely to increase, thereby shrinking their share in the industry.
Stricter environmental norms The production of textile dyestuff is a three-step process that involves synthesis; product isolation & separation; and product formulation. In the synthesis step, dye intermediates are transformed into dyestuffs. In the next step, the main product is isolated from the reaction mass and separated, in which two flows can be identified, ie product flow to formulation and the mother liquor resulting from the separation step. The mother liquor is the main source of the environmental impacts and it possesses characteristics such as high content of organic compounds, low biodegradability of many of the dissolved aromatic compounds, toxicity of many of the aromatics, acidity or alkalinity (depending on reaction conditions) and high concentration of dissolved solids (mainly mineral salts). Due to the above characteristics, there are strict environmental regulations imposed on the manufacturing of dyes and dye intermediates. In view of the stringent environmental norms, companies are taking a number of measures to comply with those. These include upgrading control measures in production technique; raising environmental awareness; end-of-pipe measures such as establishment of common effluent treatment plants (CETPs) etc can also help the companies in generating less effluent in the environment. Manish Kiri, Managing Director, Kiri Industries Ltd, says â€œThe overall awareness about the environment has increased. The compliance towards environmental norms has also risen. Industries and government are jointly working towards reducing solid and liquid wastes generated by companies. Several organisations are also employing technologies for reducing waste at the
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Dyes and dye intermediates
source. Further, technologies like reverse osmosis, ultra-filtration methods for treating wastewater are adopted so as to attain the goal of zero discharge. Effluent treatment plants are also set up by the industry. Since the industry is exportoriented, even international customers are giving weightage to this issue.” He adds, “Talking about steps taken by our company, all production processes are conscionably designed and periodically modified to minimise environmental impact, and to enable optimum worker safety and general health. The company takes pro-active measures for pollution prevention. Periodical internal evaluations are conducted, backed by third-party monitoring by an Environmental Auditor recognised by the Gujarat Pollution Control Board (GPCB). We have installed effluent treatment plant for treating the waste. We believe in zero effluent discharge policy, ie recycling and reusing the products.” Not only the dye manufacturing companies but those producing dye
intermediates are also taking steps to meet the environmental norms. Patel avers, “We believe in the implementation of 3Rs – reduce, reuse and recycle in case of effective utilisation of water. We have adopted green chemistry to ensure that 80 per cent of water is reused after distillation. We also undertake primary, secondary and tertiary treatment of effluents. Apart from effective effluent treatment, the company has also undertaken adequate measures for energy conservation.”
The way forward It is estimated that the export of dyes will increase by 6.4 per cent due to the shift of production bases from developed countries to India on account of stringent pollution control measures being adopted in those countries. Kiri states, “At present, this industry is mainly export-driven. We are mainly targeting the developing markets for the fact that colours are mainly used to process textiles, leather etc and at present mainly the developing countries
are involved in the manufacturing of these products. It can be seen that the textile manufacturing industry has shifted from the US to the developing countries.” The growth of dye sector in the future will continue to depend on the performance of end-user industries like paints, textiles, printing inks, paper, plastics and foodstuffs. One of the major factors that will impact the dyestuff industry in a big way will be strict environmental regulations. Thus, the companies in the segment need to formulate good strategies for dealing with environmental issues so as to prosper. Other than this, to achieve global standards, the industry needs to put efforts in critical areas so as to adopt aggressive growth and focus on exports, R&D, co-marketing alliances, upgradation of manufacturing facility, contract manufacturing, collaboration by cluster development, outsourcing, cost reduction, etc. Email: email@example.com
November 2012 | Chemical World
TIPS & TRICKS Risk-based inspection
Practical guide to proactive maintenance Manufacturers involved in oil & gas or petrochemical industry face increased pressure to reduce risks and improve safety and reliability cost-effectively. According to some experts, about half of the containment losses in a refinery, petrochemical or chemical process plant can be influenced by maintenance and inspection. Risk-based inspection is recognised as an effective tool to reduce risk and raise the level of safety in the chemical industry.
he correct design of a chemical plant may not necessarily imply a fully safe facility. Without adequate inspection and maintenance plans, certain equipment, sooner or later, will collapse as a result of wear, fatigue, corrosion or other circumstances. Chemical plant operators face challenge of maximising plant efficiency/reliability levels & product generation/throughput, while at the same time minimising manning & materials costs, maintenance work load, transportation & support, and downtime affecting revenue/operating costs. Thus, an effective inspection plan is one of the tools considered in the operation safety programmes to reduce the risk of accidents. Here are few pointers to be considered while incorporating Risk-based Inspection (RBI) strategy for a chemical plant:
Inspection is actually one of the procedures applied in accident prevention as a part of safety programmes. The proper use of a planned inspection programme will reduce the incidents and the potential damages. The methodology of inspection based on RBI provides a basis for risk management.
RBI is a type of inspection planning, which analyses the probability (or likelihood) and consequence of failure of an asset to calculate its risk of failure. The level of risk is used to develop a prioritised inspection plan for the asset. It may be sometimes related to Risk-based Asset Management (RBAM), Risk-based Integrity Management (RBIM) and Risk-based Management (RBM).
Chemical World | November 2012
Non-destructive testing (NDT) methods are used to prioritise inspection requirements for major oil platforms, refineries and chemical installations. The resulting inspection plan outlines the type and frequency of inspection for the asset.
Earlier, inspection system was based on ‘command and control’ or deterministic approach, with inspection modes and frequencies defined by law. The basic idea of RBI is the optimisation of inspection intervals, instead of the fixed frequencies, required by the deterministic approach. In RBI for each item of equipment, the inspection interval depends on the risk level.
potential accidents that can occur will probably also decrease.
A methodology has to be developed to optimise the inspection plans of a facility through the introduction of risk analysis as a variable. By this, an objective function can be established to analyse the variations in the overall costs, including the cost of the procedure and the cost of potential accidents. This leads to an optimum situation in which the overall cost (inspection plus accident consequences) reaches a minimum.
The cost of accidents has been shown to decrease significantly when at least one inspection is applied in the lifetime of the equipment, this influence being, of course, more important when the effectiveness of the inspection is higher.
It is important to note that one inspection during the lifetime of the equipment reduces considerably the cost of the accidents. This highlights the need of applying this type of procedure, particularly on those processes that are highly prone to accidents.
Items with high probability and high consequence (ie high risk) should be given a higher priority for inspection than items that are high probability, but for which failure has low consequences. This strategy can help companies to rationalise investment of inspection resources. E f f e c t i v e inspections can reduce risk through the decrease of the failure frequency by establishing corrective and preventive measures, which are taken into account once the inspection has identified potential failures.
