Chemical Today October 2017

October 2017 | Volume II | Issue V | ₹200

Expert Viewpoint Shipping Industry Solvents

Sector View

Crop Protection

Feature Paper

Automation

Process Ethylene Production

ETCHING

A GREEN REVOLUTION Chemical Today Magazine | October 2017

1

2

Chemical Today Magazine | October 2017

Healthy crops for

a healthy nation I

n earlier days, just stepping onto the outskirts of the city, you would start seeing plush green agricultural fields spread over acres and acres. But nowadays, this spread has become restricted and is getting positioned in between residential locations. Inspite of the growth in infrastructure, industrialization, IT, manufacturing among others, agriculture continues to form the backbone of the Indian economy. The sector accounts for about 15 percent of the country’s GDP.

CHEMICAL

TODAY

Thus, it is no surprise that the scope of agrochemicals is set to firm up in the coming years.

Added to this, the rising population and ubranization has intensifed the demand for quality food grains. All this is happening against the backdrop of declining agricultural land and reduced crop production due to pest attacks and irregular monsoons. These situations have thus justified that agrochemicals is set to become critical for our future growth. In the agrochemicals sector too, crop protection is the need of the hour.

The agrochemicals market in India is expected to become $6.3 billion by 2020, growing anually at 7.5 percent, from $4.4 billion in 2015, according to a report by Tata Strategic Management Group (TSMG) and FICCI. In the agrochemicals sector we also take a look at the pesticides market - the insecticides, herbicides and fungicides. The Indian pesticide industry is 4th largest in the world after US, Japan and China and in Generic Pesticides production in India stands at No 2 in the world after China. To know more details about the agrochemicals sector, have a look at our indepth coverage in the sector view.

For this month, we also explore the pulp & paper sector focussing on the rising global and local trends. There is a strong movement towards reducing the use of paper citing an environment friendly approach. As opposed to this, the use of paper is currently being promoted as the ecological alternative towards reducing the use of plastics. To see how to strike a balance with regards to usage of paper have a glance at our features section.

Further, we discover what is happening in process automation for the chemical industry. Read on, to know how automation can help reduce costs and achieve real-time response considering ethylene production.

To connect and to give us a bouquet or brickbats, write to editorial@worldofchemicals.com

Š 2017 worldofchemicals.com

Chemical Today Magazine | October 2017

1

Chemical Today is a monthly magazine focused on chemistry & the chemical industry.

CONTENTS SECTOR VIEW

CROP PROTECTION 40

AUTOMATION

ETHYLENE PRODUCTION 70

EXPERT VIEWPOINT

Jayakumar Krishnaswamy, Managing Director, AkzoNobel India

2

30

Eric Borgstedt,

04

NEWS NATIONAL INTERNATIONAL NEW FACILITIES CO2 PROJECT APPOINTMENTS CHEMISTRY NOBEL PRIZE 2017

06 08 10 11 12 13

EVENTS

14

PLASTIC ADDITIVES POLYOLEFIN BIOCIDES TEXTILES LUBRICANTS COATINGS

16 18 22 25 28 26

ASSOCIATION AGROCHEMICALS

34

GREEN CHEMISTRY

36

FEATURE PAPER

42

INTERNATIONAL FOCUS IRAN

44

INSIGHTS OIL & GAS, PETROCHEMICALS

40

REPORT AGROCHEMICALS CORROSION RESISTANT RESIN PULP & PAPER PROCESSING CHEMICALS WOOD PRESERVATIVE COATINGS

46 48 50 52

ACADEMIC R&D ACADEMIC SPEAK R&D YOUNG TURKS

54 60 62

JOBS

64

PRODUCTS

66

AUTOMATION PROCESS

68

EQUIPMENT AIR QUALITY MONITORING MIXING/DISPERSING MACHINE EQUIPMENT

72 74 76

GLOSSARY

78

32

Global Marketing Manager, Solvents, Aerosol & Solvents Fluorine Products group, Honeywell

Chemical Today Magazine | October 2017

QUOTES

Published for October 2017.

QUOTES

India being one of the fastest growing economies in the world, and steel finding its extensive application in areas like construction, infrastructure, power, aerospace, industrial machinery and consumer products, the sector is of strategic importance to the country. Owing to the significance of the sector and dynamic scenario in steel sector, the Government came up with National Steel Policy (NSP) 2017. With the roll out the New Steel Policy, it is envisaged that the industry will be steered with appropriate policy support in creating an environment for promoting domestic steel and thereby ensuring that production meets the anticipated pace of growth in demand

Among the government partnerships, we have inked a MoU between India and Australia on handloom, handicraft and fashion sector. Also there is a request from Australian firms to work on improving wool quality in India with Indian companies. India and Chinese government have signed a MoU so that Chinese researchers and National Silk Board can work in tandem in the field of silk research. Silk waste can be harnessed in pharmaceuticals and in beauty products and this MoU will explore opportunities in diversification and on sericulture.

BGMEA University of Fashion and Technology or BUFT from Bangladesh and India’s National Institute of Fashion Technology (NIFT) will partner for an exchange of fashion research.

Chaudhary Birender Singh, Union Minister of Steel.

Smriti Irani, Union Minister of Textile.

We want to bring the various textile value chain and handicrafts sector into one umbrella for its collective growth. We expect that the export of both textiles and handicraft products will go up after organizing events unifying the various sectors. Another major focus is to establish India as a major global sourcing for textiles and investment destination Ajay Tamta, Minister of Gujarat State for Textiles.

4

Chemical Today Magazine | October 2017

The bullish trend will continue as the demand in China, the largest consumer, is going up. The crude oil price is also looking up, lifting the synthetic rubber prices. This will reflect on the Indian natural rubber sector as well.

C P Krishnan, Whole-time Director, Geofin Comtrade.

The rise of e-commerce and access to new technologies has accelerated counterfeiting and other forms of illicit trade. That makes fighting counterfeit medical products an ever-more urgent priority for pharma companies – both in terms of patient safety and brand reputation.

Yann Ischi, Director, New Channels and Partnerships, SICPA.

Within the Volkswagen Group, we have a clear strategy for how we want to put battery-electric vehicles into series production across our brands and in many different market segments. However, a major qualification for success in the volume market is more powerful battery concepts. In Volkswagen Group R&D we are focusing on close cooperation, not only with industrial partners but also with the smart minds of the scientific community.

Dr Ulrich Eichhorn, Head, Group R&D, Volkswagen AG.

Using reverse osmosis for pre-treatment means we can reduce the consumption of specific chemicals for resin bed regeneration by around 60 percent.

Ashraf Aly Mostafa, Project Manager, Alexandria Fertilizers Co (Alexfert).

India is a very important market for polyurethanes and has a wonderful potential for growth. When leaders of the industry from all over the world get together under one roof, it leads to better production and faster growth of the industry R C Bhargava, former CEO and current Chairman, Maruti Suzuki.

India today process 565,000 mtpa of polyurethanes and this is expected to cross the 1 million mtpa mark in the next three to four years. Polyurethane is a designers polymer unparalleled by any of its kind when it comes to allowing technologists to chemically design and develop specific end products.

Mukesh Bhuta, Chairman, IPUA and Promoter, Expanded Polymer Systems Pvt. Ltd.

A host of forces are disrupting the chemical industry – geopolitical risks, changing customer desires, growth challenges, population changes, digital technology proliferation and pervasive volatility, to name a few.

Rachael Bartels, Managing Director and Chemicals & Natural Resources Global Industry Lead, Accenture.

The European market for F&F ingredients is well known for its high standards particularly for use in personal care, food & beverage products.

Philippe Faucher, Managing Director, FCI

Chemical Today Magazine | October 2017

5

NEWS NATIONAL GOVT TO BRING IN STANDARDS FOR CHEMICAL PRODUCTS

I

n order to weed out unregulated imports of sub-standard chemicals into India, the Modi government is working on introducing standards for chemical products.

“We do not have very good standards right now in case of many chemicals. The more better standards we set for consumer products, the more demand for better chemicals will be there; chemicals which are less harmful; chemicals which are more amiable to environmental sustainability. So in our ministry we have set up a committee with the joint secretary who will start this work of setting standards in chemicals. We do not have a standards cell and we have had a discussion with BIS (Bureau of Indian Standards),” said Rajeev Kapoor, secretary, department of chemicals and petrochemicals while speaking at the inauguration of “India Chem Gujarat 2017.”

“Having set the standards in products, we also need to examine to what extent we can make it mandatory, to ensure that our country is not suffering from sub-standard imports. So both the issues were discussed and will be taken forward,” he said referring to FICCI CEO forum where this issue was discussed a day before.

A report unveiled at the event held at Mahatma Mandir also bats for establishing product standards for the chemical industry.

“Establishing product standards is of paramount importance.

Availability of low quality and low performance products will eventually lead to health risks, customer dissatisfaction, negative industry image and will finally impact growth of the value chain,” states the report titled “Chemical Industry with focus to Gujarat and Speciality Chemicals” prepared by Tata Strategic Management Group. Setting of standards is one of the several steps suggested in the report that will help Indian chemical industry attain a size of

$346 billion by the year 2025. Currently (in 2016), the industry is estimated to be valued at $155 billion and contributes 3.4 percent to the global chemical industry. India ranks 14th in exports and 8th in imports of chemicals (excluding pharmaceutical products) globally. India’s chemical trade balance is negative with imports being significantly higher than the exports.

“A number of products which are either banned or regulated in western markets are still used in India. Standards which do not meet global norms will lead to lower quality products at higher prices for high-tech goods in India,” stated the report that was unveiled by Union Minister for Chemical and Fertilizers Ananth Kumar and Gujarat chief minister Vijay Rupani.

The report suggests implementation of “consumer standard” in segments like polymer additives, personal care, water treatment, flavours and fragrances, textile chemicals, colorants, construction chemicals and others. “The government should set standards and regulation across the segments to promote quality consciousness, sustainable development and efficiency improvements… Often, the domestic industry is at a severe disadvantage due to unregulated imports of sub-standard products which find a safe evacuation to India,” the report added.

It also lists out several challenges that is currently hindering the growth of the sector. “Lack of adequate physical infrastructure and sub-par chemical logistics infrastructure makes material production and movement cost intensive. Uninterrupted power supply remains a challenge for the energy intensive chemical industry. Significant glut in global chemical capacities has led to growth of imports in India. The duty structure needs rationalisation for several products in the value chain,” the report states.

Source: Indian Express

CHEMICAL TECH INSTITUTE FOR DAHEJ IN GUJARAT

U

nion minister of chemicals and fertilizers, Ananth Kumar, suggested to the government of Gujarat to set up specialized institutes at Dahej in the field of chemical engineering and technology. The suggestion was made as Dahej is now an upcoming hub for chemical industry in Gujarat as the Petroleum, Chemicals and Petrochemicals Investment Region (PCPIR) is also located there. The union minister said that the ministry is already in talks for setting up the country’s first Centralized Institute of Chemical Engineering and Technology (CICET) at Dahej.

“On the lines of CIPET (Central Institute of Plastic Engineering and Technology), we aim to set up a specialized institution. The preliminary talks are already done and this will be India’s first CICET. We hope that the state government will help allocate 10-15 acre of land for the project,” said Ananth Kumar, in his inaugural address of IndiaChem Gujarat 2017 organized at Mahatma Mandir. Gujarat chief minister gave a nod to the union minister’s proposal. “I welcome the suggestion of setting up CICETs in Dahej and as soon as we receive the proposal for this we will ensure necessary sanctions are given within a week.”Kumar compared Dahej in Gujarat as the ‘kashi’ of chemical or petrochemical industry. Industry players have pegged the Indian chemicals and petrochemicals industry to be worth $155 billion and Gujarat contributes some 50 percent to the country’s exports.

According to the Union minister, some 1.37 lakh people are currently getting employment at Dahej. “We hope to increase the number multifolds and aim at creating some eight lakh jobs by 2040,” he said.

Source: TOI

6

Chemical Today Magazine | October 2017

INDIAN OIL APPROVES RS 27K CRORE CAUVERY BASIN REFINERY PROJECT

Indian Oil Corporation logo outside a fuel station in New Delhi. Photo: Reuters

I

ndian Oil Corp (IOC) said its board has given approval to setting up of a Rs 27,460 crore refinery by its subsidiary, Chennai Petroleum Corp Ltd.

The planned refinery will be CPCLs third refinery. It currently operates a 10.5 million tonnes Manali refinery in Tamil Nadu.

The board of directors of CPCL had earlier this year recommended setting up a new 9 million tonnes a year refinery at an estimated cost of Rs 27,460 crore (with an accuracy of plus-30 percent).

CPCL, formerly known as Madras Refineries Ltd, was formed as a joint venture in 1965 between the Government of India, AMOCO and National Iranian Oil Co (NIOC) having a shareholding in the ratio of 74 percent, 13 percent, 13 percent respectively.

“The board of directors of IOC has approved for setting up a new 9 million tonnes per annum refinery at Cauvery Basin, Nagapattinam at an estimated cost of Rs 27,460 crore and for carrying out preproject activities,� IOC said in a regulatory filing.

The final approval of the project would be obtained after preparation of detailed feasibility report of the project.

Chemical Today Magazine | October 2017

It also has a smaller 1 million tonnes Nagapattinam refinery.

In 1985, AMOCO disinvested. After this, government held 84.62 percent and NIOC 15.38 percent. The government later disinvested 16.92 percent of the paid. The company was listed in 1994. IOC acquired government stake in 2000-01. IOC currently holds 51.89 percent stake in CPCL while NIOC holds 15.40 percent.

7

NEWS INTERNATIONAL WACKER TO EXPAND POLYMER POWDER FACILITY IN SOUTH KOREA

W

acker Chemie AG is expanding its existing production plants for polymer binders in South Korea. The company plans to build a new spray dryer for dispersible polymer powders at its Ulsan site.

The dryer will have a total capacity of 80,000 metric tonnes per year. Wacker also plans to build a further reactor for dispersions based on vinyl acetate-ethylene copolymer (VAE). Its dispersions will be used in the spray dryer for the production of dispersible polymer powders. With the new reactor, Ulsan’s VAE dispersion capacity will more than double. Ulsan’s plant complex, which covers the entire product chain from VAE dispersions to dispersible polymer powders, will be one of the largest of its kind worldwide.

Capital expenditures of around €60 million are budgeted for the capacity increase and for expanding local infrastructure. Scheduled to start before the end of the year, construction work is expected to be finished by Q1 2019.

“Our investment in expanding our polymer-binder production facilities in Ulsan is a key step in our global growth strategy. The additional capacity will strengthen our market position and help us meet our Asian customers’ continuously rising demand over the long term,” said Rudolf Staudigl, CEO of Wacker Chemie AG.

AKZONOBEL DEVELOPS NEW TECHNOLOGY TO MANUFACTURE ETHYLENE AMINES

A

kzoNobel’s Specialty Chemicals business said that it has developed a novel technology platform for producing ethylene amines and their derivatives from ethylene oxide. The technology significantly reduces raw material consumption per ton of product while also offers a substantially improved cost and sustainability profile when compared with existing processes.

“We are excited to announce this technology, which underlines our commitment to the global ethylene amines market,” said Joppe Smit, General Manager of AkzoNobel’s ethylene amines business.

“It offers unique benefits to our customers in comparison to mainstream technology and we strongly believe it has the potential to become a game-changer in the industry.”

The range of ethylene amines targeted includes, but is not limited to, DETA (diethylenetriamine) and TETA (triethylenetetramine), which are key building blocks in a number of growth applications such as epoxy curing, oil and road additives, and paper.

“Launching this technology strengthens our product portfolio and will further improve the company’s position as one of the leaders in the ethylene amines industry. Establishing this unique position is of strategic importance to our business,” said Egbert Henstra, managing director of AkzoNobel’s ethylene and sulfur derivatives business. The flexibility of the technology will allow the selective production of a wide range of end products, enabling the company to expand its amines product offering. AkzoNobel intends to start construction of a demonstration plant in 2018 to showcase the competitiveness of the platform and validate the products with customers.

“The development of this novel technology is another great example of AkzoNobel’s commitment to growth through innovation. In addition, it underlines our commitment to make a positive and lasting impact on a more sustainable planet,” said Peter Nieuwenhuizen, RD&I director of specialty chemicals at AkzoNobel.

8

Chemical Today Magazine | October 2017

Henstra: Launching this technology strengthens our product portfolio and will further improve the company’s position as one of the leaders in the ethylene amines industry.

P SYNGENTA, PLAINTIFFS REACH SETTLEMENT IN CORN TRAITS LAUNCH LITIGATION

laintiffs and offenders in the Syngenta MIR 162 corn litigation have reached a pending settlement to resolve litigation concerning the launch of Syngenta’s Agrisure Viptera and Agrisure Duracade corn traits.

The settlement, which is subject to court approval, would establish a settlement fund for the submission of claims by eligible claimants who contracted to price corn or corn by-products after 15 September 2013.

The proposed settlement would allow both sides to avoid the uncertainty of ongoing litigation. The settlement does not constitute an admission by either side concerning the merits of the parties’ allegations and defences.

AIR LIQUIDE ACQUIRES HEALTHCARE FIRM IN JAPAN

A

ir Liquide SA is expanding its healthcare business in Japan with the acquisition of Sogo Sangyo Kabushiki Kaisha (SSKK), a major Japanese player with a strong presence in the home healthcare and medical gases markets especially in the Tokyo region.

Present in the Japanese market for 60 years, SSKK is specialized in the medical gases field serving more than 2,000 hospitals and clinics and home treatment for patients suffering from respiratory diseases including sleep apnea, chronic obstructive pulmonary disease and chronic respiratory failure.

NISSAN ESTABLISHES NEW SUBSIDIARY IN CHINA

Chemical Today Magazine | October 2017

This acquisition represents a major development of the healthcare activity locally where it increases the number of patients served at home by Air Liquide in Japan to reach 20,000. SSKK has more than 150 employees. “With this acquisition Air Liquide pursues the development of its Healthcare activity in a growing Asian market that benefits from a strong potential. With SSKK knowhow combined with Air Liquide expertise, we will deliver greater value to healthcare professionals and patients,” said Francois Jackow, member of the Air Liquide Group’s executive committee supervising the healthcare activities.

Nissan Chemical Industries Ltd has established a new subsidiary Nissan Chemical Materials Research (Suzhou) Co, Ltd in Suzhou, China. This enables Nissan Chemical to strengthen its technical support and customer service in Chinese display market, which has significant growth potential, and to further expand Nissan Chemical’s performance materials business by actively developing products that meet market needs.

9

NEWS NEW FACILITIES CABOT, DOW TEAM UP FOR NEW SILICA PLANT

C

abot Corporation (CBT) broke ground for a new worldclass, fumed silica plant located adjacent to Dow Chemical’s Carrollton site in western Kentucky. The groundbreaking coincides with the 50th anniversary of the Dow site in Carrollton and celebrates the company’s history of innovation through silicones chemistry.

Announced in May, the new manufacturing facility is scheduled to be operational by 2020, and will extend Cabot’s long-term relationship with Dow while furthering Cabot’s position as a leading producer of fumed silica.

Upon completion, the plant will incorporate Cabot’s latest technology advances into the plant design and operations.

Additionally, the collocation enables a fence-line relationship with Dow, creating a closed-loop system that reduces transportation risks, increases manufacturing efficiencies and reduces waste.

Silicone products made at the Dow site are used by Cabot as a building block for producing fumed silica, an ultra-fine, high-

purity particle used as a performance additive in a broad range of applications. Dow, in turn, uses Cabot’s fumed silica in its silicone products as well as by-product from Cabot’s process in its operations.

“The facility will provide a long-term supply of high quality fumed silica to Dow for use in applications for fast-growing endmarkets, including packaging and construction, and will support sustainable growth for Dow, Cabot and for northern Kentucky,” said Dow DuPont CFO Howard Ungerleider.

“This is yet another example of our corporate strategy at play as we continue to invest and strengthen our core market capabilities.

As leaders in our respective industries with a shared commitment to manufacturing and safety, health and environmental excellence, collocation in Carrollton was a natural fit. We look forward to bolstering our partnership, the local economy and community with our new operation,” said Cabot’s President and CEO Sean Keohane.

TRINSEO TO OPEN NEW R&D FACILITY IN NETHERLANDS

T

rinseo (TSE) said it will open the new research and development (R&D) site in Terneuzen, Netherlands, as part of its huge investment into the company’s future. By modernizing two existing technical support center and research lab operations under one roof in Terneuzen, Trinseo has created a new plastics research center that will house 180 non-manufacturing employees.

This collaborative environment will help drive new plastics innovations within the company. The new facility will combine Trinseo’s European Development Center for Plastics with its supporting functions like supply chain, environmental health & safety, quality and procurement, forming one of the company’s European logistical centers.

Trinseo already produces a range of products on the Terneuzen site, including styrene monomer, polycarbonate, polycarbonate acrylonitrile butadiene styrene (PC/ABS), ABS, and latex binders.

These materials are produced to serve a range of industries, including automotive, construction and consumer products.

This new site will make the Terneuzen site the joint largest in Europe alongside Schkopau, Germany and bring a range of knowledge and expertise together; facilitating the creation of new innovations and providing a significant investment in the company’s future.

“Trinseo has a track record built on successful customer-driven innovations. This project will enable Trinseo to drive these developments forward and extend our unique global asset base, helping us to serve our customers even better across Europe and the rest of the globe,” said Christopher Pappas, President and CEO, Trinseo.

“This new building works as an enabler for cross-functional projects. The combination of the open office space and the new research & development facility supports Trinseo’s plans to grow the performance material division by $100 million between 2016 and 2019,” added Frans Kempenaars, director, Trinseo Netherlands.

LUBRIZOL OPENS NEW DRUMMING FACILITY, WAREHOUSE IN OHIO

T

he Lubrizol Corporation has opened a new state-of-theart drumming facility and warehouse at its Painesville Township (Ohio) manufacturing facility, both of which are part of the company’s previously announced phased investment.

Construction on the 180,000 square feet combined buildings began in April 2015. With more than half of all Lubrizol Additives products worldwide containing at least one component manufactured at the Painesville Township site, adding new manufacturing capacity and updated automated packaging capabilities was a necessity. Furthermore, these efforts are important to ensure product integrity and to improve the overall safety and efficiency of handling product drums and totes.

10

Chemical Today Magazine | October 2017

“This latest investment reinforces our commitment to the community by further ensuring the site as a key source in Lubrizol Additives’ global supply chain,” said Tom Curtis, incoming president of Lubrizol Additives.

“With our new drum filling facility, we will be able to improve safety by minimizing the manual packaging of drums, reducing packaging time for a single batch by more than 50 percent and minimizing the number of times a drum is handled by more than 70 percent. And, with 100 percent indoor storage provided by our new warehouse, we will improve the quality and appearance of packaged products delivered to our customers,” added Craig Hupp, Lubrizol Painesville Township plant manager.

NEWS CO2 PROJECT

STATOIL, SHELL, TOTAL PARTNER ON NORWAY CO2 STORAGE PROJECT

S

tatoil ASA, Royal Dutch Shell Plc and Total SA have signed a partnership agreement to mature the development of carbon storage on the Norwegian continental shelf (NCS). The project is part of the Norwegian authorities’ efforts to develop full-scale carbon capture and storage in Norway.

In June, Gassnova SF, a Norwegian state enterprise for carbon capture and storage awarded Statoil the contract for the first phase of the project. Norske Shell and Total E&P Norge are now entering as equal partners while Statoil will lead the project.

The first phase of this CO2 project could reach a capacity of approximately 1.5 million tons per year. The project will be designed to accommodate additional CO2 volumes aiming to stimulate new commercial carbon capture projects in Norway, Europe and more globally across the world. In this way, the project has the potential to be the first storage project site in the world receiving CO2 from industrial sources in several countries.

The storage project will store CO2 captured from onshore industrial facilities in Eastern Norway. This CO2 will be transported by ship from the capture facilities to a receiving terminal located onshore on the west-coast of Norway. At the receiving terminal, CO2 will be transferred from the ship to intermediate storage tanks, prior to being sent through a pipeline on the seabed to injection wells east of the Troll field on the NCS. The objective of the project, which is supported by Gassnova and other relevant governmental stakeholders, is to stimulate the

Chemical Today Magazine | October 2017

necessary development of CCS so the long-term climate targets in Norway and the EU can be reached. The collaboration will form a basis for establishing a further partnership for the construction and operational phases.

“Statoil believes that without carbon capture and storage, it is not realistic to meet the global climate target as defined in the Paris Agreement. A massive scale-up of a number of CCS projects are needed and collaboration and sharing of knowledge are essential to accelerating the development. We are very pleased to have Shell and Total as partners and believe their experience and capabilities will further strengthen this project,” said Irene Rummelhoff, Statoil’s executive vice president for new energy solutions.

“Shell has significant experience of working with governments and other experts to support the development and wide-scale deployment of CCS and are pleased to be joining forces with our joint venture partners,” added Monika Hausenblas, Shell’s executive vice president for environment and safety.

“Total’s involvement in this first commercial-scale storage project is thus fully aligned with our low-carbon roadmap and our strategy to ultimately become a global CCUS leader. The aim of this first integrated industrial-scale project, supported by the Norwegian Government, is to develop viable, reproducible commercial CCUS model in view of carrying out other major projects around the world,” added Philippe Sauquet, president, gas, renewables & power and president, strategy-innovation, Total.

11

NEWS APPOINTMENTS CHEVRON ELECTS EXECUTIVE VP AS NEW CHAIRMAN, CEO

C

hevron Corporation (CVX) has appointed Michael Wirth (56) as its new chairman of the board and chief executive officer (CEO), effective 1 February 2018. Wirth is currently vice chairman of the board and executive vice president of midstream and development, a position he has held since 2016 He succeeds John Watson, who will retire from the company and its board on 1 February 2018, after 37 years of service, including eight years as chairman and CEO. Wirth was named vice chairman of the board of directors in February 2017. Previously, he was executive vice president of downstream & chemicals for nearly a decade.

In a related move, Watson said that Mark Nelson (54) will become vice president of midstream, strategy & policy, 1 effective February 2018. In his new role, Nelson will be responsible for the company’s supply and trading, shipping, pipeline and power operating units. He will also oversee corporate strategy, as well as policy, government and public affairs. Prior to his current position, Nelson served as the president of International products, responsible for the refining and marketing businesses in Europe, Africa, Middle East, and Asia.

“Chevron has a proud 138-year history of developing the energy that improves lives and powers the world forward. I am honoured to have been selected to carry on that tradition,” said Wirth.

“Mike is ready to be Chevron’s next chairman and CEO. He has the right business experience and leadership qualities to extend the company’s success, and the board has full confidence in his ability to do so,” said Ronald Sugar, lead independent director for Chevron’s board of directors.

Michael Wirth, vice chairman of the board and executive V.P. of midstream and development, Chevron.

EQUATE NAMES EXECUTIVE VP AS NEW CEO

E

quate Petrochemical Company makes changes to its senior leadership, announces new appointments.

The board has appointed Dr Ramesh Ramachandran, currently senior executive vice president as its new CEO. In addition, it has appointed Naser Al-Dousari, manager of olefins business development at Petrochemical Industries Company (PIC) and a board member of Equate and Kuwait Olefin Company (TKOC) as its new senior VP. Dr Ramachandran will be succeeding Mohammad Hussain, who is retiring after serving as CEO for two consecutive 3-year terms and a career in the oil, gas, and petrochemical industry extending over 35 years. During his tenure, Hussain led the transition of the organization from a single-plant operation to a global leader with manufacturing operations in Kuwait, Europe, and North America.

Both Ramachandran and Al-Dousari will assume their new roles as CEO and Senior VP effective 20 November 2017 and will complete the transition process with Hussain by the end of the year.

Dr Ramesh Ramachandran, currently senior executive vice president as new CEO of Equate.

ONGC APPOINTS TECHNICAL DIRECTOR AS NEW CHAIRMAN

O

il and Natural Gas Corporation (ONGC), India’s biggest oil and gas producer has appointed Shashi Shanker as its chairman and managing director (CMD).

Shanker, is currently the director (technical and field services), ONGC, will take over the charge as CMD from October 1.

The Appointments Committee of the Cabinet under the Government of India has approved his appointment to the post of CMD, till the date of his retirement, an order issued by Department of Personnel and Training (DoPT) said. Shanker, 56, will have a nearly four-year term until March 2021.

He will replace Dinesh K Sarraf, who retires on September 30, upon attaining retirement age.

Shashi Shanker currently technical director is appointed as new chairman of ONGC. © CSR Vision

12

Chemical Today Magazine | October 2017

NEWS CHEMISTRY NOBEL PRIZE 2017

THREE SCIENTISTS WIN PRIZE FOR

IMAGING BIOMOLECULES

Jacques Dubochet, Joachim Frank and Richard Henderson, winners of this year’s Nobel prize in chemistry. photograph: university lausanne/columbia/cambridge university/epa

F

or developing the cryo-electron microscopy, which both simplifies and improves the imaging of biomolecules, Jacques Dubochet, Joachim Frank and Richard Henderson have been awarded the Nobel Prize in Chemistry.

The Royal Swedish Academy of Sciences, which awarded the prize, said the cryoelectron microscopy method has moved biochemistry into a new era.

Using this Cryo-electron microscopy method researchers can now freeze biomolecules mid-movement and visualize processes they have never previously seen, which is key for both the basic understanding of life’s chemistry and for development of pharmaceuticals.

The development of cryo-electron microscopy has provided crucial for many areas of research, not least in looking at the surface of the Zika virus. Biochemistry is now facing an explosive development and is all set for an exciting future.

Chemical Today Magazine | October 2017

As part of the prize 9 million Swedish kronor approximately $1.1 million will be divided among all the three.

Richard Henderson was born in 1945, Edinburgh, Scotland and works at the MRC Laboratory of Molecular Biology in Cambridge, UK. Electron microscopes were long believed to only be suitable for imaging dead matter because the powerful electron beam destroys the biological material. But in 1990, Richard Henderson succeeded in using an electron microscope to generate a three-dimensional image of a protein at atomic resolution. This breakthrough proved the technology’s potential.

Joachim Frank was born in 1940 in Siegen, Germany and is from Columbia University, New York, USA. He made the technology generally applicable. Between 1975 and 1986 he developed an image processing method in which the electron microscope’s fuzzy two-dimensional images are analysed

and merged to reveal a sharp threedimensional structure.

Jacques Dubochet was born in Aigle, Switzerland in 1942 and is from the University of Lausanne, Lausanne, Switzerland. He added water to electron microscopy. Liquid water evaporates in the electron microscope’s vacuum, which makes the biomolecules collapse.

In the early 1980s, Dubochet succeeded in vitrifying water – he cooled water so rapidly that it solidified in its liquid form around a biological sample, allowing the biomolecules to retain their natural shape even in a vacuum.

Last year, the Nobel Prize in Chemistry 2016 was awarded to Jean-Pierre Sauvage, Sir J. Fraser Stoddart and Bernard Feringa for the design & production of minuscule molecular machines with controllable movements that have the ability to convert Chemical energy into mechanical forces and motion.

13

UPCOMING EVENTS

EVENTS 31 October – 3 November 2017

CeMat Asia Location: Shanghai New International Expo Centre, Shanghai, China.

Organised by: Hannover Milano Fairs Shanghai Ltd Website: http://www.cemat-asia.com/EN/ The event showcases products from plant, machinery & equipment Industry.

13 – 16 November 2017

ADIPEC Location: Abu Dhabi, United Arab Emirates Organised by: dmg Global Energy Website: https://www.adipec.com/ The Abu Dhabi International Petroleum Exhibition and Conference (ADIPEC) is one of the world’s most influential events for the oil & gas industry. As a premium exhibition and conference platform, ADIPEC hosts hundreds of speakers, thousands of exhibiting companies and tens of thousands of trade professionals from around the world.

23 – 26 October 2017

KHIMIA Location: Expocentre Fairgrounds, Moscow, Russia Organised by: Expocentre Moscow Website: http://www.chemistry-expo.ru/en/ KHIMIA 2017 International Exhibition for the Chemical Industry and Science showcases products from chemical technologies, research, new materials, commercial biotechnology in medical, pharmaceutical, food, paper, textile, agricultural and electric energy industries.

01 – 04 November 2017

Paperex Location : Pragati Maidan, New Delhi, India Organised by: Indian Argo and Recycled Paper Mills Association.

Website : http://india.paperex-expo.com/Home Paperex is an internationally renowned series of exhibitions and conferences focusing on Paper, Pulp and all Allied Industries. It is the only comprehensive business platform serving the paper industry over the years.

28 – 30 November 2017

Cphi Location: Bombay Exhibition Centre, Goregaon East, Mumbai Organised by: UBM EMEA Website: http://www.cphi.com/india/ The event focuses on the future of pharmaceutical equipment and machinery. The event highlights latest knowledge and trends in the industry. It is the best place for you to source quality machinery and equipment at competitive prices and to make career changing connections.

14

Chemical Today Magazine | October 2017

PLASTIC ADDITIVES LIGHT STABILIZERS

LET IT SHINE – LIGHT STABILIZERS

EXTEND AGRICULTURAL FILM LIFE

BY HERMANN ALTHOFF

A

ccording to the United Nations estimates, over 9 billion people will be living on Earth by the year 2050. The amount of arable land needed to feed them, however, will not increase at the same rate.

Inexpensive greenhouses made from plastic film represent one way to solve this problem: With the aid of such greenhouses, the output per hectare can be increased considerably.

An important market – in several respects As a result of urban growth, and also because of increased erosion and climate change, the amount of arable land is decreasing. The challenge is how to increase the intensity of agricultural activity while keeping the products affordable.

There is limited scope to increase arable land in Asia Pacific

16

Chemical Today Magazine | October 2017

Greenhouses that can be erected very inexpensively through the use of plastic film are one possible way out of this dilemma: They provide an ideal environment for plants, protect vegetables from the effects of frost, wind and rain, ensure uniformly high quality and help fruit ripen faster. In this way, several crops can be harvested in one year. Moreover, modern plastic film can be tailored specifically to the unique light and temperature requirements of many field-grown fruits. At the same time, they help to use water more economically – a resource that has to be looked after even more closely in the coming years.

The benefits of greenhouse production are so convincing that vegetables such as tomatoes, peppers, cucumbers and eggplants are already being cultivated largely under polyolefin roofs. Currently, about 3,500,000 metric tons of film is produced worldwide every year for the agricultural market.

At the same time, the demand for agricultural film for use in greenhouses is foreseen to grow at an annual rate of about four percent. Rising demand in Asia Pacific is the major driver of the greenhouse film market. Other fast growing greenhouse areas in the world are in the Mediterranean region, South America, and Eastern Africa.

Agriculture has special requirements Optimized agriculture also includes carefully considered use of agricultural chemicals to prevent harvests from attack by pests or mold. Environment friendly solutions are advancing on this front as well. The use of sulphur, for instance, being approved for application on organic produce even in highly regulated German agriculture, is recording noteworthy growth. However, the use of elemental sulphur and other agricultural chemicals places special demands on the film used in greenhouses.

The reason for this lies in the sensitivity of thermoplastic films to UV light. This energy-rich radiation causes plastics to become brittle over the course of time via a complex, multi-step chemical mechanism. Low-cost, thin film in particular, can become useless after only a few weeks of exposure to the open sky as a result of this effect. Polymer chemistry has, of course, already developed additives that can slow this degradation reaction. However, their suitability for use in agricultural film is rather limited, since their effectiveness is reduced considerably by sulphur and acids stemming from the wooden or iron construction of greenhouses.

Halogen-containing chemicals can also contribute to the deactivation of common UV stabilizers.

Special products withstand agricultural chemicals There are, however, already alternatives in the BASF light stabilizer portfolio, specifically for the agricultural sector. Whenever converters produce a greenhouse film, they have to allow for solar irradiance, expected film durability, type of cultivation as well as type and frequency of agro-chemicals used. Chimassorb®, Tinuvin®, Tinuvin® XT and Tinuvin® NOR® light stabilizers allow converters to match any combination of these conditions.

Through use of Tinuvin® XT 100 it is possible to produce in a very economical manner LDPE (Low-density polyethylene) films that withstand severe agricultural chemicals levels and also assure a service life of two and more years even under intense sunlight.

The performance of such stabilized films is also very good when in contact with wood and metal greenhouse structures. Without a light stabilizer, they would not last even one growing cycle.

The capabilities of this UV stabilizer were verified by extensive testing at BASF over several years. This included investigating the aging characteristics of the stabilized film in detail in the laboratory. They also had to prove themselves in extended field tests in China and India.

BASF plastic additives increase durability of greenhouse film in Yunnan, China BASF’s plastic additive Tinuvin® XT 100 has been adopted

by Yuxi Xuri Plastics Production Co., Ltd, a leading greenhouse film manufacturer in China, to make low density polyethylene (LDPE) film. The film is used to cover a greenhouse for growing grapes in Yunnan province in China.

The requirements for greenhouse films are highly demanding. Greenhouse film manufacturers must allow for solar irradiance, expected film durability, type of cultivation as well as type and frequency of agrochemicals used.

Yuxi Xuri Plastics was struggling to ensure that the greenhouse film did not prematurely break down in the presence of high agrochemicals. Premature failure of the films could result in compensation payouts; and for the farmer: decreased grape yields and reduced income as well as additional costs to reinstall the film. They needed a way to stabilize the film and assure its lifetime prediction.

“With Tinuvin XT 100, it is possible for us to produce LDPE films that withstand even high agricultural chemical levels and assure a service life of up to two years, even under intense sunlight,” said Wang Ming Xian, general manager of Yuxi Xuri Plastics. “Switching to Tinuvin XT 100 helped us to regain our market share in Yunnan.”

Besides, UV absorbers which directly intercept the harmful radiation in the same way as a sun cream, compounds of the sterically hindered amine light stabilizer (HALS) class are important for protecting greenhouse films. These HALS slow down not only the weathering process due to UV radiation, but also the degradation of the material caused by heat and chemicals. Because all these trigger factors lead to the formation of free radicals – extremely reactive molecules which destroy the long molecule chains of the polyethylene – the film loses its stretch properties, becomes brittle and decays. The hindered amines of HALS compounds, incorporated in Tinuvin XT 100, intercept the free radicals and make them harmless.

With the aid of inexpensive greenhouses made from plastic film agricultural output per hectare can be increased considerably. BASF’s light stabilizer Tinuvin® XT 100 protects film made from thermoplastic resins against overly fast degradation when exposed to UV light. It also ensures the efficacy of the films over a longer period even in the presence of high concentrations of agricultural chemicals like elemental sulphur.

Author:

Chemical Today Magazine | October 2017

Hermann Althoff is Senior Vice President, Performance Chemicals, Asia Pacific, BASF.

17

POLYOLEFIN FIBRES

INVESTMENTS AND TECHNOLOGY

INNOVATION FOR FIBRES

Technology Innovator Meraklon® fibres for Hygiene applications

Beaulieu Fibres International is continuing to strengthen its position as a global supplier for polyolefin fibres. Large investments in fibres’ production are an important driver ensuring it can meet future challenges and customers’ needs. Since the acquisition of Meraklon® four years ago, the product portfolio has been broadened significantly to better serve market needs. Several investments were made to offer trilobal shaped MONO-Polypropylene (MONOPP) fibres and BICO- Fibre with a PP-core and Polyethylene (PE) sheath.

The focus however is on innovation.

Therefore, the company continues to explore possibilities for new and enhanced fibres to meet the market requirements.

Being the European leader for polyolefin staple fibres, Beaulieu Fibres International commits to staying ahead as a Technology Innovator. Today, the broad portfolio

18

Chemical Today Magazine | October 2017

includes ultrasoft fibres, high elongation fibres, high tenacity fibres, coloured fibres, BICO-fibres and fibres with various cross-sections suitable for a wide range of processing technologies. The innovation strategy is the cornerstone of its activities and key fibre innovations are set to develop which will address future market demands in segments such as hygiene, automotive, flooring and geotextiles.

Light, soft and opaque for Hygiene Beaulieu Fibres International supplies Meraklon® man-made fibres for a broad range of hygiene products. Meraklon® meets the key market requirements for softness, opacity and lightweight fabrics for baby diapers, adult incontinence products, feminine care and wipes. The fibres are tailored for the different process technologies used in the market today such as carded thermobonded, carded

Quality inspection at the fibre extrusion process.

through-air bonded, spunlace as well as needlepunch. Beaulieu Fibres International offers four fibre platforms: MONO Round PP fibres, MONO Trilobal PP fibres, BICO Round PE/PP fibres, and the recently launched Meralux platform.

On top of the advantages given by the trilobal shape, the ultrasoft property helps to achieve greater softness of the nonwoven, which is key for the hygiene and wipe market. The unique, defined cross section of the true trilobal shape achieves resilience which enhances fibre opacity and leads to a superior coverage effect and bulkiness in the finished nonwoven. This allows weight reduction of both the fibre and related nonwoven while overcoming the traditional loss of opacity associated with less material use. Meraklon® trilobal fibres are available in 1.0 to 6.7 dtex

Chemical Today Magazine | October 2017

for spun-laced and thermal calendared bonded technologies. Ultrasoft can be combined with well-being features such as Aloe Vera to add tailor-made functionality to the fibre.

The Meraklon® BICO fibres are based on a Polypropylene (PP) core and Polyethylene (PE) sheath. The PE offers excellent softness in the nonwoven. High strength and thermal stability are ensured by the solid PP core. In addition, PE’s low melting temperature at 130°C supports low bonding temperatures during processing. Meraklon® BICO fibres are globally available in 1,2dtex – 8,9dtex. The combination of properties makes the BICO fibres ideal for hygiene topsheets where softness for direct skin contact is required.