Generally, as the investment in safety increases, the risk associated to a given plant or activity decreases and the cost of the
Reference: o Bragatto P, Delle Site C and Faragnoli A, 2012, ‘Opportunities and threats of risk-based inspections: The new Italian legislation on pressure equipment inspection’, 26, 177-182, DOI: 10.3303/ CET1226030 o Italian Association of Chemical Engineering Email: firstname.lastname@example.org
New projects and expansion activities are the barometers of industrial growth. These also present business opportunities to service providers like consultants, contractors, plant & equipment suppliers and others down the value chain. This feature will keep you updated with vital information regarding new projects and capacity expansions being planned by companies in the chemical and allied industries. Agro intermediary and chemical
Pesticides & phosphoric acid
Shriya Chemicals Pvt Ltd
Virupaksha Organics Pvt Ltd
KPR Chemical Ltd
Project type Capacity expansion Project news Shriya Chemicals Pvt Ltd has proposed capacity expansion of agro intermediary and agro chemical intermediary at Lote Parshuram Industrial area in Maharashtra. Project location Ratnagiri, Maharashtra Project cost ` 715.17 million Implementation stage Planning
Project type New facility Project news Virupaksha Organics Pvt Ltd has proposed to manufacture Active Pharmaceutical Ingredients (APIs), API intermediates, fine chemicals, etc in Andhra Pradesh. Project location Nizamabad, Andhra Pradesh Project cost ` 20 million Implementation stage Planning
Project type New facility Project news KPR Chemical Ltd is reportedly planning to set up pesticide manufacturing unit and phosphoric acid plant of 50 tonne per day capacity in Andhra Pradesh. Project location East Godavari, Andhra Pradesh Project cost ` 400 million Implementation stage Planning
Contact details: Shriya Chemicals Pvt Ltd 8-Channel Tower, Plot No 75 Sector-18, Kopar Khairane, Navi Mumbai 400709, Maharashtra Tel: 022-3345 0861, Fax: 02356-272494 Email: email@example.com ---------------------------------------Caustic soda & potash
Contact details: Virupaksha Organics Pvt Ltd Plot no. B-4, IDA Gandhi Nagar Ranga Reddy 500038, Andhra Pradesh Tel: 040-23075816, Fax: 040-23720738 Email: firstname.lastname@example.org ---------------------------------------Organic chemical
Contact details: KPR Chemicals Ltd D.No.8-256, Tata Nagar Balabhadrapura Mandal Bikkavolu 533343, Andhra Pradesh Tel: 08857-237367, Fax: 08857-237333 Email: email@example.com ---------------------------------------Synthetic organic chemical
KPR Chemicals Ltd
Godrej Industries Ltd
Vasant Chemicals Pvt Ltd
Project type New facility Project news KPR Chemicals Ltd has proposed setting up of membrane cell based caustic soda (400 TPD) and membrane cell based caustic potash plant (100 TPD) in Andhra Pradesh. Project location East Godavari, Andhra Pradesh Project cost ` 600 million Implementation stage Ongoing
Project type New facility Project news Godrej Industries Ltd is planning to set up organic chemical manufacturing unit with 84,500 metric tonne per annum (MTPA) capacity at Additional Ambernath Industrial Area, in Thane. Project location Ambernath (Thane), Maharashtra Project cost Not known Implementation stage Planning
Project type New facility Project news Vasant Chemicals Pvt Ltd has proposed setting up of synthetic organic chemical unit having 4,410 tonne per annum capacity in Andhra Pradesh. Project location Srikakulam, Andhra Pradesh Project cost ` 28 million Implementation stage Planning
Contact details: KPR Chemicals Ltd D.No.8-256, Tata Nagar Balabhadrapura Mandal Bikkavolu 533343, Andhra Pradesh Tel: 08857-237367, Fax: 08857-237333 Email: firstname.lastname@example.org
Contact details: Godrej Industries Ltd Phirojshahnagar, Highway Vikhroli (E), Eastern Express Mumbai 400079, Maharashtra Tel: 022-25188010, Fax: 022-25188063 Email: email@example.com
Contact details: Vasant Chemicals Pvt Ltd Vasant Towers, 4th Floor, Behind Shoppers Stop Begumpet, Hyderabad 500016 Andhra Pradesh Tel: 040-27760905 Fax: 040-27767940 Email: firstname.lastname@example.org
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 â€˘ Fax: 022 28013817 â€˘ Email: email@example.com November 2012 | Chemical World
Latest Popular Tenders brought to you by www.tendersinfo.com Automatic sampling nitrogen and protein analyser Org
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Chemical World | November 2012
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Nitrogen generators Org : Singareni Collieries Company Ltd (SCCL) TRN : 13022384 Desc : Supply of nitrogen generators (40 Cu M per hour) BOD : November 28, 2012 Loc : Khammam, Andhra Pradesh BT : Domestic _______________________________________________
Ammonia synthesis converter R-501 Org : Department of Fertilisers TRN : 13026630 Desc : Ammonia synthesis converter R-501 replacement of S-200 basket with new S-300 basket in line-I and II ammonia plant BOD : November 28, 2012 Loc : Raigad, Maharashtra BT : Domestic _______________________________________________
SF-6 multifunctional gas analyser Org : THDC India Ltd TRN : 12999786 Desc : Supply of SF-6 multifunctional gas analyser with accessories BOD : November 28, 2012 Loc : Tehri, Uttaranchal BT : Domestic _______________________________________________
Chloronome plants Org : Military Engineer Services TRN : 12759428 Desc : Comprehensive maintenance of chloronome plants BOD : November 30, 2012 Loc : Belgaum, Karnataka BT : Domestic _______________________________________________
Electro-chlorinator plants Org
: Municipal Corporation of Greater Mumbai (MCGM) TRN : 13033479 Desc : Supply, erection, testing, commissioning of
electro-chlorinator plants at various reservoirs under Dy H E (Maintenance) BOD : November 30, 2012 Loc : Mumbai, Maharashtra BT : Domestic _______________________________________________
Electrostatic precipitator Org
: National Thermal Power Corporation Ltd (NTPC) TRN : 12826330 Desc : Upgradation and renovation of electrostatic precipitator BOD : December 03, 2012 Loc : Uttar Pradesh BT : Domestic _______________________________________________
Nitric acid & ammonium nitrate plants Org
: Rashtriya Chemicals and Fertilizers Limited (RCF) TRN : 12980492 Desc : Turnkey contractor for nitric acid & ammonium nitrate plants BOD : December 07, 2012 Loc : Mumbai, Maharashtra BT : Domestic _______________________________________________
Electrostatic precipitator Org : NTPC Limited TRN : 12625918 Desc : Renovation and retrofitting of electrostatic precipitator package BOD : December 11, 2012 Loc : Noida, Uttar Pradesh BT : Domestic _______________________________________________
Micro reactor-based continuous nitration plant Org
: High Energy Materials Research Laboratory (HEMRL) TRN : 12962749 Desc : Supply of micro reactor-based continuous nitration plant BOD : December 12, 2012 Loc : Pune, Maharashtra 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: firstname.lastname@example.org
November 2012 | Chemical World
Tamil Nadu, Nov 22-25, 2012
Punjab, Dec 21-24, 2012
Madhya Pradesh, Jan 11-14, 2013
Maharashtra, Feb 1-4, 2013
Uttarakhand, Feb 23-26, 2013
Andhra Pradesh, May 31- June 3, 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.
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Ruby House, 1st Floor, J K Sawant Marg, Dadar (W), Mumbai 400 028. • Tel: 022 3003 4651 • Fax: 022 3003 4499 • Email: email@example.com
CPhI India 2012 International exhibition on pharmaceutical ingredients, machinery, equipment, outsourcing and biosolutions; November 21-23, 2012; at Bombay Exhibition Centre, Mumbai For details contact: UBM India Pvt Ltd Sagar Tech Plaza A 615-617, 6th Floor Andheri-Kurla Road Saki Naka Junction Andheri (E) Mumbai 400072 Tel: 022-6612 2600, Fax: 022-6612 2626 Email: firstname.lastname@example.org
IPVS 2012 A trade show for industrial pumps, valves and systems; December 14-16, 2012; at Auto Cluster Exhibition Centre, Pune For details contact: Orbitz Exhibitions Pvt Ltd 202, Navyug Industrial Estate T J Road, Sewri (W) Mumbai 400 015 Tel: 022-2410 2801, Fax: 022-2410 2805 Email: email@example.com
India Water Expo An event showcasing an array of efficient water treatment processes, transportation, storage facilities, chemicals and other related equipment; February 01-03, 2013; Gujarat University Exhibition Hall, Ahmedabad For details contact: EA Water Private Limited A1/152, IGNOU Road, Neb Sarai
Chemical World | November 2012
New Delhi 110 030 Tel: 011-43100568/500, Fax: 011-43100599 Email: firstname.lastname@example.org
World PetroCoal Congress An international event showcasing trends in refining technologies, extraction & drilling equipment, consulting services, natural gases and others; February 15-17, 2013; Convention Centre-NDCC, New Delhi For details contact: Energy and Environment Foundation F1-F2, Pankaj Grand Plaza, Mayur Vihar - I New Delhi Tel: 011-2453 8318/2275 8149 Email:email@example.com
EverythingAboutWater Expo 2013 An international exhibition and conference on water & wastewater management; February 28-March 2, 2013; at Chennai Trade Centre, Nandambakkam, Chennai For details contact: EA Water Pvt Ltd A1/152, Neb Sarai IGNOU Road, New Delhi 110 068 Tel: 011-4310 0568/0572 Fax: 011-4310 0599 Email: firstname.lastname@example.org
ChemProTech 2013 An international event on chemical processing technology and equipment to be held concurrently with fine and specialty chemicals trade fair, Chemspec; April 11-12, 2013; at Bombay Exhibition Centre, Mumbai