It is possible to tailor the performance through different finishes such as

permanent hydrophilic, hydrophobic, other well-being features, and additives including Ultr asoft and TiO2.

The Meralux fibres have been recently added to the Meraklon® product portfolio.

Nonwovens made with the new Meralux fibre show higher loft/bulk. Meralux’s coverage is unique and provides nonwovens with a very closed surface, without containing additives like TiO2. With the higher loft and unique coverage, softness will be provided by the choice of raw materials. Equipped with all these features, Meralux allows basis weight reductions without losing performance.

Lightweight automotive composites and face fabrics Beaulieu Fibres International has developed a range of engineered Polypropylene (PP)

19

POLYOLEFIN FIBRES

Nonwoven geotextiles

bonding fibres (dtex range 3.3 – 17) for thermoplastic lightweight composites.

Suitable composites include door panels, underbody shields, wheel arch liners, parcel shelves and head liners. Each of the bonding fibres is designed to provide a homogenous blend and optimal moulding performance. Additionally, with their inherently low shrinkage and excellent elongation properties these bonding fibres offer dimensional stability in compression moulding. The fibre recipes are designed and customised to meet the most stringent OEM requirements in terms of heat stability, VOC/FOG and interior odour requirements. The main advantages are reduced weight, lower system cost and enhanced acoustic properties.

For automotive interior fabrics, the colour development department of Beaulieu can match any of the OEM colour masters.

The fibre recipe is designed to comply with OEM requirements in terms of UV resistance, VOC/FOG emission and flame retardance (FR). The low melt PP bonding fibres contribute to a fully recyclable system (patent pending), replacing the use of latex.

Staple fibres for floorcoverings Beaulieu Fibres International offers a full dtex range of PP fibres (dtex range 5.5 – 300) for the production of needlepunched carpet for indoor and outdoor applications, such as trade and event carpets, contract and residential carpets and also sports surfaces. Coarse fibres have been developed that offer superb shrinkage

control, dimensional stability and the high resilience required for the carpet tile market. Beaulieu Fibres International is an expert in colour development and has the knowledge to provide the appropriate functionalities in terms of colour fastness, abrasion and UV resistance.

Lightweight high-performance nonwoven geotextiles The high tenacity fibres offer unique high tensile strength of minimum 52cN/ tex (6 g/denier) without compromising on elongation. The fibres (dtex range 4.4 – 11) provide opportunities to reduce geotextile system cost by maximising machine efficiency, ensuring desired performance and saving weight (up to 15% compared with standard geotextile fibres).

Beaulieu also offers a higher dtex range for environmental applications. Heavy-duty engineering & construction requests highperformance nonwovens for railways and motorways, landscaping, erosion control, waste containment and coastal protection.

Investment programme This year Beaulieu Fibres International announced new investments in both Belgium and Italy amounting to more than €80 million over 2016-2018. The investment programme is the cornerstone of its current growth strategy in both Hygiene and Industrial Fibres. The growth strategy consists of extending the production portfolio with innovations and expanding the production capacity in order to support the industry’s growth.

Staple Fibres for floorcoverings

The investments in Belgium will enable Beaulieu Fibres International to explore its new fibre technology on an industrial scaled level.

The investments in Terni (Italy) centre on a new hygiene line equipped with the latest, state-of-the- art long spin technology to meet the increasing demand for high quality polyolefin staple fibres. It will be housed in a new building offering space for further expansion, which will be constructed at the Terni site. With the extended production capacity and the expansion with new specialty PE/PET & PP/PET-BICO fibres, Beaulieu Fibres International wants to make the Meraklon® plant in Terni a true centre of excellence for Hygiene.

The new hygiene line will enable the company to add BICO PE/PET (polyethylene/polyethylene terephthalate) and BICO PP/PET fibres to its Meraklon product portfolio for the first time.

Nonwovens made with the BICO fibre combinations have a higher loft/bulk and a good resilience. The higher melting temperature of the PET in the core of the fibre allows a broad bonding window during the production process. In particular, PE/ PET fibres address the requirements of softness in the market in combination with a higher bulkiness through the PET. Beaulieu Fibres International is the biggest European producer of polypropylene staple fibre (PP fibre). Sales representatives are located in Europe, China and recently also in the US. Source: Beaulieu Fibres International

20

Chemical Today Magazine | October 2017

BIOCIDES FOOD PACKAGING

BETTER HYGIENE IN FOOD-PACKAGING BOARD

REDUCED RISK OF REJECTED TONNAGE

AND MACHINE CORROSION

Recent advances have taken some of the mystery out of bacteria problems.

Many mills can now run with less worries.

BY MARKO KOLARI AND JUHA RINTALA Introduction Board grades which are used for packaging of food or liquids for human consumption have strict requirements regarding the hygienic quality. If microorganisms are not tightly controlled, their presence in hygienic grades like liquid-packaging board (LPB) can be extremely costly. If a production lot of board is out of spec for hygiene, the converter cannot use it. A two-day outbreak of bacterial spores on a board making machine can lead to the loss of thousands of tons of finished board, at a cost of millions of Euros.

To ensure that the hygienic quality of the final board meets the required specifications, manufacturers need to apply high-performance microbe control programs on their board machines. Over the past decade, Kemira has emerged as one of the leading global suppliers of microbe control solutions to the hygienic board industry. This has been driven by novel understanding from numerous R&D programs and mill trials, teaching how to control process conditions and avoid spore formation in wet-end. Recent results have taken some of the mystery out of these frustrating and costly microbiological disturbances. Beside the scientific facts which we have discovered, we also have concluded that high hygiene can only be achieved through very close cooperation between the biocide supplier and the mill’s production personnel.

Hygiene control is all about spore control Board machines have various hygiene targets depending on food packaging enduse. For example, LPB for milk products normally must contain less than 250 CFU

22

Chemical Today Magazine | October 2017

Figure 1a Figure 1b

of living aerobic bacteria per gram of final dry board. In reality, however, we have found the quantity of aerobic bacteria in the final board depends on bacterial spores only. These spores are thermo-tolerant forms of bacteria (“sleeping” cells) that can survive heat of dryer section, whereas all active bacteria (growing cells) are destroyed by the drying heat. Therefore, spores are the real ‘bad guys’ regarding food board hygiene. Figure 1 gives additional examples of this.

Figure 1a shows scanning electron microscope picture of cells of non-spore forming paper machine bacteria growing on stainless steel surface. None of these growing cells can endanger hygiene of final board as they are effectively killed by heat of drier section. Figure 1b shows an electron microscope picture of a mature spore just being released from a Bacillus cell. If present in wet paper web these spores will survive through heat of the drier section and are alive in the dry finished board.

Hygiene control is all about spore control.

Trouble on the machine, despite high biocide levels In our work with hygiene in mills, we have observed several food-packaging board machines that were running significant amounts of biocides but still having periodical difficulties in meeting strict endproduct hygienic specifications. Adding to the mystery, some machines can run every day with high amounts of growing bacteria in process water and still not experience spore issues.

situation for the mill management, operations and sales teams. When we came in and worked closely with the mill team, we were able to get them comfortably and consistently in specifications by applying a different control philosophy than earlier.

Achieving superior hygiene on a board machine requires close cooperation between the mill and the partner taking care of biocide dosing and monitoring spore control performance. Only complete cooperation enables preventing problems rather than only reacting to them. Success also requires intensive monitoring of wetend and all raw materials coming into the process. It may initially seem like a large effort to make, but the payback to the mill in terms of reduced lost tonnage is very significant.

Corrosion risks of intensive biocide programs Another issue that, unfortunately, does not receive much attention until it is sometimes too late is corrosion of machinery. We have information on over 30 paper and board machines that have experienced costly corrosion issues due to intense use of biocides. Machine corrosion due to biocides is an elevated risk especially in foodpackaging board machines which are often using biocide-intensive control strategies

due to the strict hygiene requirements. We have conducted basic research on vaporphase corrosion mechanisms in paper machines to improve understanding and mitigating any potential corrosion risks.

There were two key findings. Firstly, the different stabilized chlorine compounds currently on market demonstrate corrosion rates of widely different magnitudes when applied at equal dosage level in terms of active chlorine content. Secondly, laboratory experiments can never fully demonstrate the true corrosion potential in vapor phase in an individual paper machine due to machine specific conditions.

Therefore we developed an on-line probe for measuring changes in vapor-phase corrosion rate. This probe is sensitized so that it corrodes all the time and responds to chemical changes in vapor phase thereby giving a possibility to observe changes and react before corrosion actualizes in the machine. More information on biocides and corrosion is shown in Figures 2 and 3.

Figure 2. Kemira CorrStrix™ on-line

data from drying section. A new biocide program was started after shutdown with no other changes done in the wet-end of this machine. As a response the average rate of vapor-phase corrosion was significantly reduced compared to previous program.

Figure 2

R&D on spore control Our R&D programs have given us unique insight into the mechanism of sporulation, understanding what triggers it and explaining the above mentioned differences in board making processes.

This new understanding, in turn, has supported successful application of biocide solutions on hygienic board machines. One of our key findings is that the total quantity of vegetative cells and spore counts do not directly correlate. Some process tanks can have higher bacterial content but not spores, whereas another tank that may look fine based on lower total bacteria content, but is really surprisingly high in spore content.

Based on the experience gained through both R&D studies and numerous mill trials, we are now confident that we have good programs to control these hygiene issues.

We have worked in many mills which were experiencing hygiene troubles before we got involved, and had tried and failed with other biocide solutions. Extended period of running barely within specifications, very “close to the edge”, leads to a nervous

Chemical Today Magazine | October 2017

23

BIOCIDES FOOD PACKAGING

Conclusion Safely achieving hygienic conditions on a food-packaging board machine is not simple. The mechanisms of contamination and corrosion are both complex. As a result of studies both in the laboratory and mills, Kemira has created a complete package to reduce corrosion risks to machines, while at the same time ensuring hygiene in the board products.

Close co-operation among our Sales, Applications and R&D groups with the board mills has provided customers with clear competitive advantages in their board mills: Stable production combined with continuous improvement in hygienic quality. Long-term control of bacterial spores on a board machine requires special competence to select the best control strategy for each individual machine. There is no universal spore control philosophy that best fits all machines in the world.

Figure 3a

Kemira’s toolbox to combat spores in foodpackaging board is unique and the most comprehensive on the market. It includes patented products and treatment concepts such as FennoClean D and patented on-line monitoring tools such as Kemira FennOx and CorrStrix. When applied correctly, these can help you take the mystery, frustration and costs of contamination out of your food-packaging board machine.

Figure 3b

Figure 3.

Uncontrolled growth of bacteria in wet-end can cause significant build-up of biofilm on machine surfaces (a) that increases risk for web breaks and dirt defects in finished product. Biocides are frequently added both for providing hygiene of finished board and for providing machine surfaces free of such biofilms.

However, if unaware of potential corrosion risks an intense biocide use can create costly corrosion damages (b). More information about corrosion safe use of biocides in the article.

FennoClean, FennOx and CorrStrix are trademarks or registered trademarks of Kemira Oyj or its subsidiaries.

Authors:

Marko Kolari is Senior Principal Scientist, Microbiology & Biotechnology, R&D and Technology EMEA and Juha Rintala is Marketing Manager, Deposit Control, Pulp & Paper EMEA, both from Kemira Oyj, Finland.

24

Chemical Today Magazine | October 2017

TEXTILES ENZYMATIC PROCESS

ENVIRONMENT FRIENDLY ENZYMATIC DESIZING AND SCOURING PROCESS

PAD-BATCH AND CONTINUOUS PROCESS WITH SINGLE PRODUCT

BY VIBHAV NAWATHE AND SUDIPTA SENGUPTA

I

n today’s time when the environmental responsibility is becoming a challenge for textile processers, more and more people are looking towards chemical suppliers for a solution. Buyers also prefer textile processors who employ green chemistry and in turn reduce the overall environmental impact viz. carbon footprint etc. In a broad way the textile processing includes Pretreatment – Desizing, Scouring, Bleaching & Mercerization, Dyeing and washing, Printing and Finishing in which maximum ETP load and utility consumption happens during pre-treatment particularly if done in continuous process. So, the need of the hour is to develop process or product, which can substantially reduce the ETP load.

Another aspect, which really impacts the processors is the high probability of catalytic damage when the fabric is processed through continuous bleaching range. Normally it is taken care by using sequestering or chelating agents during continuous bleaching. The pH, which comes out during the bleaching is highly alkaline which in turn makes the bleaching harsh. The real challenge is to reduce the

Chemical Today Magazine | October 2017

bath pH (by using minimum amount of caustic) so as to make the process gentler while continuous processing. One of the process of doing it is to carry out an enzymatic scouring along with desizing during pad-batch process or pad-steam process, which was not so effective as Alpha amylase and pectinase produces optimum performance at different pH. The need is to make a stable product with combination of alpha amylase and pectinase and a special detergent or wetting agent, which will not affect the performance of amylase and pectinase.

It was not possible to meet all the above parameters and getting a consistent result was always an issue, but with the use of Ezyscour SPE results can be achieved without compromising the quality of processing. It is the combination of detergent, pectinase and alpha-amylase which is stable for long time, doesn’t compromise with either pectinase or amylase performance and gives excellent result either in Pad-Batch or in Continuous process. The advantage of the product is that, in case of Pad-batch process only an hour’s time is required for batching

contrary to existing norms of 6-8 hrs, where as in continuous process, it requires no steam and dwelling time of 15-20 min at 60OC is sufficient to complete the desizing and enzymatic scouring process.

The quick acting enzymes present in the formulation ensures that the desizing and scouring action are over very quickly and no need of steam required during continuous desizing. Once this process is complete the caustic concentration in the bulk can be drastically reduced and the caustic required will be only to achieve the bleaching pH and not for scouring. The product and process are robust in nature and user friendly and the robustness of the product makes it stand out from the rest.

It has robust performance through pH 5.5 to 8.5 though the optimum performance is at 5.5. This actually takes out the very practical problem of pH dependency of the process where slight variation in standard condition drastically affects the final result.

The product Ezyscour SPE is the answer to the environmental concerns of textile processing industry without compromising the quality of processing.

Authors:

Vibhav Nawathe is Senior Vice President – Textiles & Sudipta Sengupta is Head - Application & Research Center at Resil Chemicals Private Limited.

25

COATINGS SURFACE TREATMENT

BENSELER DRIVES AUTOMOTIVE

LIGHTWEIGHTING AND SUSTAINABILITY TOTAL SOLUTIONS APPROACH TO METAL PRETREATMENT

A

s a tier 1 supplier to OEMs in the automotive industry, BENSELER-Group has been using metal surface treatment solutions from Henkel Adhesive Technologies for many years. With innovative solutions focused on the specific requirements of lightweighting metals, such as aluminum and magnesium, Henkel provides a comprehensive onestop portfolio of BONDERITE process technologies that meet all needs across the entire value chain of metal pretreatment.

BY HEIKO NUERRENBERG

I

ncreasingly tighter regulatory demands and growing consumer awareness for better fuel efficiency and reduced emissions have created a strong trend among automotive manufacturers to move from traditional steel sheet or galvanized alloys to mixed metal and very light metal substrates that offer significant weight savings. The number one challenge of ensuring a reliable long-term protection of metal components against corrosion requires a solid understanding of the inherent characteristics of each specific substrate or alloy.

Lightweight brake disk shield made of aluminum, surface treated by BENSELER-Group in a chromium-free Henkel BONDERITE process using (Photo: © BENSELER-Group, TA10)

Successful anti-corrosion treatment of light metal parts can be divided into three fundamental, successive phases – degreasing, pickling (acid dip), and chromium-free conversion or phosphating – in a sequence of multiple active and rinse baths.

In addition, as each light metal alloy reacts quite different to pretreatment when compared with iron based metals, each step must be closely adapted to the precise behavior of the material.

In contrast to aluminum, for instance, magnesium has a limited suitability for zinc phosphating and is more ideally pretreated in a zinc-free conversion process.

With the introduction of BONDERITE Metal New Technologies (M-NT) in 2006, Henkel spearheaded the development of revolutionary phosphate-free pretreatment processes for multi-metal and light metal substrates (Fig. 1).

One face to the customer Today, Henkel has established itself as a global leader in metal surface treatment processes and meets the needs of its customers in this demanding market with a diversified range of BONDERITE solutions tailored to specific metals while minimizing costs and maximizing sustainability. The innovative portfolio offers nickel-free, chromium-free and zincfree processes for all kinds of individual as well as multi-metal substrates. More recent developments include highly specialized formulations, such as

26

Chemical Today Magazine | October 2017

BONDERITE M NT 160/161 for magnesium/zirconium and M NT 400 for aluminum/titanium as well as the BONDERITE M ZN Two Step Process and M NT TecTalis for combinations of steel or galvanized steel with aluminum. Henkel’s BONDERITE portfolio offers customers a “total solutions” package of chemistry and expertise covering all aspects along the entire value chain before, during and after pretreatment in the metals industry (Fig. 2).

The result is a “one face to the customer” approach, which BENSELER-Group has been taking advantage of since 1998 to speed its growth in the metals industry.

The automotive tier 1 supplier, based in Markgroningen near Stuttgart, operates 9 production sites in Germany, the Czech Republic and Switzerland, serving virtually all German, European and international car manufacturers with three business units: Organic Coatings, Thin-Film Corrosion Protection Systems, and Deburring.

In 2016, the company opened a second plant in Bogen near Regensburg, with a production area of approx. 15,500 square meters (50,000 sq ft) dedicated to cathode dip coating (CDC) of automotive body parts and structural components (Fig. 3).

Cathode Dip Coating, or CDC, is a widely used electrochemical deposition process (EDP) for anti-corrosion treatment of small and large, complex metal structures in

Fig. 2 Henkel’s BONDERITE solutions cover the entire value chain before, during and after pretreatment of single-metal as well as multi-metal substrates (Graphic; © Henkel, TA10)

high volumes. The new Bogen plant is one of three BENSELER-Group CDC operations in Germany and has a capacity for coating approx. 1,000 square meters (10,750 sq ft) of metal surface per hour. With sizes of up to 3,300 x 1,250 x 1,900 mm, many parts are made of galvanized sheet steel or steel alloys, increasingly followed by aluminum. The sequence and chemistry of baths in this plant have been optimized to the range of coatings and can be fine-tuned even to quite individual steel and aluminum alloys. Furthermore, BONDERITE M NT 2040 is used in the deoxidizing and chromium-free conversion steps for aluminum substrates. The final step for steel parts before immersion coating is a special tri-cationic zinc phosphating treatment. Both techniques serve to activate the substrate and create an ideal surface for subsequent coating and excellent corrosion protection (Fig. 4).

Fig. 3 BENSELER-Group’s new CDC plant in Bogen (Germany) features a sequence of 14 active and 16 rinse baths for the surface treatment of various different light metal substrates. (Photo © BENSELER-Group, TA10)

Next-generation surface treatment solutions, today With the development of BONDERITE M NT 160/161, Henkel has underscored its unique position as a surface treatment specialist for light metals, which are characterized by rapid growth in automotive due to their enormous lightweighting potential. The advanced M NT 160/161 process can not only be used in the conversion step of magnesium/aluminum hybrid substrates, but is also the only solution world-wide to provide magnesium parts ready for painting at the end of the very same day. The non-chromate process forms a layer that improves the paint adhesion on the substrate while offering enhanced corrosion protection. The dip bath is typically maintained at moderate temperatures of 15 to 30 °C. Conversion times range from 15 to 180 seconds, depending on the size and complexity of the components. Fig. 5 illustrates the chemistry of the technology.

Fig. 4 Zinc phosphate well activated (at right) to form a fine-crystalline adhesion layer on the substrate (scan electron microscope images, magnified 400 times) for subsequent anti-corrosion priming (SEM scans: © Henkel, TA10)

A complementary system for customers running extensive metal surface treatment processes, Henkel’s unique LINEGUARD® process control equipment combines over 40 years of experience in this demanding market with state-of-the-art PLC, sensor and HMI technology. LINEGUARD is available in modular hardware and software configurations (Fig. 6), adapted and seamlessly integrated to provide a total system solution tailored to each customer’s individual needs, from chemical pretreatment and pumps to automated process data acquisition and comprehensive documentation. BENSELER-Group here still relies on an alternative automated system.

Conclusion Henkel’s innovation leadership and global capabilities give customers a competitive lead in surface treatment, helping them take advantage of the growth potential in lightweighting metal applications throughout automotive and other important industries. With comprehensive support of all their alloy-specific needs in metal pretreatment, including cuttingedge process technology for light metal, multi-metal or hybrid substrates, automotive suppliers like BENSELER-Group can offer their end customers best-practice solutions that ensure maximum productivity, effectiveness and sustainability.