For details contact: Krunal Goda Koelnmesse YA Tradefair Pvt Ltd 1102, 11th Floor, DLH Park S V Road, Near MTNL Office Goregoan(W), Mumbai 400062 Tel: 022-2871 5207, Fax: 022-2871 5222 Email: email@example.com
Poly India A trade show for plastics and petrochemicals industries; April 25-27, 2013; at Chennai Trade Centre, Chennai For details contact: Federation of Indian Chambers of Commerce & Industry Federation House, 1, Tansen Marg New Delhi Tel: 011-2373 8760/2373 8770 Fax: 011-2332 0714 Email: firstname.lastname@example.org
PetroWorld India An event showcasing novel technologies in oil & gas sector; August 22-24, 2013; Bombay Exhibition Centre, Mumbai For details contact: Siddharth Chibba Inter Ads Exhibitions Pvt Ltd Plot No 859, Phase-V, Udyog Vihar, Gurgaon 122016, Haryana Tel: 0124-4524200/4201 Fax: 0124-4381162 Email: email@example.com
analytica Anacon India 2013 International trade fair for laboratory technology, analysis, biotechnology and diagnostics; November 12-14, 2013; at Bombay Exhibition Centre, Mumbai For details contact: Avisha Desai Project Manager MMI India Pvt Ltd Lalani Aura, 3rd Floor, 34th Road Khar (West), Mumbai 400 052 Tel: 022-4255 4710 Email: firstname.lastname@example.org
INTERNATIONAL OSEA 2012 An event showcasing innovations in oil & gas exploration and production; November 27-30, 2012; at Marina Bay Sands, Singapore For details contact: Singapore Exhibition Services Pte Ltd 1 Jalan Kilang Timor, Pacific Tech Centre Singapore 159303 Tel: +65 6233 6638, Fax: +65 6233 6633 Email: email@example.com
goods; December 06-09, 2012, at Tehran Permanent Fair Ground, Tehran, Iran For details contact: Banian Omid Exhibition Management Co Apt 10, 6th floor No 1022, near Park Saie Gas station Val i -e- Asr Av, Tehran, Iran Tel: +(98)-(21)-8872 0005/8872 0007 Fax: +(98)-(21)-8871 0252 Email: firstname.lastname@example.org
Jl. Kebon, Baru III, No. Jakarta, Jakarta Raya, Indonesia Tel: +(62)-(21)-8379 5203 Fax: +(62)-(21)-8379 5302 Email: email@example.com
Gas Tech Cairo Focussed event showcasing latest innovation, technologies and developments across the gas value chain; February 04-05, 2013; at Sonesta Hotel, Tower & Casino Cairo, Egypt
Dye+Chem Asia 2012 China Coat An exhibition providing global platform for coatings, printing inks and adhesives suppliers; November 28-30, 2012; Guangzhou, China For details contact: New Expostar (SZ) Co Limited Room 1708, 17/F, Eton Place 69 Dongfang Road, Pudong New Shanghai, China Tel: +(86)-(21)-5877 7680 Fax: +(86)-(21)-5877 7685 Email: firstname.lastname@example.org
Vietnam International Chemical Exhibition A focussed exhibition on chemical, which serves as a platform for manufacturers, distributors, end users and professionals from food, cosmetics, textile, medical and other sectors; December 05-08, 2012; Ho Chi Minh City International Exhibition & Convention Center, Vietnam For details contact: CCPIT Sub-Council of Chemical Industry Building 16, Block 7, Hepingli, Dongcheng District, Beijing, China Tel: +(86)-(10)-6427 5419 Email: email@example.com
International Paint, Resins & Coating Composite Fair An event showcasing the latest developments on the protection of
A trade fair for dyes and fine & specialty chemicals industry; December 08-10, 2012; at Sands Expo & Convention Center, Marina Bay Sands, Singapore For details contact: CEMS-Global Asia Pacific Pte Ltd 8 Temasek Boulevard, # 42-00 Suntec Tower Three, Singapore 038988 Tel: + (65) - 6829 - 2144 Fax: + (65) - 6829 - 2145 Email: firstname.lastname@example.org
Petrochem Arabia An exhibition and conference focussed on technological improvements and sustainability of the downstream and petrochemical industries; January 20-22, 2013; at Dhahran International Exhibition Center, Dammam, Saudi Arabia For details contact: Bme Global Ltd Waterfront Studios, 1 Dock Road, London, E16 1 Ag London, England, United Kingdom Tel: +(44)-(207)-5119582 Email:email@example.com
For details contact: World Promotion Centre 35 Abd Elhamed Awad St. 4th Floor, nasr City Cairo, Al Qahirah, Egypt Tel: + (20)-(2)-2273 8278 / 2273 8279 Fax: + (20)-(2)-2273 8303/2273 8304 Email: firstname.lastname@example.org
InformexUSA 2013 Exhibition and conference bringing together buyers and sellers of chemicals, chemical technologies and related services; February 19-22, 2013; at Anaheim Convention Centre, Anaheim, California, USA For details contact: Informex Holdings, LLC 300 American Metro Blvd Suite 125, Hamilton, NJ 08619, USA Tel: +1 609 759-4700 Email: email@example.com
Chemspec Europe 2013 An event dedicated to the fine and specialty chemicals industry; June 05-06, 2013, at MOC, Munich, Germany
IndoGas 2013 Leading trade fair and conference on Indonesiaâ€™s gas & oil industry; January 25-27, 2013; at Jakarta International Expo ( JIExpo), Jakarta, Indonesia For details contact: IEE Communications
For details contact: Quartz Business Media Ltd Quartz House, 20 Clarendon Road Redhill, Surrey The UK Tel: + 44 - 1737-855000 Email: firstname.lastname@example.org
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 World
November 2012 | Chemical World
EVENT PREVIEW Engineering Expo Chennai 2012
CHENNAI November 22-25, 2012 Chennai Trade Centre
OFFERING A COMPETITIVE ADVANTAGE With the passage of time, Chennai has emerged as a hub for the automotive and allied industries. Amid this as well as the growth of other industries, Network18 Publishing is all set to hold the fifth edition of Engineering Expo Chennai. This edition will provide a suitable platform to exhibitors for showcasing their products and services to prospective visitors in a competitive atmosphere. Set to be held during November 22-25, 2012, this edition endeavours to get bigger and better. Shibani Shah and Chandreyee Bhaumik
hennai, originally known as Madras, has always been a major industrial hub. Located on the Coromandal Coast of the Bay of Bengal, the city is well-connected to different parts of the country. With a number of industries located in Chennai, the industrial growth of the city is at par with other parts of the globe. According to Deepak
Highlights of this edition 200+ expected exhibitors 15,000+ business visitors expected Business transactions worth `
48 crore expected 8,000+ products on display Spread over an area of more than
4,200 sq m Showcasing more than 30 diverse industry categories
Chemical World | November 2012
Sharma, Partner, Ball & Roller Bearing Co, “Chennai, in the past few years, has grown to become the largest automobile manufacturing hub and is still growing; in short, Chennai has become a one-stop solution destination for industries.”
An evolving industrial destination Vision 2026 is to make Chennai a prime metropolis that will be more liveable, economically vibrant and environmentally sustainable as well as with better assets for future generations. According to various industry reports, the manufacturing industry of Chennai comprises large segments ranging from petrochemicals and chemical industry, electrical and automobile and several other related ancillary industries. Some of the largest industrial areas such as Ambattur and Manali are located in Chennai Metropolitan Area (CMA) and house multi-product industries. Other industrial estates at Guindy, Thirumazhisai and Thirumudivakkam house medium and small-scale industries. Chennai has a large base of leather industry and accounts for about 50 per cent of the total exports of the country. Most of the footwear industries are located within CMA. In addition, a cluster of chemical industries is located at Manali in CMA. Further, an exportprocessing zone, spread over an area of 261
acre, is located at Tambaram for apparel and other exports. Elaborating further, S Raghavan, Proprietor, Best Systems & Services, expounds, “Chennai is a potential industrial city. As major international companies are setting up shop here, the supportive and ancillary industry growth is imminent. Chennai is developing proper infrastructure and promoting new industrial areas, which attract a lot of investors. Chennaites’ work culture is also conducive to the new industries - both foreign as well as domestic.” Highlighting why Chennai has become an attractive destination, K Ravi, General Manager, MGM Varvel Power Transmissions, elaborates, “Chennai is an attractive destination because of its infrastructure, the port and the established manufacturing base, and because of its desire to grow more.” Large automobile engineering, glass and ceramic industries, are located at Maraimalai Nagar, Irungattukottai, Sriperumbudur, Thiruvallur and Gummidipoondi around Chennai. It is interesting to note that Tamil Nadu accounts for about 21 per cent of passenger cars, 33 per cent of commercial vehicles and 35 per cent of automobile components produced in India. Indeed, Chennai, the ‘Detroit of India’ is truly emerging as a major export hub for cars in South East Asia.
Engineering Expo Chennai 2012
Commenting on the scope Chennai provides, P K Sivaswami, Mentor, India Operations, Zhejiang Fit Bearing Co Ltd, avers, “Chennai is a major hub for manufacturing auto components, electric motors, two-wheelers, etc. This scale of exposure to the industry by participating in such events will help us to develop a market for our brand of bearings, which is at par in terms of quality with leading manufacturers offering competitive pricing.”