Fig. 5 Fast, effective and sustainable: chromium-free conversion coating of magnesium substrate (Graphic: © Henkel, TA10)

Bonderite and Lineguard are registered trademarks of Henkel and/or its affiliates in Germany and elsewhere.

Author:

Heiko Nuerrenberg, Metal Pretreatment at Henkel Adhesive Technologies.

Fig. 6 LINEGUARD pilot plant for comprehensive process control and documentation in metal surface treatment (Photo: © Henkel, TA10)

Chemical Today Magazine | October 2017

27

LUBRICANTS ANTIOXIDANTS

EXTENDING LIFETIME OF

FUELS AND LUBRICANTS

SONGWON’s Aminic and phenolic antioxidants designed to extend lifetime of fuels and lubricants and protect equipment and engines

28

Chemical Today Magazine | October 2017

Protecting equipment and engines Ever higher performance is required of motors and machinery as a result of increasingly stringent emission regulations as well as demand for fuel efficiency and durability of vehicles and equipment.

Lubricants are crucial to achieving today’s standards. They keep moving components of motors apart, reduce friction between them, transmit power, heat or cool surfaces, help to flush away contaminants and foreign particles, and prevent corrosion and wear. In other words, they prolong the useful life of vehicles. They also help to reduce consumption of oils and other fuels.

Manufactured by refining and processing different base oils, lubricants are used in the automobile, marine, aviation and railway industries as well as in machinery and equipment for construction and much more.

Environmental considerations and the current focus on green technologies are attracting attention to biolubricants and biofuels derived from plants and animals. Plant-based lubricants include canola, castor, palm, sunflower seed and rapeseed oil, while lanolin is one of the animal oils used.

Additives are used in small quantities to extend the life of lubricants, reduce viscosity, prevent deposits and foam formation, control viscosity and increase resistance to temperature fluctuations. Antioxidants are particularly important additives, because they prolong the life of oils, lubricants and fuels, both on the shelf and in use.

Extended focus to the fuels & lubricants industry SONGWON, the second largest manufacturer of antioxidants for polymer stabilizers in the world, offers an extensive array of specialty chemicals for a diverse range of industries including packaging, textiles, electronics, adhesives, building, agriculture, automotive and lubricants.

Founded in 1965 in Busan, its headquarters is now based in Ulsan, South Korea – strategically chosen for easy access to the Pacific. SONGWON boasts state of the art manufacturing facilities in Ulsan – an oil, petrochemical and automotive hub.

SONGWON is also the largest producer of phenolic antioxidants in Asia. The company is a relative newcomer to the fuels and lubricants industry, with roots firmly entrenched in plastics additives. In 2015, SONGWON celebrated its 50th anniversary and in the same year, SONGWON extended its focus to supplying antioxidants for the fuels and lubricants industry. Olivier Keiser, leader of fuel & lube Additives, indicates it has been a strong development of the business activities due to the clear value proposition SONGWON is bringing.

The company develops, manufactures and supplies antioxidants for lubricants and fuels that provide protection at high temperatures and extend engine oil drain intervals.

A significant shift in the competitive landscape, a globally expanding antioxidant market and particularly a growth in demand in Asia from companies relocating production of lubricants, a robust performance in SONGWON’s core business, and a management team prepared to invest in long-term sustainable growth, all combined to enable a seamless transition into the lubricant antioxidant market.

This allowed SONGWON to produce the key aminic and phenolic antioxidants for lubricant applications of these products with world scale production size in the same facility, said Gerard Mulqueen, global business manager,

fuel & lube additives, enabling SONGWON to make inroads in the estimated 250,000 metric ton per year market.

“With more than 50 years’ experience in stabilization technology, and as a major supplier of antioxidants, we are well placed to extend our additives range for fuels and lubricants,” said Keiser. “We are investing in production capacity as well as in research and development in anticipation of new industry standard requirements. In parallel, we are continuously engaging with our customers in order to develop ongoing, innovative solutions.”

To emphasize this commitment to the Fuel & Lube market SONGWON recently launched SONGNOX® L670. This industry standard nonylated diphenyl amine antioxidant (ADPA) is used with SONGNOX® L135 liquid phenolic antioxidant in automotive formulations.

“Aminic and phenolic antioxidants retard oxidation in the oil by reacting with radicals produced in the lubricant: in engine oils this helps to extend the drain interval. By preserving the integrity of the oil for longer periods antioxidants help maintain viscosity, reduce deposit and foam formation, and guard against the production of corrosion species, whilst protecting the oil at higher temperatures,” said Mulqueen.

SONGNOX® L670 and SONGNOX® L135 are both manufactured at SONGWON’s South Korean plant in Ulsan and supplied worldwide. Economy-of-scale production units in South Korea and backward integration of the key raw materials for antioxidants ensure reliability of supply worldwide and add value throughout the supply chain.

Innovation a key driver In line with the company’s aim to strengthen its position on the global specialty chemicals playing field, SONGWON this year officially opened a new Technology Innovation Center in Maeam, Korea. SONGOWN says that the new center is a major milestone for the company. Not only will it support innovation, it will enable SONGWON to take another key step forward in entering new business areas with high value and sophisticated technology.

Located on the company’s Maeam site in South Korea, the center encompasses 32,000 m² and is currently 3 stories high. However, keeping an eye on the future, the facility has been especially designed with future expansion in mind and is constructed to allow the company to add two more floors later as required. The new facility hosts both R&D, Global Application Community and Technical Service. It enables the organization to leverage the synergies between the groups, consolidate SONGWON’s technologies and support the complete development of new products from the design phase to final customer applications.

The center supports the needs of the existing and new SONGWON businesses and includes analysis labs, synthetic rooms, clean rooms, kilos lab scale rooms, polymer processing and application labs.

SONGWON’s Technology Innovation Center has been laid out to provide a stimulating environment that fosters creativity, forward-thinking and facilitate the exchange of know-how. It will also support SONGWON’s efforts to translate market needs into innovative product solutions quickly and efficiently. Having such a facility means that SONGWON can continue its legacy of innovation by enabling the company to analyze, evaluate and launch new products at an industry leading pace which will ultimately create value for customers and help them gain a competitive advantage.

Source: SONGWON

Chemical Today Magazine | October 2017

29

EXPERT VIEWPOINT SHIPPING INDUSTRY

Jayakumar Krishnaswamy, Managing Director, AkzoNobel India discusses ways in which the shipping industry is experiencing tectonic shifts of change and how the company is working towards revolutionizing this global industry.

BRINGING A

DIGITAL REVOLUTION IN SHIPPING 30

Chemical Today Magazine | October 2017

BY SHIVANI MODY Future of things to come in the marine industry.

Our team of chemical engineers, material scientists, biologists, hydrodynamic experts, physicists and – nowadays – digital innovation specialists have been developing innovative technologies for decades to transform the shipping industry.

Working on projects like biomimicry, drone technology, intelligent sensors and big data applications, we now have the ability to care for vessels at agreed performance levels with our advanced coatings and technology.

The marine industry is starting a new chapter in terms of the way ships are designed, built, operated and maintained.

Autonomous vessel operation, digital connections through global satellites and new powering solutions will lead to a whole new generation of naval architects and we will witness much more collaborative partnerships across the value chain.

Sustainability is a key driver to develop these exciting technologies and it is the only way forward in shipping. With that belief as our compass, we’ve developed a number of initiatives to limit environmental impact and increase the sustainability of products across the entire industry.

Reducing the environmental impact of shipping and increasing the share of sustainable products is not just our responsibility. We work closely with other key industry players like our recent agreement with Maersk, in which we are creating transparency on sustainable best practices in the supply chain and reducing carbon emissions. We have also partnered with the Volvo Ocean Race and The Ocean Clean Up to develop programs that will drive sustainability.

AkzoNobel is committed to undertake tangible actions towards lowering carbon emissions of the world’s shipping fleets, reducing emissions of biocides, and removing plastics from the world’s oceans as a part of its landmark initiative called sustainable shipping.

Inspiring development of improved digital solutions in marine industry.

The shipping industry is currently experiencing exciting and long-overdue tectonic shifts that will change it forever.

AkzoNobel is one of the companies to help revolutionize this global industry. As changes are taking hold across the industry,

Chemical Today Magazine | October 2017

the momentum to do things differently is growing and creating endless opportunities to innovate, create and transform.

We continue to stress the development of autonomous vessel operation, digital connections through global satellites and new powering solutions that will lead to a whole new generation of naval architects.

Digital innovative technology for the shipping industry.

At AkzoNobel we are already using Big Data, to create a digital consultancy tool called Intertrac Vision, the first ever digital tool for the shipping industry that can accurately predict the potential fuel and CO2 emission savings.

Intertrac OBM (On Board Maintenance), the latest advancement to the Intertrac range will help customers reduce cost by up to 20 percent. This online tool records, visualizes and analyzes Seastores purchasing patterns by vessel and fleet. Intertrac OBM provides greater transparency and control over OBM paint consumption as well as purchasing and has several features. These include streamlining purchasing to avoid small quantity orders and additional administration costs. It also identifies alternative ports with greater savings potential, and optimizes product choice to provide cost savings.

In addition, AkzoNobel has previewed a new web based tool Intertrac Perform.

Currently, launched as a pilot initiative, this tool measures and monitors hull performance data and validates it against predictions made by Intertrac Vision, AkzoNobel’s landmark big data tool for coating performance prediction.

Developed in partnership with University College London, this software builds on the capabilities of Intertrac, a tool which analyses the fouling challenges of different trading routes and Intertrac Vision, launched in 2015, a big data tool which combines this data with hydrodynamic analysis to predict hull performance.

With Intertrac Perform, the Intertrac range forms a complete digital solution for predicting, measuring and analysing coating performance, without the need for any expensive equipment to be installed.

Incorporating the usage of drones in shipping industry.

AkzoNobel, oil & gas tanker operator Barrier Group and DroneOps have recently joined forces to develop a drone capable of remotely inspecting enclosed spaces

and ballast water tanks. The project will use advanced virtual reality technology to deliver safer, more accurate evaluations of ballast water tanks, offshore wind farms and other enclosed or difficult to access spaces on ships and marine structures, including inspections of coatings and corrosion.

Traditionally, inspections are carried out by crew, surveyors or independent inspectors – a potentially risky activity which represents one of the most common causes of workrelated fatalities in the industry.

As the new project progresses, the drone will undergo flight trials at AkzoNobel’s UK-based coatings test site and Barrier Group’s indoor training facility.

Future dynamics of robotic technology in shipping industry.

Robotic technology is going to play a major role in the future of sustainable shipping.

In 2016, AkzoNobel successfully conducted a fully robotized spot-repair, including washing, spot-blasting, and coating application, on a Very Large Crude Carrier (VLCC). We are currently developing drones for the inspection of enclosed areas like cargo tanks and hulls where the risk of injury to people is high. In addition, Remotely Operated Vehicles (ROVs) are being engineered for sustainable underwater cleaning.

Shaping the future of shipping industry.

AkzoNobel has recently announced a new customer experience aimed at bringing company’s wealth of performance management expertise to the fingertips of its customers called ‘Digital Voyage’. This is powered by Big Data, which will provide owners and operators with instant access to the information they need to make smarter decisions, from efficiency monitoring to purchasing optimization. This will also increase transparency throughout the industry, and giving owners and operators more control over their performance and efficiency management. The integrated suite of digital tools includes Intertrac OBM (On Board Maintenance) that will help customers reduce costs by up to 20 percent.

Customers will also be able to download the recently launched International Marine Coatings App, a mobile-based application that provides customers with increased convenience and flexibility in accessing the company’s wealth of coatings data.

31

EXPERT VIEWPOINT SOLVENTS

Eric Borgstedt, Global Marketing Manager, Solvents, Aerosol & Solvents Fluorine Products group, Honeywell, talks about the changing quotients of end user industries, which is constantly keeping the solvents industry on its path of innovation.

LEADING THE MARKET

WITH PANACHE

BY SHIVANI MODY Trends and developments in the solvent industry.

There are two significant trends impacting the global supply and use of industrial solvents: A regulatory environment that drives adoption of products that are safer for the environment and the user, and new, more challenging technical requirements resulting from increased component complexity.

Regulations tend to drive awareness of both hazards and potential solutions. In the recent past, we have seen numerous countries recognize the scientific data and act to control or phase out many popular cleaning solvents including n-methyl pyrollidone (NMP), halogenated

32

Chemical Today Magazine | October 2017

CFCs (TCE and PERC) and HCFCs like HCFC-141b, among others. The increased scrutiny led to the development of several commercially viable and readily available alternatives including hydrofluoroethers (HFEs), hydrofluoro-olefins (HFOs) and workplace mitigation techniques to reduce worker exposure. Some of these technologies have very favorable environmental properties. HFO-1233zd has an ultra-low global warming potential of 1, is non-ozone-depleting, and is nonflammable. This new class of products is becoming the standard for environment and worker safety.

The second trend is driven by the increasing complexity of modern cleaning and surface treatment. Mechanical parts

and components, such as those employed in the aerospace and medical device applications, are generally shrinking in size and increasing in complexity. Conventional cleaning solutions are limited in their ability to adequately penetrate and remove contaminants due to their relatively high surface tensions. Surface tension is related to cleaning power, and this is one aspect any practitioner must consider when changing solvent operations.

Growth opportunities for solvents.

The global market for solvents is quite large and growing, not just with industry growth but also by gaining share from not-in-kind aqueous cleaning as global sensitivity to the

responsible supply and use of scarce water resources is increasing. With that said, growth opportunities tend to be segmented and regionally specific. Where legislators have acted to encourage conversion to modern alternatives, we see significant opportunities even in those segments that are historically slow to change.

Sectors with growth potential in emerging markets.

Markets segments that place a high premium on precision cleaning for critical end use applications (eg. medical device assembly) will always be first to explore new alternatives. But the price of new alternatives can sometimes discourage early adopters in the most cost sensitive segments. This is always a concern when adopting any new technology. So many use a total cost of ownership approach that includes indirect factors like water usage/savings, regulatory compliance, and enhanced workplace safety that can be factored into the analysis. When all costs incurred or avoided are balanced, new technology is more attractive than many people might think. And, a growing base of users tends to drive the price of new products down over time as manufacturers benefit from economies of scale.

Understanding customer demands.

Solvents have many different industrial users, and the requirements depend on their location in the value chain and ultimate customer requirements. For example, solvents used as feedstock or chemical intermediaries have very different requirements compared to solvents used for component cleaning just prior to mechanical assembly. Very generally speaking, solvent users look for performance, compatibility with existing production schemes, operating economics, regulatory compliance, and workplace or end-user safety.

Market potential of solvents in developed and emerging markets.

Industrial solvent use is quite diverse and defies broad classification regardless if located in a high-growth region or developed market. The first and most important common denominator is acceptable performance in the target application, with changes in operating costs perhaps more important in some regions/applications than others.

Insight into company’s solvents/ fluorinated solvents business.

Honeywell invested significant resources to develop HFO solvent technologies into

Chemical Today Magazine | October 2017

a global solution engineered to balance compliance with current and proposed regulations with improved performance at a reasonable cost. Honeywell’s HFO products are now providing environmentally preferable solutions in automobile air conditioning, industrial chillers and commercial refrigeration, consumer air conditioners, and polyurethane insulation, to name a few.

Honeywell Solstice® Performance Fluid solvents are being used for critical cleaning and solvency in a growing number of aerospace, medical device, micromachining, and automotive markets worldwide. The National Aeronautics and Space Administration in the United States recently selected Solstice Performance Fluid as its preferred solvent to replace AK-225 for critically cleaning in oxygen propulsion rocket systems. The list of end uses is growing and diverse, including replacing HCFC-141b in HVAC/R refrigeration circuit cleaning and HFC-365mfc in many types of aerosol spray formulations.

Company’s business plans in Asia Pacific region.

Honeywell’s Fluorine Products business has significant presence and footprints in Asia Pacific regions with decades-long history. As of today, Honeywell Fluorine Products business is serving customers across the region with its advanced nonozone-depleting and next-generation low-global-warming-potential solutions and address the environment needs. Asia Pacific region continues to be a key growth engine for Honeywell and we see great micro trends in the regions as environment protection, energy efficiency, urbanization and smart manufacturing, which are all great opportunities for us to drive our refrigerant, foam, and aerosol & solvents business.

Honeywell will continue to invest R&D and manufacturing capabilities in the regions and provide APAC customers with more innovative and environmental solutions to meet their special needs, and we can also leverage the experience and domain expertise to global, which is the core for Honeywell’s “East for East, East to Rest” strategy.

Focus on R&D and innovation.

Honeywell has invested significant technical resources in the development of HFO solvent technologies, introducing Solstice Performance Fluid, PF-2A, PFHP, PF-C and EZ Flush. Honeywell is continuing to devote effort to develop HFO solvent technologies to expand the portfolio of technical cleaning capabilities

to meet the broad range of current and future customer needs.

Challenges in the industry.

Manufacturers of solvents need to ensure their innovation keeps pace with the challenging cleaning needs of industry and customers. As parts and components are getting smaller and more complex, it becomes critical to deliver more functionality. Also the difficulty, to remove all soils and contaminants from the internal and external surfaces of these parts, increases. In addition to be able to clean, it is also important to confirm that their solvents meet regulatory compliance requirements around the world.

Making sustainability a reality.

Fluorocarbons (CFCs, HCFCs and HFCs) have historically been used as safe and efficient chemicals for a variety of applications, including working fluids for refrigeration and air conditioning, blowing agents for plastic foam insulation, aerosol propellants, and industrial solvents.

However, due to environmental concerns over ozone depletion and global warming, these historical materials have been or are in the process of being phased down.

Honeywell, a major global producer of fluorocarbons, has stepped up to the challenge of developing a new generation of fluorocarbons that maintains or improves the excellent performance attributes of the prior generation fluorocarbons while reducing environmental concerns. The new generation materials, which are of the class of materials known as haloolefins, are being commercialized by Honeywell today under the Solstice® name. The Solstice® family of products includes several products specifically engineered and optimized to meet the needs of the myriad of end-use applications where these products will be used. Solstice® Performance Fluid has been developed for the solvents industry.

It has excellent performance but with a significantly improved environmental profile.

Meeting regulatory requirements for solvents globally.

Regulatory requirements are generally determined by the importing country, with a few exceptions, such as the European Union. In industrialized nations, countries follow the Montreal and Kyoto Protocols and are now implementing the recently signed Kigali amendment. The HFO technologies Honeywell has developed meet current regulations, specifically having the lowest global warming potential and ozone depletion values available in the market today.

33

ASSOCIATION AGROCHEMICALS

SOWING A

GREEN GROWTH STORY

BY SHIVANI MODY Trends in the agrochemicals and pesticides industry.

The emerging trends for Agrochemicals/Pesticide Industry is good. The next generation Agriculture in the country will include all possible sustainable solutions for crop protection which will include Crop Protection Chemicals, Bio-technology and Seed treatment. The sector faces many challenges but the solutions for the same will lead India in becoming a global manufacturing hub for quality Pesticides/Agrochemicals. Govt. of India is also encouraging and promoting the concept of “Make in India” and thereby manufacturing in India, and effective steps taken in that direction will boost Indian Agrochemical industry.

Opportunities for the agrochemicals and pesticides industry in India.

In India, use of Herbicides and Fungicides are increasing.

But consumption of agrochemicals in India is still one of the lowest in the world. Currently per hectare usage of agrochemical formulations in India is only 0.6 kg/ha against 5-7 kg/ha usage in UK; 13 kg/ha usage in China & Japan; 4.5 kg/ha usage by US and world average usage of 3 kg/ha.

Only 25 to 30 percent of cultivated area in India comes under crop protection umbrella. Government’s own estimate puts annual crop losses due to pests and diseases in India over Rs 90,000 crores. While our population at present stands at 130 crores, it is expected to reach 150 crores by 2030. There is a dire need to pace our agricultural production, particularly in an era of climate change and ever reducing farmland due to urbanization and housing needs, which forces conversion of agricultural land to non-agricultural usages.

Agrochemical industry has a key role in Indian Agriculture to minimize crop losses due to pests and diseases and to increase agricultural productivity of the country, which can contribute to balance the growing needs. The scenario provides greater scope for growth of the industry in coming years.

Export potential in India for agrochemicals and pesticides industry.

Pradip Dave, President, Pesticides Manufacturers and Formulators Association of India (PMFAI) & Chairman, Aimco Pesticides Limited, gives a holistic growth story of agrochemicals and crop protection industry in India.

34

Chemical Today Magazine | October 2017

Export of pesticides from India has seen strong growth in recent years. India is one of the largest exporters of pesticides to world market, which mainly constitutes Generic pesticides. Presently Indian pesticide industry is 4th largest in the world after US, Japan and China and in Generic Pesticides production India stands at No 2 in the world after China.

Presently India exports pesticides worth Rs 13,000 crores to world markets. Agrochemicals worth $4.1 billion are expected to go off-patent by 2020. This will provide opportunities for Indian Agrochemical Industry to increase their exports, which has greater expertise in Generic segment. The product areas mainly will include Insecticides, Herbicides and Fungicides.

Impact of ban on 18 pesticides by Union Government.

The final decision in this regard is still pending as the Government has received large number of objections against the notification issued in that regard. The 18 pesticides proposed to be banned are all Generic Pesticides having large export scope. The very reason given for review – “review of products banned in one or more countries” itself is wrong. If a product is banned in any other country for any cause or concerns, Expert Committee must have the scientific approach to first determine relevant issues of concern, and their relevance in Indian context, then ask Indian registrants to address that concern.

There must be some parameters for review.

Moreover the manufacturers have not been given opportunity by the Review Committee to defend their respective products.

Exploring potential available due to products going off-patent.

As mentioned above, this will be good opportunity for Indian companies as Indian Companies have greater expertise in Generic segment. Access to new off-patent products and innovations could help Indian companies provide new molecules to Indian Farmers as well as export to international markets.

PMFAI had filed a case in Gujarat High Court against CIB&RC policy guidelines allowing registrations for “imports of readymade Pesticide Formulations without registering its Technical Grade Pesticides” in the country. Though “deemed registrations” for Technicals were granted for 3 years under this guidelines, the Importers were deliberately not registering the Technical Grade pesticides in India even after 3 year period of deemed registrations, with an intention to continue monopoly in Formulations based on such Technicals and avoid competitions from Indian companies.

In the matter, Gujarat High Court given directives to the Government to frame guidelines more transparent as well as more effective so as to provide equal treatment to the indigenous manufacturers as well as importers who are importing such pesticides manufactured outside India. CIB&RC framed new guidelines TIM (Technical Indigenous Manufacture) v/s. FI (Formulation Import) which allow indigenous manufacturers register the Technical Grade Pesticides and its Formulations by submission of required data. From April 2016 Registration Committee started implementing the new guidelines and granted registrations to Indian companies for Bispyribac Sodium Technical and Bispyribac Sodium 10 percent SC formulations. This has resulted

Chemical Today Magazine | October 2017

in Indian manufacturers selling the Herbicide Bispyribac Sodium 10 percent SC formulations at a price of Rs 3500 per liter which earlier were sold by importers at Rs 8000 per liter.

Advancement and growth drivers for synthetic pesticides.

Global Synthetic Pesticides market is mix of strong performing segments such as Herbicides and Fungicides and less used Insecticides. Increase in Insecticides sales are expected to occur mainly in developing regions most notably Brazil and other Central and South American countries.

According to trends global market of Synthetic Pesticide should reach $71.00 billion by 2021 from $56.2 billion in 2016.

Market potential of agrochemicals and pesticides in developed vs the emerging markets.

Global Agrochemical Market is mainly concentrated in the major developed countries such as US and European nations. Europe has the largest share in the Agrochemical market followed by Asia, Latin America and North America.

Herbicides are most widely used Agrochemical products globally, followed

by Insecticides and Fungicides. Fungicides is the highest growing segment which helps increasing the yield, improving quality and in seed treatment.

While developed markets mainly use Herbicides and Fungicides, developing regions mainly use Insecticides.

But usage of Herbicides and Fungicides are increasing.

R&D and innovation in agrochemistry.

Research & Development for new molecule discovery by Indian companies are at a very low key, as Indian companies spend only 1-2 percent of the revenues for R&D against global MNCs which invest about 8-10 percent, which needs improvement.

With large number of molecules getting off-patent in 2 years, we expect more innovations to bring out newer formulations from Indian companies.

Challenges in the agrochemicals and pesticides industry.

As far as India is concerned, allowing registrations for imports of readymade pesticides formulations to the country is real threat, which will harm the growth of indigenous manufacture particularly MSMEs. Surprisingly basic Customs Duty applicable on imports of readymade pesticide Formulations (finished product) is 10 percent, same as on Technical Grade material is working against the indigenous manufacturers and the concept of ‘Make in

India.’ The policy needs to be corrected by the regulatory authorities. Restrictions also need to be brought on imports of not only Formulations but also Technical Grade pesticides which are already manufactured in the country.

Pesticides registration guidelines impact for the industry.

Pesticides regulation in India is one of the most stringent in the world, which many times create undue delays in granting of registrations.

Fast track Export Registrations with minimum data requirements is another area which lacks attention of the authorities as export orders are very timebound depending on Agriculture Season in different countries and timely delivery is very important, otherwise customers will look for suppliers from other countries.

Central Insecticides Board & Registration Committee (CIB&RC) will be implementing “Improved/Harmonized Guidelines for Registration of Pesticides in view of Make in India initiative of Government of India” which is expected to encourage domestic manufacturing and restricting imports.

As mentioned earlier, another area of concern is allowing Registrations for Imports of readymade Pesticides Formulations without registering Technical Grade Pesticides in the country which needs to be stopped. No major agricultural nations in the world follow such a system including USA, Europe, Brazil, China, Australia and Argentina, then why India? This will not only harm interests of indigenous manufacturers, but also will make way for flow of sub-standard pesticides to the country harming Indian Agriculture and environment.

GST implementation impact on the agrochemicals and pesticides industry.

Government of India’s decision to impose 18 percent GST on Pesticides/ Agrochemicals, which is a hike of 6 percent from the earlier Excise duty of 12 percent is likely to affect the pesticide industry and the Farming Community.

On one hand Government is talking about the need for supporting Agriculture sector and Doubling Farmers Income by 2022 and on the other hand imposing levy of 18 percent GST on pesticides, which is one of the key agri inputs used by farmers to protect their crops from the ravages of pests and diseases. This is not at all in conformity with policies of Doubling Farmers income.

It is pertinent to note that Agri inputs other than pesticides like Fertilizers attracts only 5 percent GST. We have appealed the Government for minimum Taxation of 5 percent GST on pesticides.

35

GREEN CHEMISTRY CHEAPER, GREENER BIOFUEL PROCESSING CATALYST IDENTIFIED

F

uels that are produced from nonpetroleum-based biological sources may become greener and more affordable, thanks to research performed by the University of Birmingham and University of Illinois’ Prairie Research Institute that examines the use of a processing catalyst made from palladium metal and bacteria.

B

iofuels are made from renewable materials such as plants or algae, and offer an alternative to petroleum-based sources. However, many biofuels are costly to produce because the precursor product, bio-oil, must be processed before it is sent to the refinery to be turned into liquid fuel.

The research team have identified and tested a new processing method.

“Bio-oils could potentially form an increasing part of the transport fuel mix.

Although the government intends to phase out petrol vehicles by 2040, biofuels could still be required for hybrid vehicles, as well as haulage, aviation and marine applications. The conversion of algae to crude bio-oil is attractive because it does not use food crops and is near carbon neutral,” said professor Joe Wood of the University of Birmingham.

Published in the journal Fuel, their findings point to a cheaper, more environmentally friendly and renewable catalyst for processing that uses common bacteria and the metal palladium, which can be recovered from waste sources such as discarded electronics, catalytic converters,

36

Chemical Today Magazine | October 2017

street sweeper dust and processed sewage.

The bio-oil produced in the lab from algae contains impurities like nitrogen and oxygen, but treating it with palladium as a catalyst during processing helps remove those impurities to meet clean-air requirements. For the palladium to do its job, the bio-oil needs to flow past it during processing. Previous studies have shown that allowing the oil to flow through porous carbon particles infused with palladium is an effective method, but those carbon particles are not cheap. Professor Lynne Macaskie, from the school of biosciences at the University of Birmingham, developed techniques for supporting an array of metal nanoparticles on bacteria, which act as a renewable catalyst support.

Wood. “Key to the increase in the biofuel market is the removal of nitrogen and oxygen components to make them more in-line with fossil fuel compositions so they can be blended with diesel for use in engines.”

“For many years we have collaborated to test such particles in a range of catalytic applications in chemical engineering, ranging from organic chemistry to fossil fuel upgrading, so this work represents the next step in making renewable biofuels using the catalysts,” said Wood.

The work was carried out in collaboration with Dr B K Sharma of the Prairie Research Institute, University of Illinois at Urbana Champaign funded through the Birmingham-Illinois Partnership for Discovery, Engagement and Education programme. The Natural Environment Research Council, UK also supported this research.

“We found our product to have similar effectiveness to a commercial catalyst,” said

The more costly commercial catalyst has the added benefit that it can be used over and over without extensive processing, whereas this group’s palladium-on-bacteria catalyst would need to undergo processing to be reused.

The researchers at biosciences are working on developing recycled catalyst using second life bacteria from fermentation processes and precious metals extracted and recycled from road dust.

BIODEGRADABLE MICROBEADS FROM CELLULOSE

S

cientists and engineers from the University of Bath have developed biodegradable cellulose microbeads from a sustainable source that could potentially replace harmful plastic ones that contribute to ocean pollution.

Ocean microplastics pollution Microbeads are little spheres of plastic less than 0.5 mm in size that are added to personal care and cleaning products including cosmetics, sunscreens and fillers to give them a smooth texture. However they are too small to be removed by sewage filtration systems and so end up in rivers and oceans, where they are ingested by birds, fish and other marine life.

It is estimated that a single shower can result in 100,000 plastic particles entering the ocean, contributing to the eight million tonnes of plastic that enters the ocean every year. It is feared that the particles could enter the food chain, harming wildlife but also potentially ending up in our food.

As a result of recent campaigning by environmental groups, the UK Government has pledged to ban plastic microbeads in 2017.

Biodegradable microbeads Now a research team, from the University’s Centre for Sustainable Chemical Technologies (CSCT), has developed a way of producing a biodegradable renewable alternative to plastic microbeads in a scalable, continuous manufacturing process.

The beads are made from cellulose, which is the material that forms the tough fibres found in wood and plants. In this process our scientists dissolved the cellulose to reform it into tiny beads by forming droplets that are then “set”. These microbeads are robust enough to remain stable in a bodywash, but can be broken down by organisms at the sewage treatment works, or even in the environment in a short period of time.

polypropylene, which are cheap and easy to make. However these polymers are derived from oil and they take hundreds of years to break down in the environment.

“We’ve developed a way of making microbeads from cellulose, which is not only from a renewable source, but also biodegrades into harmless sugars.

“We hope in the future these could be used as a direct replacement for plastic microbeads.”

Continuous manufacture process Davide Mattia, professor of chemical engineering and part of the CSCT, said: “Our goal was to develop a continuous process that could be scaled for manufacturing.

We achieved this by working together from the start, integrating process design and chemistry optimisation.”

The beads are made using a solution of cellulose which is forced through tiny holes in a tubular membrane, creating spherical droplets of the solution which are washed away from the membrane using vegetable oil. The physical properties of the beads can be tweaked by changing the structure of the cellulose, for example making the beads harder. A team, led by Scott and including Mattia (Chemical Engineering) and professor Karen Edler (Chemistry) has also just been awarded funding of just over £1 million by the Engineering & Physical Sciences Research Council to develop porous beads, capsules and microsponges.

They will work with industrial partners, to develop materials that could be used in cosmetics and personal care products, or impregnated with agrichemicals for use in, for example, slow release fertilisers.

The researchers anticipate they could use cellulose from a range of “waste” sources, including from the paper making industry as a renewable source of raw material.

They have published their results in the journal ACS Sustainable Chemistry and Engineering.

Dr Janet Scott, reader in the department of chemistry and part of the CSCT, said: “Microbeads used in the cosmetics industry are often made of polyethylene or

Chemical Today Magazine | October 2017

37

GREEN CHEMISTRY LIGNIN ‒ MUCH MORE VALUABLE THAN JUST AS WASTE

L

ignin, a substance considered as a waste product in biomass and ethanol production, will now reach its proper value as bio-oil in new products.

L

ignin is a natural substance in biomass, but it is unwanted in processes like production of paper or ethanol. In those processes lignin is considered as waste, and is used as fuel in heat and power plants. At the University of Boras a team of researchers investigate methods to extract and refine lignin for better purposes than burning it.

While the commercial lignocellulose to ethanol plants use the lignin after pretreatment as biomass feedstock to heat and power plants, in the Horizon 2020 project AGROinLOG, lignin will instead be transformed into bio-oil based products.

The researcher Swarnima Agnihotri has spent a year at the University of Boras refining the methods to extract the lignin from the lignin rich wheat straw. She explained: “If biofuels are to become a reality, we need to realize the industrial potential

38

Chemical Today Magazine | October 2017

of lignin and get more value from it,” she said. “Seeing the complexity and richness of its functional groups, there are various potential applications of lignin by converting it in variety of value added products like high performance carbon fibre, bio-oil and vanillin, to name a few.”

The project aims at utilizing an agricultural residue, wheat straw, which is available in surplus in Sweden, and also in other European countries.

“Wheat straw lignin valorization will add value to the whole process, and in turn provide benefit to industry, as well as further insight in creating value from lignin, which has been considered a waste until now,” she said Integration of lignocellulose based feedstock in ethanol plants is not new.

There are a number of techniques already producing ethanol from lignocelluloses at commercial scale.

“It is the high investment costs and the low profitability of the process which needs to be addressed. The goal with this AGROinLOG project will be to see the possibilities of adding a high valuable byproduct eg. biooil, to the whole production chain, and therefore increase the profitability of the process.

The next step “Now, when we have optimized an efficient pretreatment process for effective lignin extraction from wheat straw, we will scale up the process, and the pure lignin obtained will be transformed into biooil through a hydrothermal liquefaction process done, that is, extracting liquid and get a concentrated oil.

The bio-oil product obtained will be a high valuable byproduct since it can be further upgraded in refineries to obtain green chemicals and biofuels,” she said.

AIRLINE INDUSTRY COULD FLY THOUSANDS OF MILES ON NEW BIO-JET FUEL

A

Boeing 747 burns one gallon of jet fuel each second. A recent analysis from researchers at the University of Illinois estimate that this aircraft could fly for 10 hours on bio-jet fuel produced on 54 acres of specially engineered sugarcane.

Plants Engineered to Replace Oil in Sugarcane and Sweet Sorghum (PETROSS), funded by the Advanced Research Projects Agency Energy (ARPA-E), has developed sugarcane that produces oil, called lipidcane, that can be converted into biodiesel or jet fuel in place of sugar that is currently used for ethanol production. With 20 percent oil – the theoretical limit – all of the sugar in the plant would be replaced by oil.

“Oil-to-Jet is one of the direct and efficient routes to convert bio-based feedstocks to jet fuel,” said Vijay Singh, director of the Integrated Bioprocessing Research Laboratory. “Reducing the feedstock cost is critical to improving process economics of producing bio-jet fuel.

Lipidcane allows us to reduce feedstock cost.”

This research analyzed the economic viability of crops with different levels of oil. Lipidcane with 5 percent oil produces four times more jet fuel (1,577 liters, or 416 gallons) per hectare than soybeans. Sugarcane with 20 percent oil produces more than 15 times more jet fuel (6,307 liters, or 1,666 gallons) per hectare than soybeans.

“PETROSS sugarcane is also being engineered to be more cold tolerant, potentially enabling it to be grown on an estimated 23 million acres of marginal land in the Southeastern US,” said PETROSS Director Stephen Long, Gutgsell Endowed professor of Plant Biology and Crop Sciences at the Carl R. Woese Institute for Genomic Biology at the University of Illinois. “If all of this acreage was used to produce renewable jet fuel from lipid-cane, it could replace about 65 percent of national jet fuel consumption.”

“We estimate that this biofuel would cost the airline industry $5.31/ gallon, which is less than most of the reported prices of renewable jet fuel produced from other oil crops or algae,” said Deepak Kumar, a postdoctoral researcher at Illinois, who led the analysis.

This crop also produces profitable co-products: A hydrocarbon fuel is produced along with bio-jet fuel or biodiesel that can be used to produce various bioproducts. The remaining sugar (for plants with less than 20% oil) could be sold or used to produce ethanol. In addition, biorefineries could use lipidcane bagasse to produce steam and electricity to become self-sustainable for their energy needs and provide surplus electricity, providing environmental benefits by displacing electricity produced with fossil fuels.

Chemical Today Magazine | October 2017

39

SECTOR VIEW CROP PROTECTION

© DuPont

ETCHING

A GREEN REVOLUTION

BY DEBARATI DAS

I

ndia has historically grown on the foundation of agriculture. And over the decades, even though the country has witnessed the rise of industrialization, information technology and various other sectors, agriculture still forms the very backbone and pillar of the country’s growth.

And hence, it comes as no surprise that this sector accounts for about 15 percent of the country’s GDP. The onus on agriculture has further intensified due to the rising population of the country which has led to the rising demand of food grains as against declining farmlands due to spreading urbanization.

Thus, the need of the hour is to increase the farm yield from the available land and ensure reduction of crop losses due to pest attacks.

40

Chemical Today Magazine | October 2017

According to a report by Tata Strategic Management Group (TSMG) and FICCI, the agrochemicals market in India which was estimated at $4.4 billion in 2015, is expected to become $6.3 billion by 2020 with a 7.5 percent growth annually. But to sustain this growth, adequate crop protection is the need of the hour. The TSMG forecasted that the Indian crop protection industry is estimated to grow by 7.5 per cent per annum to reach $6.3 billion by 2020.

Hence the growth of the agricultural sector has to be supported by the growth in the application of crop protection solutions.

“Only 25 to 30 percent of cultivated area in India comes under crop protection umbrella. According to government

estimates, annual crop losses due to pests and diseases in India is over Rs 90,000 crores. While our population at present stands at 130 crores, it is expected to reach 150 crores by 2030. There is a dire need to pace our agricultural production, particularly in an era of climate change and ever reducing farmland due to urbanization and housing needs, which forces conversion of agricultural land to non-agricultural usages,” said Pradip Dave, president, Pesticides Manufacturers and Formulators Association of India (PMFAI) & chairman, Aimco Pesticides Limited.

Crop protection come in many forms and the Indian crop protection industry is dominated by insecticides which hold about 60 percent of the industry share.

This is followed by other segments like

fungicides and herbicides which hold 18 percent and 16 percent share respectively.

Sprouting Challenges Even though the consumption of crop protection products in India is low as compared to other countries, this only serves as an opportunity of growth for the crop protection market in the country due to the rising awareness about these products, increasing farm labour wages and the desperate need for more yields to feed the growing population.

However this industry still faces several hurdles in its growth path.

Ignorance isn’t always bliss: Majority of farmers in India still staunchly follow the traditional methods of farming. The lack of education and illiteracy in this sector had led to low awareness about agrochemical products, the requisite to use these products and the correct way to use them. Various government initiatives are making an attempt to educate the farmers on the need and process to use crop protection products. Several policy measures by the government aim to enable farmers to gain timely and adequate credit support. But a more collaborative approach by the industry, government & regulatory bodies would help change the scenario.

Manual or Technology driven approach: This sector still depends on manual labour for most of the farm work done, mostly because they are available at low cost while technological alternatives are much costlier. That is the reason why various crop protection products, like herbicides still do not capture a huge market; because farm jobs like weed plucking etc. is done manually. There is a need to understand the return on investment that advanced crop protection solutions can offer.

Case of counterfeit: This market faces a huge challenge from the rising sale of dubious and fake products which does more harm to the farm land. This also jeopardises the credibility of genuine manufacturers and their products among farmers who are already in the realm of ignorance. The government and industry players need to work together to keep a tab on spurious products entering the market.

Managing supply chain: The agricultural sector in India is spread across the lengths and breaths of the country while being distinctly diverse across the geography. Seasonal demand from different parts of the country, unpredictability of pest attacks and high dependence on monsoons are some factors that the industry players have to constantly address. Hence managing the inventory and tackling the distribution costs with effective supply chain management is a huge challenge for the companies.

Spending on R&D: There is a need to encourage R&D and strategic alliance between large MNCs and Indian counterparts. This way the country will have the same level of high end technological solutions to boost agriculture as the world uses. According to reports, agrochemicals worth $4.1 billion are expected to go offpatent by 2020 providing significant export for Indian companies to manufacture generic products.

“This will be good opportunity for Indian companies as Indian companies have greater expertise in generic segment. Access to new off-patent products and innovations could help Indian companies provide new molecules to Indian farmers as well as export to international markets,” said Dave.

Trends in crop protection Drastic reduction in arable land, decreasing farm size, increasing pest attacks, low per hectare yield, change in food consumption pattern, are the reasons which is giving rise to an imbalance in the demand and supply in the country’s food chain. But from challenges sprouts opportunities. Crop protection can play a major role in bringing back the balance.

Chemical Today Magazine | October 2017

Adopting global technology: To keep in tune with the changing food consumption habits and ensure sustainable yield, the Indian agro sector needs to change its stance and adopt modern methods, global practices and latest technologies of farming like agronomy, fertigation, seed treatment, biotechnology, etc. Making agrochemicals will not just ensure a better yield but have the most of the available land without any wastage.