Glorious past edition
The 4th edition of Engineering Expo Chennai in 2011 offered a unique platform to the exhibitors for showcasing their products and business enhancement. There were more than 5,000 products displayed and about 12,692 visitors, and the event generated a business transaction worth `41.98 crore. Apart from showcasing the best in terms of engineering innovations and technologies, Engineering Expo Chennai 2011, served as a conducive platform in amalgamating the capabilities of the state with specific needs of the industries. With a strong base in MSME, this exhibition offered a unique advantage by not only
Glimpses of previous edition 175+ exhibitors 11,359+ visitors 5,000+ products displayed ` 41.98 crore business generated
42,000 sq m exhibition area 85,000 kg machinery moved Delegations from more than 84 different companies such as Apollo Tyres; Brakes India; Bharath Weld Equipments & System; Bureau Vertas India; Valeo Systems; Petro Constructions; Lucas TVS; Wabco TVS; RK Engg Works; Indian Navy; Hyundai; Larsen & Toubro; Michellin Tyres; Foxconn India and many more
providing new opportunities for enhancing the business, but also for augmenting the existing process with cost-effective technologies. Being an all-inclusive engineering show, the event provided an opportunity to exhibitors from various sectors to spread awareness about their products and services. Describing the reason for his participation, Raghavan adds, “We were inspired by the visitors’ profile and response to the Expo.” With the Expo expected to get bigger and better this year, the organisers are looking forward to larger number of exhibitors and visitors. Elaborating further, Ravi says, “Our experience last year was good and we are looking forward to better prospects this year.”
From the organiser’s desk Engineering Expo turns 11 this year. Elaborating on the success graph, Sandeep Khosla, Chief Executive Officer, Network 18 Publishing, comments, “After 10 successful years of service to the industry, Engineering Expo today has established itself as India’s largest multi-location trade show on manufacturing. The Expo is a preferred destination for small and medium enterprises as well as manufacturing & engineering organisations to further their growth and that of the industry at large.” “For the 2012–13 season, we have eight editions spread across an equal number of locations of a rising India. Keeping our esteemed exhibitors and valued customers in mind, we have made elaborate provisions to offer a never before experience. These, we reckon, will add substantial traction to the industrial growth of the nation,” Khosla adds.
High expectations from exhibitors With the Engineering Expo Chennai 2012 on the anvil, it is time for the exhibitors to build up on their expectations. Discussing his expectations from the Expo, Sharma states, “We are expecting a huge footfall from quality buyers. We look forward to spreading awareness about the availability of world-class quality products and generating new possibilities of developments in products & services.” While exposure to potential clients and quality visitors is the major expectation of the exhibitors, Raghavan adds, “We want to exhibit our
New attractions in this edition o Panel discussion aims at providing a roadmap to infuse growth in the region o Institutional Buyer Involvement Plan to attract delegations from large corporate and major institutions o Improvised visitor profiling – profile, scan, filter and bring in visitors as per exhibitors’ requirements o Providing business networking support to exhibitors by leveraging Network 18 Publishing’s industry connect o Credit rating facilities for the benefit of exhibitors o Providing complete travel solutions for exhibitors o Offering logistics services to ensure smooth cargo handling, custom clearing, transport compliance, etc
potential in providing innovative solutions to typical requirements of process industries.” Continuing in this regard, Manoj Kumar, Director, Apex Auctions India Pvt Ltd, informs, “We are sellers of equipment, machine and tools pertaining to the manufacturing industry and are participating in the Engineering Expo Chennai for the first time. We want to gain exposure to the small and medium enterprises, small-scale industries, etc taking part in the Expo.” Seconding these thoughts, K Balaji, Chief Executive Officer, Aquaflow Enterprises, elaborates, “We are hoping to generate enquiries. Last year, we had participated in the Expo and this is the second time for us. This Expo is beneficial for us since Chennai is the manufacturing hub, and therefore, we are aiming to generate a lot of business from here.” Sharing his expectations, Ravi adds, “We are anticipating visitors from sectors such as auto, pharma, chemical, automation, material handling, construction and packaging to visit us. We are focussing on our range of products such as gearboxes, gear motors, motors & brake motors, and are aiming to establish our brand.” Email: email@example.com
November 2012 | Chemical World
EVENT PREVIEW IPVS 2012
All pumped up for novelty in fluid control The growth pace of the Indian economy and its huge potential have attracted major companies in the pumps and valves sector from across the world to come and invest in India. The sixth in its series, the Industrial Pumps Valves & Systems (IPVS) exhibition is all set to present a plethora of opportunities to the international as well as Asian pumps & valves industry and related segments. It will showcase products and technologies for the benefit of the growing Indian process industry. Avani Jain
he process industry’s growth is highly dependent on the progress of the pumps and valves sector. The country has been home to leading manufacturers of industrial pumps and valves since many decades. Providing a platform for the pumps, valves and allied industries to showcase their products and technologies, IPVS serves as a major industry gathering for the international as well as Asian manufacturers. The three-day event, organised by Orbitz Exhibitions Pvt Ltd, scheduled to take place from December 14-16, 2012, at Auto Cluster Exhibition Centre, Pune, Maharashtra, acts as a networking place for the international manufacturers who wish to enter Indian and Asian market as well as for the domestic companies to showcase new technological advancements in this sector. IPVS 2012 is organised in association with Europe Pump Manufacturers Association (EUROPUMP), and Korean Pump Co-operative. Commenting on the importance of events such as IPVS 2012, M Harikrishnan, Project Manager, Orbitz Exhibitions Pvt
Chemical World | November 2012
Ltd, notes, “At exhibitions like this, one gets to see a range of pumps and valves at a single place. Further, for the buyers of pumps and valves, an exhibition such as IPVS offers an opportunity to add to their database of vendors of pumps and valves. They can also explore technologies to weed out problems faced by them, for which some exhibitors may have some unique solutions.”
The growth story continues… IPVS has a long success story. IPVS 2011 saw close to 100 companies exhibiting their products. Riding on the success of its previous editions, IPVS 2012 will be bigger, more incisive and impressive. More than 150 exhibitors are expected to participate in the event. In addition, there would be country pavilions from China and Korea. Apart from these, there will be exhibitors from Germany, Italy, Sweden, USA, Japan, Singapore and the UK. Also, there would be buyer-seller meets, and workshops on specific topics conducted by S L Abhyankar, a pump expert, and R K Srivastava, Wholetime Director, Kirloskar Brothers. This event will also see launch of various new products. Harikrishnan notes, “There will
be quite a few product launches at IPVS 2012. The total business volume expected during the trade fair is anywhere between $ 20 and $ 50 million.” Taking into account the overwhelming response received at its inaugural edition, the much awaited Industrial Pipes and Compressor Expo 2012 (IPCE) will once again run concurrently with IPVS 2012. This is organised with a view to bring together the industrial piping and associated systems such as gaskets, couplings, elbows, and other hydraulic machinery at a common platform.
Looking forward The Indian pump manufacturers are on a high, given the strong upswing in fluid handling industry, irrigation and urban infrastructure projects. With IPVS becoming an international platform, Indian pump manufacturers have an added advantage in knowing and catering to the global market needs. Harikrishnan concludes, “Pune being the OEM capital of India and the hub of pumps & valve industry, we expect a turnout of at least 5,000 to 8,000 industry-specific business visitors.” Email: firstname.lastname@example.org
EVENT REPORT Engineering Expo Ahmedabad 2012
AHMEDABAD October 5-8, 2012 Gujarat University Exhibition Hall
Gujarat, a manufacturing hub housing a large number of Small & Medium Enterprises (SMEs), multinational companies, etc, has witnessed tremendous industrial growth in the last few years. The recently held Engineering Expo Ahmedabad 2012 succeeded in adding further impetus to this growth by offering the manufacturing fraternity, especially the SMEs in the segment, a perfect platform to boost business and profits. Meeting the expectations of exhibitors and visitors alike, the Expo has reached yet another milestone and promised to define new horizons in its next edition. A report… The Chief Guest B B Swain (centre) inaugurating the Engineering Expo Ahmedabad 2012 in the presence of Sunil Shah (second from left) and Richard Moore (third from left)
ujarat, renowned for its vibrant and buoyant economy, has been at the forefront of industrial growth, thanks to the entrepreneurial culture of its people and strong infrastructure focus of its policy makers. In this backdrop, the 11th edition of Engineering Expo Ahmedabad, held from October 5-8, 2012, proved to be a catalyst in accelerating this growth, further, by bringing the industry veterans from the manufacturing sector, especially SMEs, together under one roof and offering ample business opportunities. Organised by Network 18 Publishing, the Expo has emerged as one of the major trade platforms for the industry.