Going hi-tech: Various farms globally have begun using technology to its benefit for monitoring their farms against pests. Smart farming and implementing Internet of Things (IoT) are concepts which are catching up in the agricultural business. High-precision crop control, useful data collection, automated farming techniques and ability to innovate the landscape of current farming methods are some of the things that are coming up. IoT sensors across the farms are providing farmers with useful information about crop yields, rainfall, pest infestation, and soil nutrition. For instance a farmer is immediately notified of a certain pest infestation which can be dealt immediately curbing the chances of widespread crop destruction. BASF recently collaborated with Infosys for their digital offering, Maglis, which helps farmers manage fields and supports them in making better decisions on how to grow monitor and manage their crops. “The use of technology in agriculture has quickly become an effective way to improve crop yield and productivity. We have worked with BASF alongside farmers and the agricultural community to create digital solutions that help them manages their fields more effectively,” said Sandeep Dadlani, president and global head, manufacturing, retail, CPG and logistics, Infosys.

Although a distant dream, such technology for crop protection in India is not an impossible aim.

Biopesticides: This is a segment in crop protection which is slowly picking up. An amalgamation of traditional yet modern approach, farmers are increasingly accepting the use of bio-alternatives to various chemical laden crop protection solutions. According to TSMG, biopesticides currently represent only 4.2 percent of the overall pesticide market in India, but this segment is expected to have an annual growth rate of about 10 percent in the coming years. This is an area where players can concentrate and explore the potential of plant origin pesticides and other alternatives that will not just keep a farm pest free but also ensure an organic yield and reduce poisoning of the soil with chemical laden products.

Integrated Pest Management (IPM): This is a new method of crop protection which is trending in the agrochemicals market in India. The IPM is a sustainable and an eco-friendly approach to pest management that combines biological, mechanical, physical, and chemical methods to keep pest population at below economic threshold levels. This method is executed in three stages, namely prevention, observation, and intervention.

Bayer India’s Crop Science division recently undertook an IPM Project in Punjab and Haryana, to help cotton farmers effectively manage the havoc created by whitefly that resulted in heavy losses in these regions. Cotton growers in both states were guided on scouting techniques and methods of taking informed pest management decisions for whitefly-based on economic threshold level of the pest throughout the season. “In both Punjab and Haryana, whitefly was effectively managed and project cotton farmers achieved a good average yield of seed cotton of over 1000 kg of seed cotton / acre. This is a remarkable yield improvement from the previous two years when cotton farmers obtained very low yields due to severe attack of whitefly,” said Peter Mueller, head of Bayer Crop Science, South Asia.

This is probably the best time for the Indian agriculture to thrive with new researches, new ideas and new experiments on farming.

41

FEATURES PAPER

IT’S A PAPER WORLD !!!

Changing trends in paper manufacturing.

42

Chemical Today Magazine | October 2017

BY DEBARATI DAS

P

aper is an indispensable part of our daily life.

Be it a tissue paper in your backpack, stickons on your refrigerators for reminders, a piece of paper for making your grocery list, a travel ticket, a movie bill, a calendar on your work table, or a dictionaryat any point of time, you always have a paper on you.

But the use of paper is consistently witnessing a shift.

On one hand, the rising use of electronic devices is steadily encouraging the trend of going “paperless” to avoid wastage of paper. Like many others, over the years, I too have shifted to various mobile apps for making reminder lists, reading books and news, finding words on online dictionaries, referring to calendar, using e-tickets instead of pritouts, and doing my small part towards a greener planet by reducing wastage of paper when it can be genuinely avoided.

However, on the other hand, paper is also rising as the only ecological alternative to plastic which is doing more damage to the planet. So, there is a significant rise in the use of paper bags, paper packaging, etc. Despite several environmental concerns, the requirement for paper will always remain. The need of the hour however, is to evolve with changing times without compromising the green cover of the planet.

Here are some of the trends which are globally governing the transition of the paper industry.

Smart packaging: This is an era of online shopping, which has radically transformed the packaging business and opened up avenues to be creative in delivering well packed goods. The use of paper in this industry has definitely shot up exponentially but smart packaging will guarantee a revolution in this industry. Development of new eco-friendly packaging solutions, innovative packaging with minimal wastage, reusing packaging materials, etc. will ensure a sustainable growth of this industry.

Paper for wellness: There is an overall rise in the adoption of healthy lifestyle, not just in homes but also in work places and public spaces. Hence the need for hygienic solution is on the rise and hence tissue papers, towels and other sanitary products made of paper are on the rise. There is a need to be innovative in the way paper can be used in a sustainable matter. Instead of virgin paper towel, napkins and tissue papers, recycled paper sanitary products made from post-consumer materials can divert valuable fiber from landfills. This will lead to less harvesting of trees for sanitary products.

Green Construction: The rise in urbanization has also led to the rise in the demand for housing and construction materials, which includes paper, pulp and wood alternatives to cement and metals.

Pulp & paper industry can play a major role in this segment.

Going Green: There are a lot of policies and government mandates for adopting sustainability.

Various company goals are governed by the overall sustainability achieved.

The paper industry can plan an active role in reducing a company’s

Chemical Today Magazine | October 2017

environmental footprint by innovating “green products” while maintaining the quality and cost comparable to traditional products.

Smart IoT Paper: The use of technology can be the game changer for the paper and packaging industry. According to market research group Smithers Pira, while the smart-packaging industry will grow at an annual rate of 8 percent to become a $7.8 billion industry by 2021, the IoT packaging will grow at an astounding 18 percent per year to almost $2.2 billion.

IoT can be used in the entire supply chain of paper manufacturing right from raw material gathering to recycling. The technology can help in realtime information gathering about the amount, condition and maturity of the tree stock ensuring optimal harvesting.

Different industry needs paper with different quality variables based on weight, moisture, opacity, brightness, caliper, ash, etc. With IoT solutions you can have a “smart” reel of paper which can produce rolls as per specific buyers based on a specific profile. This will bring down the downtime, maintain the quality of paper and significantly reduce the wastage of paper in production.

Suppliers could have a realtime connection with their paper producers and monitor the production process. Logistics can be more self-organised and flexible based on real-time information about shipment requirements.

Once delivered, the use of the paper products can be monitored and returned back for reuse. For instance, smart dispensers using IoT can wirelessly communicate with building management to keep restrooms stocked while alerting waste paper pile for recycling.

Encouraging Agro forestry: Every piece of paper thrown in the dustbin does not necessarily mean making a bald patch in the forest. Paper industry can be a well-organized agro-based operation instead of forest-based where farmers can grow trees in otherwise useless patch of lands to provide sustainable raw material to the paper industry.

This way, agro forestry will provide jobs in rural areas, support the local economy and productively utilize otherwise unused lands while preserving the ecology of the planet without disrupting the forests.

Furthermore adopting a scientific approach in this industry will make the whole process more sustainable. For instance, using younger trees to provide raw-material for paper mills is more ecological as according to scientists, younger trees absorb more carbon dioxide from the air.

Therefore, a scientific approach to agro forestry will help reduce some of the risks of climate change.

More research by the paper industry will help bring in sustainable and environmental solutions.

Paper is a very environmentally friendly material, especially when compared to alternatives such as plastic, however, a change in stance can bring in a balance between using paper and conserving nature.

43

INTERNATIONAL FOCUS IRAN

BOOSTING GROWTH PROSPECTS Chemical industry to get relief from Economic Embargo

44

Chemical Today Magazine | October 2017

BY SONAL SRIVASTAVA

I

n spite of facing a lot of headwinds, Iran represents the second largest economy in the Middle East region. According to the latest data by the World Bank, growth of the economy in Iran accelerated at a pace of 9.2 percent in the second quarter. Iran’s economy mainly thrives on the production and export of oil and petroleum products as the country ranks as the third major crude oil producer among other OPEC countries.

As oil products continue to remain a major cost driver in the petrochemical industry, the chemical sector of the country is intertwined with the fortunes of the oil sector. In post economic-embargo Iran, chemical products are emerging as a major export commodity, levelling the export rate of carpets.

Chemical Sector: Status Quo According to recent news updates, the exports in the chemical industry represent over 2 million bpd as compared to the crude oil. Besides petrochemical products, the other end uses of the chemical industry include defence, automotive, construction, power, mining, and electronics. Application of chemical products also expends to the agricultural industry, flavour & fragrance, and consumer goods industry. Moreover, the progress of chemical sector in Iran will depend on the construction of unfinished projects that were kept on hold due to imposition of international sanctions.

According to a recent research, the growth prospects of the chemical sector in Iran is significantly dependent on the construction of 67 unfinished projects, which can be completed if the country will secure $70 billion. Surge in projects related to infrastructural development will continue to boost the petrochemical production positively. Further, a clutch of companies including BASF, Linde, Total, Air Liquide, Mitsui & Co., and Shell had discussed with the authorities in Iran regarding the prospects of joint-ventures and collaborations.

With such collaborations, the chemical sector in Iran will continue to remain the bright spot in the economy. Relief from international sanctions has further made inroads for Iran in the trade and business world. The authorities in Iran are initiating

Chemical Today Magazine | October 2017

negotiations with the firms that are based in Asia and Western countries. In order to accelerate the economic growth, Iran will have to economically connect with international banks, implement domestic reforms, and recover FDIs. While Iran represents the third largest reservoir among the OPEC countries, the related trade deals with the other countries are likely to be sealed in lower cash. As compared to the oil and gas industry in Iran, the chemical sector has been lagging in terms of progress and development. Historically, there has been a lack of small-sized and mediumsized firms in the Iran chemical sector.

Relief from International Sanctions Imposition of international sanctions on the nuclear program left the petrochemical sector in Iran in tatters. The international sanctions on the nuclear program led to several sanctions on the oil and gas industry in 2016. Due to the imposition of sanctions, the economic growth in Iran bounced back at nearly 6.4 percent.

With the imposition of international sanctions, several developments related to the infrastructural projects and trade associations were kept on hold.

Moreover, the tools and equipment in various industries were outdated due to insufficient funds and economic downturn.

Bound to such factors, the chemical sector in Iran was subject to sharp decline post the imposition of sanctions on the petrochemical industry by the US. Relief from the international sanctions will continue to create lucrative growth opportunities for the chemical sector. After the sanctions were lifted, the authorities in Iran took initiatives to negotiate with the firms based in the other countries. A recent news update reveals that Iran was permitted to uplift its production capacity to nearly 3 million bpd between January and June.

Growth Prospects of Chemical Sector Several micro and macroeconomic factors are likely to impact growth of the chemical industry in Iran. A recent news update by the Islamic Republic News Agency, Iran has announced a long-term solar energy reactor,

which will reserve and generate solar energy for use in domestic applications.

Production of such reactors for generation of electricity will further witness demand for chemical products. Moreover, another news report published that Iran plans on building a petrochemical complex of $11.9 bn in Mokran. This petrochemical complex will represent the third-largest complex, and will have a production capacity of 25m tonnes per year. However, insufficient funds and growing inflation is likely to pose significant challenges for the authorities to implement the projects. Due to such factors growth in the chemical industry in Iran is likely to be knotted with downturns.

Economic Impact on the Chemical Sector Over the years, the economy of Iran has been beset with declines and stagnation as the country has been subject to revolutionary upheavals and costly wars. However, relief from the imposition of international sanctions has bagged lucrative growth opportunities for the chemical industry.

As the sanctions are lifted, the economy of Iran can connect with the international banks economically, and attract investments. According to several news reports, the authorities in Iran are taking initiatives to negotiate with firms based in other countries. The chemical sector in Iran can benefit significantly through such negotiations due to increasing demand for implementation of infrastructural projects, and other sectors. Further, with more funds the industry can adopt advanced technology, which can accelerate the production process.

On the other hand, plummeting oil reserves attributed to crude oil prices and imposition of policies regarding economic stability in the international market could hinder growth of the economy in Iran. Widespread unemployment will further pose significant threats to the economic growth prospects.

All in all, the chemical sector in Iran is expected to witness a healthy growth rate over the coming years attributed to several lucrative opportunities bagged through collaborations among market players and implementation of government projects Author: Sonal Srivastava is Features Writer at Future Market Insights

45

REPORT AGROCHEMICALS

INDUSTRY DRIVEN

BY CROP PROTECTION CHEMICALS DEMAND 46

Chemical Today Magazine | October 2017

Industry Insights The global agrochemicals market size was valued at $215.18 billion in 2016. Fertilizers, crop protection chemicals and plant growth regulators were some of the widely used agrochemicals in 2016. The industry is driven by the growing demand for crop protection chemicals due to frequent outbreaks of pest attacks on crops, which result in heavy losses. New food processing, manufacturing, and packaging techniques have resulted in a flourishing food & beverage sector globally. This has led to an increase in the demand for agricultural products such as food grains, oilseeds, vegetables, and fruits, which, in turn, is driving the agrochemicals market growth. The growing animal husbandry sector has increased the demand for animal feed, further triggering the demand for agrochemicals such as fertilizers and plant growth regulators.

As seen in the figure above, fertilizers accounted for the majority of the share in the US in 2016.

The growing demand for macronutrients, such as nitrogen, phosphorus, and potassium, has boosted the fertilizers market in the country. Low availability of arable land has also triggered the demand for fertilizers in the US since 2005.

The US was among one of the countries with the highest agricultural output in 2016 with corn being its major product. The mechanization of agricultural activities, lower fund borrowing rates, and growing food processing industry are some of the key factors driving agricultural sector in the country, consequently propelling the demand.

Product Insights Fertilizers, crop protection chemicals, plant growth regulators and adjuvants were some of the majorly used agrochemicals in 2016. The growing awareness about the benefits of these chemicals which include high efficiency and ease of use has played a key role in the growth of this market.

In terms of revenue, plant growth regulators are projected to grow at the highest CAGR of 6.3 percent from 2017 to 2025. Plant growth regulators such as cytokinins and auxins shorten the growth time of crops, thus reducing their harvesting time. The products received a major boost on account of the growing trend of organic farming, which includes the use of herbal medicines.

In terms of revenue, fertilizers accounted for 58.8 percent of the global market in 2016. Nitrogenous fertilizers, which are known to aid plant growth, were the most widely applied fertilizers in the same year. These products improve the quality of the soil by enhancing their nutritive content, which has made them indispensable in the agricultural sector. However, with the advent of biofertilizers, the demand for chemical fertilizers is expected to slow down over the forecast period.

Application Insights Agrochemicals are widely used in cultivation of

cereals & grains, oilseeds & pulses, and fruits & vegetables. Cereals & grains is the largest application segment of these chemicals. The growing demand for whole grain products as the source of carbohydrates and fibre is expected to be the biggest driver of this segment.

In terms of revenue, cereals & grains accounted for 37.2 percent of the market share in 2016. The segment witnessed a steep rise in the demand owing to aggressive advertisements and branding from multinational players, such as Kellogg Co and General Mills, which, in turn, has increased the penetration of agrochemicals. These crops are prone to frequent attacks from pests and insects, due to which, the demand for crop protection chemicals such as pesticides and fungicides has also gone up in this segment.

The demand for pulses & oilseeds, in terms of revenue, is expected to grow at the highest CAGR of 4.9 percent from 2017 to 2025. Pulses, such as soybeans, lupin beans, and red lentils, are known to possess high amounts of proteins, which has increased their consumption in everyday meals.

Similarly, the growing demand for edible oil has increased the market for oilseeds. These factors are expected to promote market growth in this segment.

Regional Insights Asia Pacific witnessed the highest demand for agrochemicals in 2016. The region has seen a change in the consumption patterns on account of urbanization and rapid income growth. Processed food, meat, and dairy consumption have been witnessing growth in this region. Factors, such as trade liberalization, reduced costs of transport, and modernization of the food sector, have been the major market drivers. Europe, in terms of revenue, accounted for 14.6 percent of the market share in 2016. Western European countries, such as Spain, Germany, France, and Italy, dominated the region in 2016. However, countries in East Europe, such as Bulgaria and Romania, have witnessed rapid growth on account of increasing investments in the agricultural sector and better water preservation techniques. These factors have resulted in growing agricultural activities in this region, consequently boosting the demand for agrochemicals.

Competitive Insights The global agrochemicals industry was dominated by major players, namely, Bayer CropScience, Agrium, BASF and DuPont. These players, headquartered in different regions, are known for dense distribution networks and high R&D budgets. For instance, in 2016, BASF invested over $2 billion in R&D activities.

Acquisition was one of the key strategies adopted by these players in the recent past in an attempt to maintain their market shares. In 2016, Bayer CropScience, Germany, acquired Monsanto, one of the largest agrochemical companies in the US, for $66 billion, making it the largest allcash transaction in the industry. This acquisition strengthened Bayer’s position in North America.

Source: Grand View Research Inc

Chemical Today Magazine | October 2017

47

REPORT CORROSION RESISTANT RESIN

© pkm construction & srp chemicals. all rights reserved.

DEMAND FOR COATINGS

TO DRIVE MARKET GROWTH 48

Chemical Today Magazine | October 2017

Industry Insights The global corrosion resistant resin market size was valued at $6,614.5 million in 2016.

It is expected to witness significant growth on account of increasing demand for coatings from various end-use industries majorly oil & gas, chemical processing, marines and others.

The developing interest for corrosion resistant resins in the composites application is one of the major factors boosting the consumption of corrosion resistant resin. In addition, conventionally used metals, for example, carbon steel and aluminum are increasingly being replaced by composites owing to factors such as cost viability and low maintenance.

As corrosion leads to significant revenue losses in the chemical industry, corrosion resistant resin materials are expected to witness growing demand in the industry.

Coatings is expected to be the largest application over the forecast period due to the anti-corrosive properties offered by the product, which not only provide protection but also extended life to metal parts that are exposed to harsh conditions.

Asia Pacific is expected to be the potential market for corrosion resistant resin manufacturers over the forecast period.

The region, in terms of value, is anticipated to witness high growth over the forecast period. Swiftly expanding industrialization, GDP development and the demand for improved and modern infrastructure are expected to fuel the interest in corrosion resistant resins in the region.

China is the biggest market for corrosionresistant resins owing to the presence of well-established industries in the country.

Apart from China, countries such as Japan, India, and South Korea are contributing toward the development of the corrosion resistant resins market.

Asia Pacific is a key area for the worldwide market of consumption of corrosion resistant resin die to its developing construction industry in China and India.

The increasing foreign investments coupled with end use industry such as power generations, tanks and pipes, development, marine, and oil & gas are likely to drive the market for corrosion resistant resins in the area.

As per the India Brand Equity Foundation (IBEF), a trust by the Department of Commerce, Ministry of Commerce and

Industry, Government of India, the construction industry in the country is anticipated to be valued at $5 billion by 2020. In addition, the growing foreign investments in industries and transportation in developing economies is expected to boost the development of corrosion resistant resin market in Asia Pacific.

Product Insights Epoxy resin product section is expected to be the largest and fastest-growing market for corrosion resistant resin due to its excellent corrosion resistance property, easy application, and reasonable cost. Epoxy coatings are generally used to counteract erosion in manufacturing equipment, tanks for destructive chemicals, underground storage tanks, industrial scrubbers, effluent management and pressure transfer pipe.

Vinyl resin coatings/paints are widely used in the marine industry to prevent ships from corrosions. Traditional methods for applying defensive paints are increasingly being replaced by resins in different enduse industries such as oil & gas, and car, and others. This can be attributed to the properties of composites, for example, simple establishment, corrosion resistance, and simplicity of operation at lifted temperatures.

Regional Insights Asia Pacific emerged as the dominant market, accounting for over 43 percent of the revenue in 2015. Modern infrastructure in the region is expected to fuel the demand for corrosion resistant resins in the region.

The demand for the composites application in Asia Pacific was over 258.1 kilotons in 2015 and is expected to grow at a CAGR of 6.3 percent over the forecast period. The growing composites and infrastructure industry is expected to fuel the composites demand in the region over the forecast period.

The North America market was valued at over $1,300 million in 2016. The growth can be attributed to the growing demand for lightweight and environmentally sustainable composite materials from the automotive industry. Various government regulations, such as CAFE Standards in the US are pressurizing OEMs to incorporate lightweight materials to curb the overall vehicle weight, which in turn is expected to contribute toward the growth of North America market.

Source: Grand View Research Inc

Chemical Today Magazine | October 2017

49

REPORT PULP & PAPER PROCESSING CHEMICALS

MARKET TO EXPAND AT

A HIGH GROWTH RATE

© Kehdem Media

50

Chemical Today Magazine | October 2017

Introduction: Chemical pulping is the process of converting wood chips, with the help of certain chemicals, into paper pulp, utilized further for producing paper. This method utilizes chemical cooking, in which single cellulose fibres are obtained as an outcome of the breaking up of wood or some similar raw materials.

There are various chemicals that can be used to carry out the chemical pulping process. A few of them are sodium sulphide, sulphurous acid, caustic soda etc. Pulp and paper processing chemicals are a group of chemicals that are used to modify the properties of the paper during manufacturing including change in colour, brightness, water resistance, strength etc.