Grand opening The inauguration function was graced by the presence of Chief Guest B B Swain, Vice Chairman & Managing Director, Gujarat
Chemical World | November 2012
Visitors thronging the stalls at the event
Industrial Development Corporation; Richard Moore, Group Manufacturing Manager, UK Carbon & Graphite Company; Sunil Shah, Chairman, Gujarat Innovation Society; Sudhanva Jategaonkar, Associate Vice President, Network 18 Publishing; and Archana Tiwari-Nayudu, Executive Editor, SEARCH, Network 18 Publishing. Engineering Expo Ahmedabad was well-organised. It was not only appreciated by industry veterans from the country but also professionals from abroad were overwhelmed to see such an event being organised on a huge scale. Moore averred,
“I am surprised at the range of products displayed at this Expo. Some of these products are really good & competitive, which need to be promoted in the European market as well. My message to the exhibitors would be that this is a professional show and you need to take this level of professionalism into your manufacturing plants as well. An event like Engineering Expo is a first step for taking the industry to the next level. The exhibitors should not only focus on India but the world market as well.” During the inaugural session, an exhibitor directory featuring the list of
Engineering Expo Ahmedabad 2012
all the exhibitors of Engineering Expo Ahmedabad 2012 was also unveiled.
Gujarat as a manufacturing hub The manufacturing industry in Gujarat has highly evolved, over the years. Commenting on the growth of manufacturing sector in the state and the importance of Engineering Expo, Swain said, “Manufacturing is one of the core sectors in Gujarat. The State Government has launched ambitious projects for the sector as the objective is to enhance the growth of the industry. In such a scenario, an event like this can add to the growth of the manufacturing segment as it focusses a lot on the small and medium enterprises. The event is a good platform for promoting business, branding and trading. It has really grown bigger since last few years and is a one-of-its-kind Expo.”
Bringing SMEs into limelight The distinguished guests saw this mega trade show as an encouraging initiative from the industry’s point of view. Being the largest SME gathering in the state, the Expo has really helped SMEs immensely. Shah noted, “SMEs in the manufacturing segment have limited resources. So, if they want to travel to different places for gathering knowledge about different products, it would not be feasible for them. Thus, in such a scenario, an event where a cross-section of machinery is displayed under one roof can truly benefit the SMEs. They can not only gather knowledge about different products but also have physical access to the various products and technologies. Thus, such events can really aid the growth of industry.”
Valuable experience for exhibitors Being an all-inclusive engineering show, the event provided an opportunity to exhibitors from various sectors to spread awareness about their products and services. Bhavin Siddhapura, Chairman, Macht Exim LLP, noted, “We first participated in 2010 and since then we are regular exhibitors in different editions of Engineering Expo, irrespective of the city in which it is held.
It has helped us in brand building and spreading awareness about our products, leading to a good number of business enquiries.” The exhibitors received an overwhelming response and generated many leads with potential to generate revenues. S J Gijare, General Manager - Handling Equipment Division, CTR Manufacturing Industries Ltd, said, “Though such exhibitions do not generate immediate revenues, these surely help a company in the long run as there is ‘word of mouth’ publicity. Moreover, events like these help us to tap customers who are not from the city where we have our office.” Highlighting the long-term fruitful association with the organisers, Bijal Shah, Director, Sharad Industrial Products Pvt Ltd, said, “We have been participating in the Engineering Expo since last three years. Over the years, the event has become highly professional. The Panel Discussion organised as a prelude to the Expo further increased the credibility of this event.” There was a general consensus that Engineering Expo has highly evolved over the years and becoming better with each edition. Major Amitava Mittra, Chief Operating Officer, BGI Engitech Pvt Ltd, said, “The event seems to be a great success. The organisers have put in great efforts to provide us everything we wanted and on time. I heartily congratulate the organisers for putting up such a great show.”
Displaying a sense of contentment The event attracted several visitors from leading industrial centres in and around Gujarat. Their satisfaction with the show can be gauged from the fact that most of them are eagerly looking forward to next year’s edition. Ashish Shah, Senior Marketing Manager (Materials), InspirOn Engineering Pvt Ltd, opined, “I have attended previous year’s Engineering Expo as well, and every year, the event has helped us in locating at least four to five suppliers. We would like to attend this event in the future too as such exhibitions really enhance our knowledge about the industry.” Engineering Expo provided a common networking platform for leaders in the
Highlights of this edition 225 exhibitors pan India 15,190+ business visitors Business transacted worth
` 60.70 crore 13,136 business leads generated
15,000+ products displayed More than 1,00,000 kg machinery moved in for display industry to showcase their products and this helped the potential customers in taking better business decisions. “Engineering Expo helps us gather information about the various products available in the market. We are able to interact with several companies at one time under the same roof. This event has really helped in the growth of my business,” noted Vijay Patel, Marketing Manager, Prism Group of Company. Another visitor, Dr B S Munjal, Head, Structural & Thermal Analysis Division, Scientist/Engineer - SG - Space Application Centre, Indian Space Research Organisation, said, “This Expo has helped us in widening our technical horizons and gathering maximum information about the products we require.” It is not only the organisers and exhibitors who believed that the event has evolved over the time, but even regular visitors shared the same sentiment. Satish Prajapati, Proprietor, Conquest Engineering, averred, “What lures us to Engineering Expo is the brand image of Network 18. It really provides an impetus to the event. Every year, the event is getting better than what it was in the last season.” Taking the next leap forward, the upcoming editions of this multi-location trade show are gearing up to offer the best business prospects to one and all. Don’t miss the opportunity! Email: email@example.com
November 2012 | Chemical World
Practical process research and development Author: Neal G Anderson Price: ` 6,900
Organic chemistry forms the base of the entire gamut of synthetic chemistry. Designed to provide a comprehensive approach to organic process research and development in the pharmaceutical, fine chemical, and agricultural chemical industries, this book describes the synthesis and evaluation of processes. This helps to design strategies in order to launch key compounds in the market in a cost-effective manner. It describes the approaches to solve process development problems, including route, reagent, and solvent selection; optimise catalytic reactions; chiral syntheses, with special emphasis on green chemistry. The book prominently highlights the current trends in chemical process R&D for small molecules. Work-up and prospective considerations for pilot plant and manufacturing scale-up have been explained in detail. New topics such as green chemistry, genotoxins, enzymatic processes are explained. Although the first edition contains useful older examples that readers may refer to, this edition offers new insights. An interesting feature of this book is that it presents practical guidelines for implementing and troubleshooting processes. This book will be a reference guide to students and academicians of higher organic chemistry, and especially to scientists working with R&D in organic chemistry.
With greater inroads in the field of process engineering, a new approach is being found in bioprocessing. Bioprocessing encompasses many steps required to synthesise, isolate and formulate new products. It is widely being considered a viable synthesis option and is gradually replacing conventional chemical processing for certain organic compounds. The field of bioprocessing involves many areas of expertise and requires the fulfillment of several conflicting criteria for success. Biological and chemical expertise is required to develop the process for synthesis and purification whereas a wide range of engineering expertise is needed for designing the facilities and reaction engineering. This book is a comprehensive and practical guide to bioprocessing facility design and operations. It is subdivided into four sections that offer indepth coverage of process systems, system components, support systems and facility design. The first and third sections delve into the two types of equipment required in the plant, one in which the actual product is synthesised or processed such as the fermentor, centrifuge and chromatographic columns; and the other type that supplies support for the facility or process including air conditioning, water and waste systems. Part two describes essential components such as pumps, filters and valves. The last section covers planning and designing an entire facility along with requirements for containment and validation of the process. This book will be helpful for professionals, students and academicians in the field of biotechnology, biochemistry and organic chemistry as well as those involved with the pharmaceutical industry.
Bioprocess engineering Edited by: Bjorn K Lydersen, Nancy A Dâ€™Elia and Kim L Nelson Price: ` 1,295
Reviewer: Nita Mehta, Associate Professor, Chemical Engg Dept, Thadomal Shahani Engg College
Available at: Wisdom Book Distributors, Hornby Building, 1st floor, 174, D N Road, Mumbai 400 001 Tel: 022-2207 4484/6631 8958, Telefax: 022-2203 4058, Email: firstname.lastname@example.org
Chemical World | November 2012
PRODUCTS This section provides information about the national and international products available in the market
Hot water system Hot water system is the most versatile and compact hot water generation system. It provides highly efficient solution to instantaneous hot water generation using energy-efficient heat exchangers that ensure less energy consumption. It has a pre-assembled skid for ease of installation and requires up to 75 per cent less space for installation when compared to conventional hot water tank heating systems. It can also be installed with storage (buffer) vessel for semiinstantaneous applications and in conjunction with solar-based hot water systems. The hot water system not only heats the water to a desired temperature using low pressure steam but also maintains the required temperature of water with better temperature control using automation and control. Application areas include pharmaceutical industries where single fluid heating
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Industrial plastic components A wide range of industrial plastic components is available in ABS, polycarbonate, EVA, polyacetal, nylon, HDPE, PP, HIPS, PVC and PET. Also offered are rings, closures, spacers, bushings, gears, lids, clamps, housings, handles, brackets, caps, connector brackets, electrical switch boxes, pumps and valve components, etc. A S Engineering Works Mumbai - Maharashtra Tel: 022-65277554, Mob: 09833617762 Email: email@example.com Website: www.asengineeringworks.com
November 2012 | Chemical World
Rotary evaporator Rotary evaporator is used for efficient and gentle removal of solvents from samples by evaporation. It has a safe and innovative design with a unique reversing feature for better evaporation. In case of a power cut, the motorised lift has a ‘safety stop’ function, where the evaporator piston is automatically lifted out of the heating bath. Rotation speed ranges from 20-270 rpm. Bath heat ranges from 20-180°C, adding versatility by allowing use of water or oil. Digital rotation speed display is on all models, making for easier repetition of parameters. In the digital models, temperature control of the heating bath is done by a micro-controller eliminating sudden uncontrolled boiling or bumping. It has an infrared interface for data transfer from the heating bath to the drive unit and RS 232 interface for PC remote operation. Control models offer all this along with additional functions like integrated vacuum controller, integrated solvent library, automatic boiling point recognition, colour graphic display, display of distillation curves and USB interface. System components include the main unit
and accessories such as the water baths, glass wares, vacuum pumps, circulating chillers, etc. Cole-Parmer India Pvt Ltd Mumbai - Maharashtra Tel: 022-67162209/2222 Email: firstname.lastname@example.org Website: www.coleparmer.in
Filter press The sparkler-type filter press (model BPSF– 8) consists of stainless steel shell and top cover, which use bolts to give pressuretight enclosure. The filter cartridge assembly inside the shell consists of several horizontally arranged disc-type filter plates with perforated supporting screens, filter media and interlocking cups. Bombay Pharma Equipments Pvt Ltd Mumbai - Maharashtra Tel: 022-28594877 Email: email@example.com Website: www.bombaypharma.com
Cooling tower The evaporative Fibreglass Reinforced Plastic (FRP) cooling tower has a vertical induced draft counter flow design with uniform water distribution and optimal heat transfer. The tower casing is made of tough FRP and has sufficient structural strength to withstand high wind velocities and vibrations. The fill splits the air and water into several streams, increasing the time of contact. Automatic rotary sprinkler system is made of nylon 66 material, rotary head and sprinkler pipe distribute the hot water over the entire space of the filler. Sprinkler pipes are non-clogging, require low pressure to operate and assure uniform water flow with minimal operating pump head. The performance of cooling tower depends upon the water distribution over the fills. The water is distributed evenly through a wide spray angle without any dry pockets. Gem Equipments Ltd Coimbatore - Tamil Nadu Tel: 0422-2363800 Mob: 09366631697 Email: firstname.lastname@example.org Website: www.gemindia.com
Chemical World | November 2012
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Subscription Department, Network18 Media & Investments Ltd, A Wing, Ruby House, JK Sawant Marg, Dadar (West), Mumbai 400 028. email@example.com
Diesel and gasoline nozzles The diesel and gasoline nozzles are designed for use on farm and consumer pumps. The lightweight tensalloy aluminium diesel nozzle provides high flow capacity required by truck stops and terminal operations. Micro-touch valve provides smooth operation and exceptional flow control. Super tough nylon hose guard and hold-open clip and easy-to-change lockout style spout assembly are other important features. The lightweight diesel nozzle offers efficient refuelling. Dixon Asia Pacif ic Pvt Ltd Mumbai â€“ Maharashtra Tel: 022-40931555 Email: firstname.lastname@example.org Website: www.dixonvalve.com.au
Energy saver Sensor-based energy saver automatically switches the air-conditioners On and Off when the temperature in the room is achieved. There is a 3-minute compressor protection time interlock between each On/ Off operation. The existing air-conditioner has a crude non-sensitive thermostatic control, which senses the grill temperature to switch the air-conditioner On/Off, whereas the energy saver has a precision sensor, which can be placed, in any part of the room to switch the air-conditioner On and Off. This helps in maintaining the comfort temperature in most used part of the room. Gautam Enterprises Mumbai - Maharashtra Tel: 022-28750421 Email: email@example.com Website: www.gautament.com
Lubricant additives and reactive surfactants The lubricant additive is an organo-molybdenum compound developed with original technology. It can reduce friction and help save fuels, minimise metal wear & extend machine life. The additive gives good lubricity performance even under severe conditions, prevent degradation of oil, and extend oil life. Adeka India Pvt Ltd Mumbai - Maharashtra Tel: 022-40263301 Email: firstname.lastname@example.org, Website: www.adekaindia.com
November 2012 | Chemical World
The rotary evaporator is used for distilling a wide range of liquids. It has an attractive appearance backed by innovative features in the areas of safety, functionality and ergonomics. The evaporator automatically lifts the receiving flask out of the heating bath if the power cuts off. This means that the ongoing test and any distillate already produced are unaffected by the stoppage. The patented geometry of the distillation condenser also provides a larger cooling surface area for distillation. The associated heating bath is ergonomic and safe.
The automated multi-titration system is equipped with a comprehensive Windows-based titration operating system, and is capable of multiplexing. With a PC and user-friendly software, the system controls every aspect of titration analysis, from real-time runs to calculated results. The system performs a variety of specific titrations, such as pH, thermo titration, optical, conductometric and on-line titrations. It also includes four titration endpoint-sensing methods available with rapid multiplexing between thermometric, potentiometric, conductometric and chemiluminescence.
IKA India Pvt Ltd Bengaluru - Karnataka Tel: 080-26253925, Mob: 09845387684 Email: email@example.com, Website: www.ikaindia.in
Multiflo Instruments Pvt Ltd Navi Mumbai - Maharashtra Tel: 022-27780880 Email: firstname.lastname@example.org Website: www.multifloinstruments.com
Laser particle size and shape analyser
Electronic dosing pump
The laser particle size and shape analyser is available in wet and dry mode feeding. Low-cost particle sizers for small-scale industry and colleges, mid-range models for quality control, and top-of-the-line models for large-scale industry and research institutes are available. These analysers find applications in pharmaceuticals, cement, pesticides, battery material, graphite, petrochemicals, metallic powders, catalysts, etc.
The electronic dosing pump is available from 0-20 lph. It is compact in size and lightweight. The pump is diaphragm-type solenoid-operated pumps. The diaphragm is made of PTFE and backed by hyphalon. It can also be provided with automatic flow switches and level controllers. The pump is suitable for applications in water and wastewater treatment, fuel metering and other chemicals dosing in many process industries.
MeasureTest Corporation Mumbai - Maharashtra Tel: 022-22027982, Mob: 09869012701 Email: email@example.com, Website: www.measuretest.com
Swing check valve
Positive Metering Pumps (I) Pvt Ltd Nashik - Maharashtra Tel: 0253-2381993, Mob: 09326781757 Email: firstname.lastname@example.org, Website: www.positivemetering.com
The swing check valve comes in sizes ranging from 65 to 300 mm. This valve meets the design requirements as per BS 1868/API 6D/ASME B16.34 and testing requirements as per API 598/EN 12266-1. Face-to-face and end-to-end dimensions (Dim A) conform to ASME B16.10, drilling and flange dimensions conform to ASME B16.5, and butt weld end dimensions conform to ASME B16.25. To ensure long and trouble-free valve performance, seating surface is accurately machined, precisely aligned and perfectly lapped. Materials of construction are carbon steel and stainless steel.
The turbine blower is designed to suck or to compress gases/non-explosive air mixtures. It is absolutely oil free with air flow capacities that range from 42 to 1100 m3/hr with maximum vacuum up to 500 mbar and maximum pressure up to 550 mbar. It is light-weight due to Al construction and have 100 per cent oil-free non-pulsating continuous air flow. The blower requires practically zero maintenance and have silencers on both suction as well as discharge ports. These find applications in areas such as pneumatic conveying systems, industrial vacuum cleaners, printing and paper handling, air pollution monitoring equipment and dental suction equipment.