Owing to the increasing degradability of plastic and polythene bags, governments across the world have put regulations on their use as a packaging product in the commercial and industrial sector. This is increasing inclination of end use industries towards adoption of paper made products for packaging and other applications as well.

Paper products find their major uses in the publishing industry, for writing, cardboards, brown paper etc. The pulp and paper processing utilizes various stages and at different stages, various chemicals are used.

These chemicals enhance the physical and chemical properties of the end product along with making the process easy and more economic. Due to increasing requirement of paper from various end use industries, the demand for pulp and paper processing chemicals is expected to increase at a high CAGR over the forecast period 2016–2026.

Market Dynamics: A key growth driver for the pulp and paper processing chemicals market is the growing demand among consumers for brighter, glossier, and high quality paper. Furthermore, the growing use of recycled paper in the pulp and paper market is increasing the demand for water treatment chemicals, which are important for the recycling process. The chemicals such as flocculants, biocides and coagulants are used for the recycling process in the pulp and paper industry.

Pulp and paper processing chemicals enhance the opacity, water resistance, strength and other aesthetic and performance properties of the paper. Specialty chemicals and additives used in the processing of pulp and paper are generally cost intensive chemicals and they account for significant value shares in the overall pulp and paper processing chemicals market. Owing to growing usage of these chemicals, the market for the pulp and

paper processing chemicals is expected to increase at a healthy CAGR in the coming future.

Market Segmentation: Pulp and paper processing chemicals market can be segmented on the basis of pulping process, chemical type, and application.

On the basis of pulping process, pulp and paper processing chemicals market can be segmented as follows Kraft Pulping Chemical Pulping Other On the basis of chemical type, pulp and paper processing chemicals market can be segmented as follows Specialty additives Fillers and Coating Pigments Bleaching Deinking Chemicals Pulping Chemicals On the basis of application, pulp and paper processing chemicals market can be segmented as follows Kraft Paper White Paper Cardboard Specialty Paper Others

Regional Outlook: The industrial and commercial sectors of the North America and Western European countries are very strong, and key suppliers for various chemicals used across different industries, including the pulp and paper industry, are based in these regions. This makes North America and Western Europe a key supply region for the pulp and paper processing chemicals.

High industrialization growth in the Asia pacific region, especially in China and India, is estimated to fuel the demand for paper products in the region, in turn, giving boost to the growth of the pulp and paper processing chemicals market. Driven by the regulations on the plastic products, and growing application base for paper, the pulp and paper processing chemicals market is anticipated to witness a significant growth in both the developed and developing countries over the coming years.

Source: Persistence Market Research

Chemical Today Magazine | October 2017

51

REPORT WOOD PRESERVATIVE COATINGS

ROBUST MANUFACTURING TECHNOLOGIES

TO DRIVE NORTH AMERICA MARKET © TWP®

T

he North America wood preservative coatings market is estimated to be valued at more than $2,000 Mn by 2017 end, and is expected to expand at a CAGR of 5.2 percent over the forecast period to be valued at more than $3,300 Mn by 2027 end. The wood preservative coatings market in the region is projected to exhibit a CAGR of 4.9 percent in terms of volume over 2017–2027. North America is anticipated to reach 868,047 tonnes by 2027 end from 539,973 tonnes in 2017. Adoption of robust manufacturing technologies such as UV technologies is a major factor leading to the growth and maturity of the North America wood preservative coatings market.

The rise in single family homebuilding in the US likely to foster growth in the consumption of wood preservative coatings in North America The single family housing model accounts for a major share in US housing constructions. The growth in single family housing is becoming prevalent in the US over multi-family housing, thereby increasing the demand for lumber, which in turn drives the wood preservative coatings market. Wood is considered to be a least energy intensive building material as compared to other building materials such as plastic, steel, concrete etc, that require more energy to convert the raw materials to the end product. Also, factors such as the availability of wood at cheaper costs compared to its substitutes, wide range of types and sizes and high material stiffness

52

Chemical Today Magazine | October 2017

of wood further fuel the consumption of wood preservative coatings.

Canada has around 30 percent of the world’s boreal forest that consists of trees such as larch, poplar, pine etc. Production of soft wood constitutes a major share in Canada, wherein the conversion of wood to various products is significant.

According to the Canadian Wood Council, the forests in Canada are more protected than any other country in the world with independent certifications. Soft wood from Canada is exported to the US, representing one-third consumption. A large production of lumber necessitates the requirement of wood preservative coatings in order to prevent the wood from decaying due to environmental factors such as climatic conditions. The presence of robust forestry coupled with sustainable forestry management fuels the wood preservative coatings market in North America.

The Energy and Environmental Design programme of the US Green Building Council certifies wood preservative coating products that have low VOCs and are formaldehyde free. Also, the presence of toxins and carcinogenic ingredients in the products are verified and if present, restrictions are imposed. These stringent standards and regulations help in driving revenue growth of the wood preservative coatings market in North America.

High solid technology, low odour and high durability products for interior wood coatings is the new trend in North America

The trend of usage of water-borne coatings is significant in the North America wood preservative coatings market. An increasing awareness among consumers regarding the usage of eco-friendly coating products is prevailing. Also, UV wood coatings are being used for industrial applications owing to the fast curing and high production efficiency offered by such coatings. Besides, high solid technology involving less solvent and more solids use is currently a prominent trend in the North America wood preservative coatings market. Also, low odour and high durable coatings are increasingly preferred by consumers in the North America wood preservative coatings market.

Insect repellent segment is estimated to hold major share both in terms of value and volume Preservative coatings for wood products are essential for increasing the product life span. Among various preservatives, insect repellent is estimated to hold major share both in terms of value and volume owing to its inherent advantages of protection from decay. The borates, azoles, pentachlorophenol etc. type of insect preservatives are more preferred by consumers. The market for stains and varnishes is quite fragmented with the presence of several domestic players. The demand for wood preservative coatings for protective as well as decorative purposes influences the stains and varnishes segments.

Source: Future Market Insights

ANNOUNCEMENT & CALL FOR PAPERS ME-TECH Refining

ME-TECH Petrochemicals

19 & 20 February

21 & 22 February

Consequences & Possible Solutions • Technology Options for Maximising Conversion • Optimum Solutions for Residue Upgrading • Panel Discussions

Petrochemicals • Refining & Petrochemicals Integration • Viability of Liquids Cracking in MENA Region • Overcoming Middle East Feedstock Challenges via New Technology • Panel Discussions

• Overview, Markets & Projects for Refining • Focus on Clean Fuels Technologies • IMO MARPOL VI - The Implications,

• Overview, Markets & Projects for

Companies that Presented in 2017

For Sponsorship & Exhibition Opportunities or to Register please contact us on: Tel: +971 (0) 44214642 or Email: office@europetro-me.com

www.me-tech.biz

SPECIAL FEATURE Conference Workshop 20 February HOSTED BY

ACADEMIC R&D BIOLOGISTS REVEAL EFFECTS OF

USING CHEMICALS

The number of insects in Germany is declining rapidly – in the state of North Rhine-Westphalia alone, it has dropped by three-quarters within only 25 years.

In a new study, biologists at Bielefeld University show the effects of pesticides and how even slight traces lead to long-term damage to beetles. One finding is that leaf beetles lay roughly 35 per cent fewer eggs after coming into contact with traces of a frequently used pesticide – a pyrethroid. The researchers also showed that female offspring develop malformations through the poison. The biologists have published their study in the journal ‘Environmental Pollution.’ cultivated fields that are meant to be managed without poisons,” said Caroline.

The new study shows that pesticides can interfere with communication between insects. When choosing their mating partners, mustard leaf beetles (Phaedon cochleariae Fabricius) rely on chemical stimuli, which enable them to recognize potential mates.

Hydrocarbons on the surface of the beetle body act as a type of scent that serves as an identity mark.

“For the first time, we have been able to show that contact with pesticides changes this chemical signature on the body surface,” said Dr Thorben Muller, the main author of the study. “As a consequence, beetles may fail to recognize suitable mating partners for reproduction. This alone may already reduce the number of offspring.”

“The offspring of beetles that have eaten leaves contaminated with pesticides develop more slowly than the offspring of beetles that have fed on untreated leaves,” said Thorben.

However, it is not just the development of offspring that is delayed. “Female leaf beetles whose parents had contact with such chemicals develop antennae of different length. This malformation can impair partner choice and the choice of egg laying places.”

A

ccording to the Federal Ministry for the Environment, in some parts of Germany the insect population has declined by 80 per cent since 1982. In North RhineWestphalia, the Regional Office for Nature, Environment, and Consumer Protection (LANUV) reports a decline of 75 per cent between 1989 and 2013.

54

Chemical Today Magazine | October 2017

“Recent years have seen a continuous increase in the use of herbicides,” said professor Dr Caroline Muller, head of the department of chemical ecology. One problem is that “Up to now, little was known about how pesticides affect insects outside the cultivated fields. The wind also potentially carries them to ecologically-

The results of this research may also be transferred to other insects. “Bees and wasps communicate in a similar way to beetles by using chemical signals,” said Caroline. “If they incidentally come into contact with traces of pesticides, this could also influence their mate selection and lead to a decline in offspring.”

“Herbicides should be authorized only when it is certain that they will not damage the development and reproduction of untargeted organisms in the long term,” she concluded from the present findings.

ANTIMALARIAL DRUGS OFFER

A SMORGASBORD OF NEW HERBICIDES

A

team of plant biologists and chemists from The University of Western Australia (UWA) in collaboration with staff from chemical company BASF have used the surprisingly close relationship between plants and malarial parasites to turn a molecule developed for possible malaria treatment into a new herbicide.

Centre of Excellence in Plant Energy Biology, said there was a desperate need for new herbicides, especially ones that work differently.

Published in Angewandte Chemie, the research builds on recent work by the group that found many off the shelf antimalarial drugs are herbicidal; a twist on an evolutionary connection made in the 1990s when herbicides were shown to interfere with processes in the malarial parasite.

“Herbicides are integral for modern day agriculture, but the spiralling costs to develop new herbicides have hindered their progress.”

Dr Joshua Mylne, a principal investigator with UWA’s School of Molecular Sciences and affiliated with the national ARC

Chemical Today Magazine | October 2017

“As we ponder herbicidal applications, we expect to be able to repurpose some of the molecules and discover new ways of using them,” Mylne said.

Associate professor Keith Stubbs, a chemical biologist also from UWA’s School of Molecular Sciences said it was exciting to find so many new herbicidal molecules. “In the past 30 years, no truly new herbicidal molecule has entered the agrochemical market,” Stubbs said.

“By using tiny seeds of the model plant Arabidopsis we examined a library of antimalarial compounds and selected the best one - MMV006188. We then examined several variations of it to determine which points were important for its potency”.

“This is just the first example we have and a test case of what we can do to develop new herbicides. We may not just find new herbicides, but by working with plants could reveal how some antimalarial molecules work, which could also contribute to drug development in the fight against malaria.”

The study ‘Exploiting the evolutionary relationship between malarial parasites and plants to develop new herbicides’ was supported by the UWA Office of Industry & Innovation and the Australian Research Council.

55

ACADEMIC R&D SWEETER WAY TO MAKE GREEN PRODUCTS Researchers invent novel process for extracting sugars from wood.

A research team led by Basudeb Saha (above right) at UD’s Catalysis Center for Energy Innovation, a DOE Energy Frontier Research Center, has invented a new process that could make forest and farm waste a cheaper, sustainable alternative to the petroleum used in manufacturing thousands of products.

T

he shampoo you washed your hair with this morning, the balloons for the party, refrigerators and sunglasses, medicine and mosquito repellent, guitar strings and fishing lures, these — and thousands of other products we use every day — contain chemicals made from petroleum. But researchers at the University of Delaware (UD) can now offer manufacturers a much sweeter alternative to this fossil fuel.

A UD research team has invented a more efficient process for extracting the sugars from wood chips, corn cobs and other organic waste from forests and farms.

This biorenewable feedstock could serve as a cheaper, sustainable substitute for the petroleum used in manufacturing tons upon tons of consumer goods annually — goods that consumers want to be greener.

More than half of consumers in the US are willing to pay more for environmentally friendly products, according to GfK MRI’s Survey of the American Consumer, reported earlier this year.

Basudeb Saha, associate director for research at UD’s Catalysis Center for Energy Innovation — a US Energy Department-designated Energy Frontier Research Center — led the effort, which involved scientists from UD and Rutgers University. The results are published in

56

Chemical Today Magazine | October 2017

ChemSusChem, a top interdisciplinary journal focusing on sustainable chemistry.

“To make greener chemicals and fuel, we’re working with plant material, but we don’t want to compete with its food value,” Saha said. “So instead of taking corn and extracting its sugars to make ethanol, we’re making use of the stalks and cobs left over after the corn is harvested, as well as other kinds of waste like wood chips and rice hulls.”

Although the past decade has seen a shift toward using such waste, referred to as lignocellulosic biomass, to create chemicals for producing biodegradable plastics, pharmaceuticals, cosmetics and biofuels, biorefineries have struggled with finding steady supplies and with high processing costs. Although wood chips and corn cobs may sound like simple, inexpensive materials, they are hard to break down chemically.

UD invents one-step technology Industry currently separates out the sugars from the lignin through a twostep process using harsh chemicals and reaction conditions in the first step, and an expensive enzyme in the second step.

This process makes the resulting sugars expensive and the end products, though

renewable, less competitive than those produced with petroleum.

The process invented at UD, however, is just one step. It doesn’t require a separate pretreatment step commonly used in biorefineries to disintegrate the lignin from the sugar polymers cellulose and hemicellulose. UD’s one-step technology integrates the pretreatment step and the hydrolysis of cellulose and hemicellulose in one pot and operates at considerably low temperature (85°C) and short reaction time (one hour), which makes the method energy efficient. It’s water efficient, too.

The key to the technology, which has been filed as an international patent application

by UD, is the use of a concentrated solution of an inorganic salt in the presence of a small amount of mineral acid. The concentrated salt solution requires a minimal amount of water.

The unique properties of the salt solution make the method very efficient, Saha said, with up to a 95 percent theoretical yield of sugars.

What’s more, the team has integrated the process with another step, called the dehydration reaction, which converts the sugars to furans in the same pot and enables the salt solution to be recycled.

Furans are highly versatile compounds used as starting materials for making specialty chemicals.

Sunitha Sadula, a postdoctoral researcher at UD’s Catalysis Center for Energy Innovation, a DOE Energy Frontier Research Center, works in the lab to extract sugars from wood chips, corn cobs and other forest and farm waste.

The UD innovation employs process intensification, the performing of several steps in an integrated fashion, resulting in the use of less energy and water. This concept, implemented on a large scale, is the focus of RAPID, a Manufacturing USA Institute being led by the American Institute of Chemical Engineers, which also involves UD as a key player.

“Our process enables - for the first time - the economical production of feed streams that could profoundly improve the economics of cellulosic bioproducts manufactured downstream, not to mention the environmental benefits of replacing petroleum,” Saha said. “More than 10,000 million metric tons of carbon emissions were reported in 2010 from conventional fossil fuels and chemicals, which has a long-term catastrophic effect on our environment.”

The study’s co-authors included postdoctoral researcher Sunitha Sadula and research associate Weiqing Zheng from UD and Prof Marianthi Ierapetritou, chair of the Department of Chemical and Biochemical Engineering, and graduate student Abhay Athaley from Rutgers.

Chemical Today Magazine | October 2017

From waste materials such as wood chips and corn cobs, UD researchers are extracting sugars that can replace petroleum in the manufacture of thousands of consumer products.

57

ACADEMIC R&D RESEARCHERS STUDY POLYCYCLIC

AROMATIC COMPOUNDS IN COAL

T

he organic matter in coal contains polycyclic aromatic compounds (PACs) of varying quantities in diverse soluble and insoluble forms. PACs in coal are of special interest for organic geochemical studies as they have been successfully used as biological marker compounds (biomarkers) and indicators of thermal maturity.

However, challenges exist when applying PACs in understanding the organic geochemistry of coal. For example, what are the sources of PACs in coals? How do they transform during the long-term coalformation history? Is there any regular relationship between the PAC and macromolecular structural changes?

Researchers from the University of Science and Technology of China (USTC) revealed the close relationships between the distribution of PACs in coals and the process of coal formation, which is beneficial for identifying the origin of PACs and their role as biomarkers.

Recently, a collaborative research group led

by Dr WANG Ruwei at USTC of Chinese Academy of Sciences and Dr SUN Ruoyu at Tianjin University reviewed the application of geochemical parameters of PACs in coal as useful tools to trace the coalification process from the molecular perspectives, and to understand the biogeochemical processes (eg. depositional environment, geological settings, igneous intrusion) occurring during coal formation. The study was published in Earth-Science Reviews.

Researchers conducted comprehensive study on coals collected from the south margin of North China coal basin and the coal mines in southwestern Illinois and eastern Pennsylvania, US. The obtained experimental results were presented in the framework of coal geology, coal petrology, coal chemistry and molecular dynamics.

Researchers conducted comprehensive study on coals collected from the south margin of North China coal basin and the coal mines in southwestern Illinois and

eastern Pennsylvania, US. The obtained experimental results were presented in the framework of coal geology, coal petrology, coal chemistry and molecular dynamics.

Through analysis on the previously published 230 literature data with combined methods, researchers found that PACs in coal mainly derive from biosynthetic compounds of high plants and microbial/fungal precursors followed by rearrangement and fragmentation reactions occurred during coal maturation.

The occurrence of PACs are affected not only by coal rank, but also by their origins eg. depositional environment, precursor materials, formation history and geological ages.

Moreover, it was found that wildfire and igneous intrusion events in the coalforming geological history could result in different relationship of reflectance vs. molecular signatures, which are quite different from those of the normally metamorphic coal.

Proposed evolution processes of PAH in magmatic-affected coal of different rank.

58

Chemical Today Magazine | October 2017

63

ACADEMIC SPEAK RESINS

BUILDING A CAR

OF THE FUTURE Research focus.

Imagine your next car with a chassis that is safe enough to withstand catastrophic collisions, light enough for you to lift and move around plus it saves you in fuel, with extremely low carbon emissions. This is set to become a reality with cars made of lighter but stronger carbon fiber composite structures where a thin fiber, less than 10 times smaller than the width of a human hair, is glued within a polymer matrix (resin). Stronger than steel and lighter than aluminum, carbon fibers are essential materials for the future of low cost, sustainable mass transport, electronics and renewable energy manufacturing. Half of a Boeing 787 Dreamliner is made from carbon fiber composite materials. This has enabled a 20 percent improvement in fuel economy and significant reduction in carbon dioxide emissions. In automotive industries, the use of lightweight composites has the potential to exceed future emission requirements, with weight savings of up to 45 percent. In order to translate the benefits from using this material to other large volume vehicle platforms, cure cycle times of less than 1 min must be achieved. The two critical challenges for the manufacturing of next generation of carbon fiber composite materials are achieving (i) cost effective materials and (ii) high rates of production. Our recent breakthrough findings on resins have the potential to revolutionize the way we make composite materials and address these challenges. The novel research has indicated that rapid cure resins are not only possible but also will lead to flexible, formable and recyclable materials with excellent mechanical performance.

Dr Nishar Hameed delves into how carbon fibers are the path breaking materials of the future for low cost, sustainable mass transport, electronics and renewable energy manufacturing.

Dr Hameed is ARC DECRA Fellow and Senior Research Fellow at the ‘Factory of the Future’ - Faculty of Science, Engineering & Technology, Swinburne University of Technology, Australia.

60

Chemical Today Magazine | October 2017

The Factory of the Future represents Swinburne’s industry portal for advanced manufacturing. One of the major focuses of our team at the Factory of the Future is to create an open access facility for the automation of high volume carbon fiber composite production. The carbon fiber composite manufacturing is predicted as the viable niche for global industry, but positioning industries to participate in this growth market will require the development of flexible, automated composite production processes. The major challenge for the industry is to increase production rates through automation thereby reducing cost, enabling high volume manufacture and broadening the applications for carbon fiber composites.

Our focus is to design and synthesize novel epoxy systems that are scalable enough to adopt in to the current and future composite manufacturing technologies.

Important considerations are to be able to achieve fast cure rates, flexibility and formability, recyclability and self-healing behaviours in the resin systems and also to develop resins that can withstand high temperature environments.

Technology used to produce fast cure resins.

The research performed by our research team discovered new epoxy thermoset compositions that are malleable and thermoformable after cross-linking. The flexibility is induced into a standard brittle epoxy polymer by incorporating ionic liquids. The new polymer can behave like brittle thermosets, ductile thermoplastics and elastomeric rubbers in one composition just by changing the formulations. Further research identified new epoxy formulations that have substantially improved cure reactions or fast cure resins. This means the epoxies can be cured in a matter of seconds and the formulation is completely tuneable.

It is also noted that the new technology also decreases the cure temperature (~50 percent) relative to the traditional process, representing a large decrease in energy consumption for the curing process.