Met-Flow Controls Pvt Ltd Hubli - Karnataka Tel: 0836-2332599, Mob: 09345886999 Email: email@example.com, Website: www.metflowindia.com
Shree Siddhi Vinayak Industries Thane - Maharashtra Tel: 0250-28458372 Email: firstname.lastname@example.org, Website: www.minivacpumps.com
Chemical World | November 2012
PVC cable tray The rigid PVC perforated cable tray is an ideal replacement to MS tray. This PVC tray is not affected by any corrosive chemicals and is waterproof. It is used outside for prolonged periods as it is UV stabilised to resist ultraviolet rays of sun. It is available in width ranging from 50 mm to 300 mm, flange heights of 25 m and 50 mm and with a standard length of 2.9 m. The cable tray is lightweight and maintenance-free. It is joined by socketed jointing system, which means no coupler plate is required. Supreme Electroplast Industries Mumbai - Maharashtra Tel: 022-28873428, Mob: 09820306252 Email: email@example.com Website: www.supshitl.com
Simulator The simulator is an apparatus that provides (for testing purpose) conditions like those, which are encountered in real operation or replica of real plant with real-time data. Real-time simulators are offered for refinery: VDU, CDU, FCCU with emulated TDC-3000 console, fertiliser: ammonia and urea plant simulation with emulated Yokogawa DCS console, power plant 210 MW on KWU and LMZ turbines. Triangle Simulation Pvt Ltd Mumbai - Maharashtra Tel: 022-24095682, Mob: 09969074960 Email: firstname.lastname@example.org Website: www.trianglesimulation.com
Silicone grease Silicone grease is a single component modified silicone system. It does not harden, dry out or melt even after 1000 hours at 200째C, showing good di-electric and lubricating properties. It wets and adheres to dry surfaces of metals, ceramics, plastics etc, providing high surface resistivity under moisture condensing conditions. Anabond Ltd Chennai - Tamil Nadu Tel: 044-24402311/13 Mob: 09825688244 Email: email@example.com Website: www.anabond.com
November 2012 | Chemical World
Fasteners and steel metal components
The fasteners and sheet metal components are useful in plastic injection-moulding machines and rubber industries. The components include full thread spindle, HTS hex head bolt, nuts, washers, spiral pin, plugs etc. These materials are offered as per ISO, DIN, IS, BS, JIS and ASTM standards. The materials are made from MS, carbon steel, alloy steel, stainless steel, brass, copper, PVC, nylon, fibre and spring steel. These components are used in hydraulic-pneumatic pumps & valves, electrical, electronics, machine tools, materials handling equipment, home appliances, washing machines, refrigeration and air-conditioning plants, etc.
PVDF pipe has the characteristic stability of fluoro-polymers when exposed to harsh thermal, chemical and ultraviolet environments while retaining the properties of a conventional thermoplastic material. Its features are high chemical resistance, low temp resistance, mechanical strength and toughness, abrasion resistance, thermal stability and low permeability to gases and liquids.
Zenith Industrial Products Mumbai - Maharashtra Tel: 022-28470806 Email: firstname.lastname@example.org Website: www.zip-india.com
Rotary dryer Rotary dryer is used for drying wet powders and cakes. It consists of a rotating drum with angle lifting blades, which lift the feed as the drum rotates and showers in the stream of hot air flowing through the drum. The capacity ranges from 100 kg/hr to 50,000 kg/hr and operating temperatures go up to 600°C. Raj Process Equipments And Systems Pvt Ltd Pune - Maharashtra Tel: 020-4071001, Mob: 09766441144 Email: email@example.com Website: www.rajprocessequipment.com
Wear plate and wear pad The wear plate and wear pad overcome the problems of wear in critical sliding surfaces of machinery. It is used in sugar mills, cement plants and other engineering applications. It is a modified bronze-sintered PFE material with inherent characteristics of self-lubrication, low friction and high load-bearing capacity. The wear-resistance property is enhanced by special wear-resistance additives. It can withstand high working pressure of 115 kg/cm² and temperature of –218°C to +260°C. It is fungus-resistant and not affected by weather/moisture and most chemicals. Rollon Bearings Pvt Ltd Bengaluru - Karnataka Tel: 080-22266928 Email: firstname.lastname@example.org, Website: www.rollonbearings.com
Chemical World | November 2012
Sangir Plastics Pvt Ltd Mumbai - Maharashtra Tel: 022-28726120 Email: email@example.com Website: www.sangirplastics.com
Hydrogen gas detection system The hydrogen gas detection system is used for detection of hydrogen gas. It uses a 3-status technology, which displays in terms of low/medium/high concentration. It has selectable slide switch for audio and visual built-in solid state buzzer. The system has the facility to function five gas detectors with independent alarm latching facility, potential free N.O/N.C contact and recorder output. The system is equipped with 4-wire technology and maturity timer. Subtronics (India) Pvt Ltd Mumbai - Maharashtra Tel: 022-24224461 Email: firstname.lastname@example.org Website: www.subtronicsindia.com
Analyser The analyser is a portable device with computer and printer interface capable of storing up to 1,000 results. To meet this demand by chemical industry, UEPL has come out with a portable and microprocessor based instrument for the measurement of Chemical Oxygen Demand (COD) in effluent water. The instrument cuts down the analysis time from the present four to five hours to less than two hours. It requires ten times less sample and correspondingly fewer amounts of chemical reagents cutting down the cost of analysis by ten times. Uniphos Envirotronic Pvt Ltd Mumbai - Maharashtra Tel: 022-61233500, Mob: 9909994063 Email: email@example.com Website: www.uniphos-she.com
Formaldehyde analyser The formaldehyde analyser measures absolute concentrations of formaldehyde (HCHO) in aqueous solution. It has a RS232 serial port for computer interface The measurement ranges from 0 to 5 Îźg/ml. The analyser finds numerous applications in various segments and hence has a huge market demand. It is available in varied specifications as per requirements and needs. The equipment is available at pocket-friendly price. Uniphos Envirotronic Pvt Ltd Mumbai - Maharashtra Tel: 022-61233500, Mob: 9909994063 Email: firstname.lastname@example.org Website: www.uniphos-she.com
Nano enclosure Nano enclosure is specifically designed for nanoparticle research and manipulation. The nano enclosure has been validated for nanomaterial containment. It features a spacesaving design where no separate filtered exhauster is required and which runs with low decibellevel operation. It provides user protection during nanoparticle manipulation and dry powder chemical handling. It functions as a Class I enclosure; room air enters the front of the enclosure and passes through a filter prior to exhausting back to the room. As the nano particles are small and prone to static charge, the enclosure features a ULPA filter, stainless steel liner and an ioniser. The ULPA filter is capable of capturing and containing very small particulates, 0.12 Îźm or larger, at 99.999 per cent efficiency and returns clean air to laboratory. The interior sides, baffle, air foil and integral work surface are stainless steel that helps dissipates static charge and the built-in ioniser neutralises static charge on interior surfaces by emitting ions into the airstream. This helps reduce weighing errors and attraction of particles to the enclosure surfaces. Cole-Parmer India Pvt Ltd Mumbai - Maharashtra Tel: 022-67162209 / 2222 Email: email@example.com Website: www.coleparmer.in 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 World
November 2012 | Chemical World
LIST OF PRODUCTS
Accelerated ageing test ............................ 53 Acoustic enclosure .....................................FIC Agitator .............................................. 19, BIC Aluminium extrusion .................................. 31 Amino acid analyser .................................... 86 Analyser ....................................................... 82 Analytical instrumentation .........................BC Atomic absorption spectrophotometer........ 86 Automatic and contained discharge ............ 29 Bag filter ................................................ 75 Ball valve ..................................................... 13 Batch disperser ............................................ 19 Bellow & dip pipe ......................................... 4 Bulk bag filler.............................................. 76 Butterfly valve ............................................. 13 Cake pressing ......................................... 29 Calorimeter ................................................. 19 Centrifugal fan ............................................ 57 Check valve ................................................. 13 Chemical & pharmaceuticals ...................... 81 Chemical pump ........................................... 83 Chemical tank ....................................... 79, 81 Chemistries & column ...............................BC Chromatography data software .................BC Compositional & trace metal analysis ........ 53 Container .................................................... 79 Continuous or batch filtration .................... 29 Cooling tower ............................................. 76 Custom moulding ....................................... 79 Diesel and gasoline nozzle ...................... 79 Diesel, petrol & fuel oils ............................. 53 Disperser ..................................................... 19 Drum & carboy ........................................... 79 Dry vacuum pump ....................................FIC Dust collector .............................................. 75 Electronic dosing pump .......................... 80 Energy saver ................................................ 79 Evaporator ................................................ BIC Exhibition - Engineering Expo .................. 59 Failure analysis ....................................... 53 Fasteners and steel metal components ........ 82 Ferrous casting/non-ferrous casting ............ 31 Filler compositional analysis ....................... 53 Filter press ................................................... 76 Flexible hose................................................ 83 Flexible screw conveyor ............................... 76 Forged components ..................................... 31 Forged steel gate valve ................................ 13 Formaldehyde analyser ................................ 83 FRP battery stand ....................................... 27 FRP cable tray, canopy .............................. 27 FRP grating................................................. 27 FRP handralls & fencing ............................ 27 FRP ladder, luminaries ............................... 27 FRP poles & mast ...................................... 27 FRP storage tanks, structural profiles ......... 27 FRP underground fuel tanks....................... 79 Fuel storage ................................................. 24 Gas chromatography ............................... 86 Gate valve .................................................... 13
Gear oil ....................................................... 53 General purpose grade ................................ 33 Globe valve .................................................. 13 Hast alloy ............................................... 13 Heat exchanger .............................. 8, 61, BIC Heat transfer equipment ............................. 57 Heating bath ............................................... 19 High performance liquid chromatography BC High pressure blower .................................. 57 High pressure homogeniser ........................ 19 Hose ............................................................ 83 Hot air generator ........................................ 75 Hot plate ..................................................... 19 Hot water generator .................................... 75 Hot water system ........................................ 75 Hydrogen gas detection system .................. 82 IBR steam boiler ..................................... 75 Industrial plastic component ....................... 75 Industrial valve ............................................ 31 Informatic ...................................................BC Ink quality ................................................... 33 Inline disperser ............................................ 19 Inorganic ceramic adhesive ........................... 3 Insulated box ............................................... 79 Jet black grade ........................................ 33 Kneading machine .................................. 19 Laboratory reactor .................................. 19 Laboratory software..................................... 19 Large diameter welded pipe ........................ 79 Laser particle size analyser .......................... 86 Laser particle size and shape analyser ......... 80 Lighting system ........................................... 24 Lined valve .................................................. 13 Lined valve & pipe fitting ............................ 4 Lubes - engine oil ....................................... 53 Lubricant additives and reactive surfactant. 79 Machined component ............................. 31 Magnetic stirrer ........................................... 19 Material handling container ........................ 79 Material identification................................. 53 Media and entertainment company ............ 71 Metallography ............................................. 53 Mill ............................................................ 19 Monel .......................................................... 13 Monoblock pump ........................................ 83 Multi stage cake washing ............................ 29 Multi-titration system ................................. 80 Nano enclosure ....................................... 83 Nickle aluminium bronze............................ 13 Non metallic pump ..................................... 83 Non return valve ........................................... 4 Non-IBR steam boiler ................................ 75 Overhead stirrer...................................... 19 Pallet ...................................................... 79 Petrol ........................................................... 53 Pigments quality.......................................... 33 Pilot plant.................................................... 19 Piping system from polypropline .................. 6 Plants for thermal processing ...................... 61 Plate heat exchanger ................................... 61
Plug valve .................................................... 13 Pollution control equipment .................... BIC Polymer characterisation ............................. 53 Polypropylene process pump ....................... 83 Power distribution ....................................... 24 Power rental ................................................ 24 Pressure and vacuum filtration.................... 29 Process gas blower....................................... 57 Product assemblies ...................................... 31 Production HPCL ...................................... 86 PTFE lined valve & pipe fitting................... 4 Pump .................................................. FIC, 83 Pump for chemical equipment .................... 11 PVC cable tray ............................................ 81 PVDF pipe .................................................. 82 PVDF pump ............................................... 83 Roots blower........................................ FIC Rotary dry vacuum pump............................ 57 Rotary dryer ................................................ 82 Rotary evaporator ............................ 19, 75, 80 Rotary gear pump........................................ 83 Seamless pipe.......................................... 79 Self-priming mud pump ............................. 83 Self-priming sewage pump ......................... 83 Service provider ..................................... 15, 41 Silence flow packages ................................. 57 Silicone grease ............................................. 81 Simulator ..................................................... 81 Spray dryer ............................................... BIC Stainless steel pipe....................................... 79 Strainer .......................................................... 4 Super duplex................................................ 13 Swing check valve ....................................... 80 Teflon-lined butterfly valve .......................4 Teflon-lined check valve, ball valve .............. 4 Teflon-lined sampling valve .......................... 4 Teflon-lined valve & pipe fitting .................. 4 Tefzel HHS isotactic PP material ................ 6 Testing ........................................................ 53 Thermic fluid heater ................................... 75 Thermoplastic valve ...................................... 6 Titanium ..................................................... 13 Transmission fluid....................................... 53 Truck blower ............................................... 57 Tube ............................................................ 79 Tubular drag conveyor ................................ 76 Turbine blower ............................................ 80 Turned component...................................... 31 ‘U’ tube ................................................... 79 UPLC .........................................................BC Used industrial machinery plants & equipment ..81 Vaccum conveyor .................................... 76 Vacuum booster pump ..............................FIC Vacuum or hot gas drying........................... 29 Vacuum system .........................................FIC Vertical glandless pump .............................. 83 Water soluble grade ................................ 33 Wear plate and wear pad ............................ 82 Welded pipe ................................................ 79
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Chemical al W World | November 2012
LIST OF ADVERTISERS
Advertiser’s Name & Contact Details
Aeron Composite Pvt Ltd
T: +91-79-65258500 E: firstname.lastname@example.org W: www.aeroncomposite.com Analytical Technologies Limited
T: +91-265-2253620 E: email@example.com W: www.ais-india.com Anup Engineering
T: +91-2646-250025 E: firstname.lastname@example.org W: www.megamachineryindia.com BHS-Sonthofen (India) Pvt. Ltd.
T: +91-40-23315341/45 E: email@example.com W: www.bhs-sonthofen.in Carbon India
T: +91-11-23236666 E: firstname.lastname@example.org
T: +91-79-26403839 E: email@example.com W: www.devpumps.com Dow Chemical Interational Pvt Ltd
Advertiser’s Name & Contact Details
G M Engineering T: +91-2827-287658 E: firstname.lastname@example.org W: www.gmengg.com
Hapman India T: +91-265-2517505 E: email@example.com W: www.hapman.in
Heattrans Equipments Pvt.Ltd. T: +91-79-25840105 E: firstname.lastname@example.org W: www.heattrans.com
W: www.engg-expo.com FIC
T: +91-11-45457777 E: email@example.com W: www.everestblowers.com
T: +91-79-25840105 E: firstname.lastname@example.org W: www.fluidltd.com
Schmidt Bretten (I) Pvt Ltd
T: +91-20-24338642 E: email@example.com
Shiva Analyticals (India) Limited
T: +91-80-27971322 E: firstname.lastname@example.org
Hi-Tech Applicator T: +91-79-25833040 E: email@example.com W: www.ptfeindia.com
HRS Process Systems Ltd T: +91-20-66047894 E: firstname.lastname@example.org W: www.hrsasia.co.in
IKA India Private Limited T: +91-80-26253900 E: email@example.com W: www.ika.in
W: www.shivatec-india.com Sintex Industries Ltd
T: +91-2764-253500 E: firstname.lastname@example.org W: www.sintex-plastics.com Suraj Limited
Jyoti Ceramic Industries Pvt Ltd 3 T: +91-253-2350120 E: email@example.com W: www.jyoticeramics.com
Fluidtech Boilers Pvt Ltd
E: firstname.lastname@example.org W: www.surajgroup.com Swam Pneumatics Pvt Ltd
T: +91-120-4696222 E: email@example.com W: www.swamatics.com Tata Chemicals Ltd
T: +91-22-6665828 E: firstname.lastname@example.org W: www.tatachemicals.com
Everest Blower Systems
W: www.dow.com Engineering Expo
Network 18 Media & Investments Ltd 71 W: www.network18online.com
Advertiser’s Name & Contact Details
UNP Polyvalves India Pvt Ltd Pentair Water India Pvt Ltd 11 T: +91-120-4199444 E: email@example.com W: www.pentair.com Perennial Technologies Pvt Ltd 24 T: +91-20-22953511 E: firstname.lastname@example.org W: www.powerrental.co.in Raj Process Eqpts & Systems(P) Ltd BIC T: +91-20-40710010 E: email@example.com W: www.rajprocessequipment.com
T: +91-265-2649248 E: firstname.lastname@example.org W: www.polyvalve.com Vijay Engineering Corporation
T: +91-11-23215170 E: email@example.com W: www.vechoses.com Waters (India) Private Limited
T: +91-80-28371900 E: firstname.lastname@example.org W: www.waters.com
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November 2012 | Chemical World
Published on Oct 31, 2012
Chemical World is a monthly magazine for the chemical process industry. Published by Network 18 Ltd., it delivers the latest trends and tech...