Fast cure resins to be crucial for manufacturing large volume composites.

It is estimated that weight reduction of up to 45 percent is feasible in a standard mid-sized sedan by introducing carbon fiber composites into the vehicle system that will contribute to an effective cost savings of $3.42/lb. This requires a significant amount of light-weighting primarily involving automated and rapid cure composite manufacturing. The current costs can be reduced significantly if complex automotive parts are formed at the rate of under 3-minute cycle time.

The cost of prepreg is prohibitive for high volume automotive applications and this has driven the search for fast cure resin systems that can be infused in processes such as liquid compression moulding.

As such there is currently a worldwide demand for rapidly curing thermoset resins (typically epoxy) that qualify the processing rates without sacrificing the final material properties.

Ways in which this material scores over others.

Inducing fast curing and recyclability in polymers via covalent adaptable networks and bond breaking and reforming behavior have been investigated in recent years in a few initial studies. Very recently, IBM researchers have made breakthrough recyclable thermosets and organogels by the condensation of paraformaldehyde.

However, these techniques may involve

Chemical Today Magazine | October 2017

novel synthetic monomers or energyintensive processes making them expensive to scale up and commercialize. There are no recent scientific breakthroughs reported in rapid curing of epoxies other than the trials and upgrades on the existing industrial epoxy grades by the manufacturers.

It is highly desirable not to push new processes into an established industry, but to determine the best way to develop innovative materials that can feed into the existing manufacturing processes to support high rate production speeds. The innovation of our technology is to induce flexibility, recyclability and significantly improve the curing rate and thus advance the current generation epoxy polymers correlating to minimal disturbance of established manufacturing procedures.

Commercializing the technology.

A significant advantage of the project is that the novel thermosets can be made from readily available materials and the process can be adopted directly into the established manufacturing procedures with minimal capital investment and personnel training. This new class of resin will benefit the rapidly growing global automotive composite industry. The technology is under development and we are open for discussions with motivated manufactures/ industries to scale up and commercialize the technology.

Plans for future research.

Our aim is, simply, Industry 4.0 Manufacturing. Industry 4.0 facilitates agile manufacturing through cyberphysical smart factories, where machines communicate and cooperate with each other and with humans in real time, enabling companies to connect with customers and supply chains across the globe. As a part of Industry 4.0 initiative we dedicatedly focus on next generation of large volume composite manufacturing, aiming to achieve fast throughputs at low cost. Automated manufacturing in conjunction with rapid materials processing is predicted to be the pathway to achieve this goal. Along with new technologies in automation and robotics, the future composite manufacturing will see a huge development in novel resins and composites that incorporate multiple functionalities and non-traditional behaviours. This includes resins with tuneable physical and chemical properties and fibers and composites with smart sensing functionalities.

Scope for carbon fiber research in India.

India is currently going through an industrial revolution especially in manufacturing with major initiatives such as Make in India, for example. This is the right time to invest in R&D, new technologies and join hands with global leaders in the space to work together to be a part of such development. The aerospace and automotive industry in India is booming and it is important to think about technology development that benefit such sectors. To be successful in this environment, both researchers and manufacturers will require granular understanding of markets, new technological capabilities and new business capabilities. Carbon fiber composites is a major and niche area that has a lot to offer to Indian manufacturing sectors.

There are multiple media and government releases about utilizing these technologies and in-house and collaborative initiatives.

Swinburne is open to collaborations and our strategy is to work together for outcomes of impact that benefit both sides.

Research areas youngsters can consider for industry benefit.

Carbon fiber composites and associated technologies such as novel resin development are important areas of research in manufacturing.

Young researchers should focus on “low cost materials and manufacturing” and “faster processing technologies” and that’s the future. Also ‘inducing smart functionalities into materials and systems’ is also an area of interest. We identify carbon fiber and graphene as the new materials in manufacturing. Research innovations and technology developments with these materials can lead their industrial utilization.

Challenges faced during research.

Our research is becoming more and more multidisciplinary. For example, our team is now focusing on smart composite development that can sense the external environment/stimulus while in manufacturing and in service. The challenge here to have experts who has knowledge in both materials/manufacturing and system integration/sensors. We would be able to overcome these challenges by collaborating with other researchers who have complementary skills. We are now in the process of identifying the right team of people/institutions to work together and address major challenges in the roadmap.

61

R&D YOUNG TURKS

SOCIETY FOR SCIENCE & THE PUBLIC

Experiments on biodegradation of chlorpyrifos

Prashaant Ranganathan Project

C

must be free from adverse effects on the environment and the ecology of farming.

Exposure to the pesticide even at very low levels leads to death of honey-bee larvae and to memory and learning deficits in adult bees threatening their survival.

CPFS contaminates air and ground water up to 13 KM from the site of application for up to 8 years. Urgent measures have to be developed to degrade the pesticide residues in farm soils. These procedures

An ideal means of achieving this is to employ naturally-occurring bacteria in the soil to degrade the pesticides. When an effective strain of bacteria is isolated for the biodegradation, the strain may not be efficient. It was hypothesized that the surfactant Triton X would be effective in accelerating the biodegradation of CPFS by bacteria. Soil sample was collected from a farm under aseptic conditions. The various strains of bacteria present in the soil were isolated and cultured in a medium of CPFS, increasing the concentration of

hlorpyrifos(CPFS) is a pesticide extensively used by farmers. It is extremely dangerous to human and animal health, even at levels of 0.1 ppm.

Pre-natal exposure to CPFS results in neurological problems.

the pesticide solution gradually. Only the strain that was resistant to the pesticide survived this procedure.

This strain was then collected and studied for its effectiveness on the biodegradation of the pesticide. The degree of degradation was assessed using MS-GS and the growth of the colony was measured using optical density measurements. Experiments were conducted on the degree of biodegradation in the presence of different concentrations of the surfactant Triton X. The degree of biodegradation increased from 30 percent in the absence of Triton X, to about 90 percent in the presence of Triton X. Š Society for Science & the Public

62

Chemical Today Magazine | October 2017

JOBS Q.C. Chemist Company: Huntsman Date Posted: 12 September Country: India City: Ankleshwar

Job Description: The aim of this position is to give support to the Technical department of all SMU’s. To coordinate with regional QA, QC whenever needed and requires knowledge to handle instruments like ph meter, kf titrator, stirrer.

Production Shift-In Charge Company: AkzoNobel Date Posted: 07 September Country: India City: Raigad

Jr. Executive - QC Company: Pfizer Date Posted: 13 September Country: India City: Aurangabad

Research Chemist Company: Eastman Date Posted: 02 September Country: US City: Longview

Job Description: The Shift-In Charge will be responsible for actual plant operation and day to day manufacturing activity as per procedure. He will also need to supervise process operators to carry out manufacturing of Organic Peroxides.

Job Description: The candidate should maintain laboratory instruments to ensure proper working order and troubleshoot malfunctions when needed and needs to be well experienced about chromatographic analysis (HPLC & GC).

Job Description: Company is seeking qualified candidates to fill the research chemist position in the Technology Process Innovation organization in Longview, Texas.

Research Chemists generally work in conjunction with peer PhD Chemist/Engineers and BS Chemists to identify, scale-up and commercialize breakthrough process technologies.

Production Engineer Company: Solvay Date Posted: 11 September Country: India City: Panoli

Job Description: This position will be based out of the Specialty Polymers Plant at Panoli and the person will report to the Production Manager. He should coordinate the activities related to the identification, monitoring and control of key process parameters.

Process Engineer Company: Evonik Date Posted: 14 September Country: China City: Xinzhuang

Scientist, Downstream Process Development Company: Sanofi Date Posted: 14 September Country: US City: Framingham

Job Description: Evonik’s Process Engineer has to develop, initiate, support and lead projects to increase production performance, product quality, safety and cost efficiency at the production sites in Asia.

Job Description: The designated person will apply his/her solid understanding of scientific principles and professional practices to contribute to MSAT-Process Science mission.

Senior Research Scientist, Paper and Board Surface Treatment Company: Kemira Date Posted: 06 September Country: Finland City: Espoo

Job Description: The company is looking for an experienced and innovative Senior Research Scientist for sizing and performance team in the Espoo R&D center. As a Senior Scientist and Project Manager in projects, the person will focus on surface treatment and conversion of paper and board.

Senior R&D Scientist Company: Lonza Date Posted: 01 September Country: UK City: Castleford

Job Description: Working as part of the R&D Group, with a strong laboratory focus (70 percent of time), the R&D Scientist will be responsible for the delivery of robust, high quality product lines to add to a world leading portfolio of industrial timber preservatives and fire retardants.

Website: http://www.worldofchemicals.com/chemical-jobs.html

64

Chemical Today Magazine | October 2017

PRODUCTS

Epoxy resin UV adhesive for dome coatings P anacol launched Vitralit® UC 6686-a UV-curing epoxy resin adhesive.

Extremely hard and scratch-resistant, it is perfect for dome coatings and decorating glass & plastics.

It is an epoxy resin based single-component adhesive, which cures rapidly under UV light. Developed especially for dome coatings, its high viscosity makes it ideal for automatic dispensing and application with precise pattern.

Once cured, it is extremely hard and scratch-resistant and has a transparent, brilliant high-gloss surface that does not yellow. It has been successfully used in decoration of glass perfume bottles. The adhesive can be cured with both UV gas discharge and UV LED lamps. Very good adhesion of applications over a large surface can be achieved with Honle’s LED Spot 100 at a wavelength of 365 nm.

Contact: Panacol-Elosol GmbH Daimlerstr. 8, D-61449 Steinbach/Taunus, Germany Tel: +49 61 71 62 02 0 Email: info@panacol.de Web:https://www.panacol.com

High-performance dispersion for interior vehicle parts lamination J

owat now supplies a new high-performance dispersion for the lamination of interior car parts: The special formulation of the dispersion based on polyurethane has been developed especially for the high requirements in real leather lamination applications and supports the manual positioning and repositioning of the sewn leather covering. In addition, the new PU dispersion 158.97 can also be used for lamination with thermoplastic foils and textile composites. During the development of the new PU dispersion 158.97 from the Jowapur® product series, Jowat focused on the very high requirements for lamination processes with real leather, as they are used for instance in the manufacture of dashboards or door side panels. The new dispersion has significant advantages especially in manual edgefolding operations. Of course, Jowapur® 158.97 also fulfils the requirements for demanding lamination applications with all kinds of thermoplastic decor foils as well as textile foam and nonwoven composites.

66

Chemical Today Magazine | October 2017

Contact: Jowat Corporation P.O. Box 1368, High Point, NC 27261, USA Tel: (336) 434-9000 Email: info@jowat.com Web:http://www.jowat.com

Barrier coatings useful for food packaging applications M ichelman’s Michem® Flex Barrier 3510 is a transparent, high oxygen barrier coating that can extend the shelf life of oxygen sensitive products. After being applied to either polymer or preferably polyester substrates in packaging laminate structures used in food packaging applications, it can reduce oxygen transmission rates up to < 5 cc/m2/day. It preserves product appearance and flavor, and potentially minimizes preservative use. Michem® Flex Barrier 1000 offers brand owners the latest in food safety innovation. This new coating acts as both an oxygen and mineral oil migration barrier, making it ideal for numerous food packaging applications. It is formulated for use on paper substrates, where it reduces mineral oil migration to less than 0.6 mg per 1 kg of food.

Contact: Michelman, Inc. 9080 Shell Road, Cincinnati, OH 45236-1299 USA Tel: +1 513 793 7766 Email:coatings@michem.com Web:http://www.michelman.com

Water-based dyestuffs for leather finishing L ANXESS has added new, water-based dyestuffs to its portfolio of leather finishing products. The Levaderm WB range includes the color shades yellow, orange, red, bordeaux, blue, navy blue, green, light brown, medium brown, black brown, gray and black. They are suitable for spray or throughfeed dyeing, effect, base and top coats.

“The new Levaderm WB range is characterized by high yield, pure brilliance, very good leveling power and excellent fastness properties,” said Dr Thomas Brackemeyer, head of the organic leather chemicals business line in LANXESS’s leather business unit (LEA). Levaderm WB dyestuffs are solvent-free and not flammable. All products meet the requirements of REACH Annex XVII, Entry 43, with regard to the manufacturing, marketing and use of azo dyestuffs. They are also not based on heavy metals such as lead, mercury, chromium (VI), arsenic, nickel or cobalt.

Contact: LANXESS AG Kennedyplatz 1, 50569 Cologne, Germany Phone: +49 221 8885 0 Email:lanxess-info@lanxess.com Web:https://lanxess.com

Chemical Today Magazine | October 2017

67

AUTOMATION PROCESS

CHANGING GEARS

FOR NEXT GEN AUTOMATION

Nikolaus Kruger, Corporate Sales Director, Endress+Hauser Group says that the industry is technologically ready for IIOT but only the mindset needs to be changed to bring in this paradigm shift in automation.

68

Chemical Today Magazine | October 2017

BY SHIVANI MODY Global trends in process automation Our business in the global chemical industry has grown steadily in recent years with a focus on safety and product innovations for continuous improvements.

In emerging markets, there is an increasing demand for safety-related products meeting the trend of rising regulatory requirements. Furthermore, mergers and acquisitions are driving the consolidation of the chemical industry.

Key trends driving the measurement segment.

In automation, one question keeps us busy: How can we help our customers to optimize and continuously improve their plant efficiency and availability? A smart transmitter does not help if the intelligence is not connected with the application.

Smart devices become an enabling element as part of modern maintenance architectures. Inventions and technological solutions such as Heartbeat Technology support these objectives.

Furthermore our customers request more advanced analyzers (PAT) with less installation effort to allow for inline and just-in-time quality control.

Process automation market in India.

The potential for process automation in India is huge. Process automation in the chemical and petrochemical industry is considered to be much ahead of other process industries. And both of the industries have been growing during the last decade at a two-digit compound annual growth rate. Investing in intelligent automation and control systems for efficient manufacturing, plant optimization is the way forward for the Indian chemical and petrochemical industry. In this increasingly competitive and globalized environment it makes sense for Indian chemical industries to keep up with global trends and adopt new technological innovations. We see the demand for innovative solutions in organic and inorganic chemicals including petrochemicals, specialty chemicals, agrochemicals, pharmaceuticals (API) and biotechnology products.

Process automation for enhanced productivity and quality.

Today digitalization strategies are defined in the major companies - now we need to find use cases for proper implementation.

The technologies are ripe for the Industrial Internet of Things but a mentality shift in the industry is required. Therefore, we need partners in order to deliver joint value propositions. That is why Endress+Hauser, together with partners such as BASF, SAP and others, created a platform for the chemical industry through which data

Chemical Today Magazine | October 2017

can be exchanged. The platform enables new forms of data-based cooperation and shows how effectiveness and efficiency in chemical production can be increased significantly, for example through predictive maintenance.

Need for the automation solutions in India.

Due to the nature of the industrial processes, safety in terms of people and assets is paramount. Rising market competition, globalization and the need to conform to quality benchmarks have expanded the use of automation solutions in the chemical and petrochemical industries. Also, curbing CO2 emissions, lower power consumption and reduction of industrial waste are some of the policies and regulations laid down by the government that create big opportunities for automation solutions.

The breakdown of machinery industry had a negative impact on production processes, which may lead to the loss of substantial revenue for manufacturing companies. The lack of automation in traditional chemical and petrochemical industries increases downtime in production activities and disrupts the manufacturing process.

Disruptions such as frequent power outages cost huge amounts of money per hour due to production downtime. This is another reason why there is a strong demand for automation solutions.

Bringing an end to unplanned downtimes.

Maintenance and safety are real challenges in the chemical industry, for example when the temperature rises in an application.

To avoid unplanned shutdowns, the replacement of outdated technology in chemical processes is strongly recommended. The advantage is clear: investing in new technologies results in optimized and smooth processes meeting chemical market demands.

Endress+Hauser instruments provide customers with accurate measurement and process data as well as a reduction in maintenance efforts through reduced downtimes for calibration and proof testing. We offer safe in-process cleaning and calibration and, thanks to integrated Heartbeat Technology, self-diagnostics as well as effortless proof testing.

Improving supply chain management with IIOT. Digitization offers a great potential with regards to the supply chain. The evolution of the digital supply chain is seen as a next big change across the complete supply chain for maintaining safety. This will also affect the topics of integrated planning and execution, logistic visibility, procurement, smart warehousing, spare parts management and more.

R&D and innovation focus Endress+Hauser has a comprehensive production in India for the Indian market.

Nevertheless, our products are available all over the world with the same technology, manufactured according the same high quality and safety standards. Of course we adapt our products to specific needs of local markets with regards to mechanical or technical specifications or regulatory requirements.

When it comes to R&D, a key focus is the Industrial Internet of Things (IIOT).

Endress+Hauser already offers instruments that monitor their own status during the process, while making the sensor and process data available via Internet-based platforms. The seamless integration of instruments into the customerâ&#x20AC;&#x2122;s automation and IT systems permits ongoing optimization of maintenance cycles and process controls, among other things.

Challenges faced by service providers.

The chemical industry is a significant driving force for the economy as a whole. In many different processes, new substances and innovative products emerge that pave the way for developments in many other industrial sectors. Increasing globalization of markets and companies, growing competition and increasing safety requirements due to stricter regulations and laws are affecting the chemical industry.

Furthermore, the cost of raw materials and energy rises steadily, technical solutions become increasingly complex while the number of skilled workers continues to decline. As a solution and service provider, we help our customers to optimize processes, increase safety, meet regulatory requirements and reduce costs to guarantee competitiveness in the long term.

Expansion plans in India.

In India, Endress+Hauser has been active for more than 20 years. Currently there are nine regional offices across the country and manufacturing facilities for flow, level, pressure and temperature measurement engineering. Our business grows steadily in India, which is an important market for Endress+Hauser with a huge potential. We will continue to invest to strengthen our position in the market. We have recently acquired the analytical companies Kaiser Optical System, SpectraSensors and Analytik Jena on a global scale, which are all expanding in India. With these investments, we are able to cover a broader value chain from the laboratory to the field. From the customerâ&#x20AC;&#x2122;s perspective, our portfolio offering becomes more attractive and future-ready for the growing Indian market.

69

AUTOMATION ETHYLENE PRODUCTION GAS PURITY MEASUREMENT

FOR ETHYLENE PRODUCTION REDUCE COSTS AND ACHIEVE REAL-TIME RESPONSE

BY YEETIONG KOH The dramatic growth of the ethylene market – reaching 200 million tons globally by 20201 – relies heavily on Asian production capability and capacity. Approximately half of the world demand for ethylene is for the manufacture of polyethylene, but it is also used to make vinyl chloride, ethylbenzene and many other valuable intermediate products such as ethylene oxide, ethanol ethylene oxide and ethanol. Ethylene has stringent purity requirements that must be verified in production and at custody transfer points as the presence of impurities can poison catalysts and affect downstream processes, leading to costly repairs and downtime. Measurement of purity directly impacts the bottom line.

70

Chemical Today Magazine | October 2017

The criticality of ethylene purity analysis means that the precision and reliability of the measurement is, of course, paramount, but speed and cost reduction are also important to prevent potential process upsets and to assure optimum throughput.

The faster a reliable purity measurement can be achieved, the greater the product to market. For this reason, any significant advance in ethylene purity analysis that promises to lower costs and increase speed without sacrificing accuracy can have a major impact on the profitability of ethylene production plants. Such an advance is represented by the introduction of new quantum cascade laser (QCL)/ tunable diode laser (TDL) technologies

for ethylene analysis. Since the current technologies used for measuring gas purity both in production and custody transfer are reliable but relatively time consuming, the use of laser spectroscopy for measuring gas components has been a subject of interest for some time. Limitations in the technology, however, made it largely an experimental issue – until recently. The problems arising have been due to the fact that in spectroscopic laser gas analyzers, the external path that the light travels prior to entering the measurement cell can cause interference when the gas of interest is also present in the atmosphere, as is the case in the product purity measurement point of ethylene manufacturing.

Ethylene producers must certify that their product meets specification, but atmospheric moisture or carbon dioxide, for example, can negatively impact the measurement. The interference of atmospheric gases is conventionally dealt with in such ways as purging the laser path with nitrogen or scrubbed air to reduce the presence of the analyte in the analyzer housing, but these tactics make the use of the laser cumbersome and inappropriate for real-time use. In other words, no improvement on current technologies.

The potential of laser technology for gas purity analysis has finally been realized in a multi-component hybrid QCL/TDL gas analyzer that has been developed to remove the external light path by using a novel zero gap design. By reducing the external path length to < 1mm, the spectrum arising from it can be almost entirely interferencefree as ambient air has minimal effect on the measuring spectrum. Compared to an analyzer with an external path length of 0.5m, this is a reduction of a factor of 500 for the traverse of the light path. This practically eliminates any spectrum from the external light and enables detection of sub ppmv levels of H2O, CO2, and other gases present in the atmosphere without the requirement to purge the analyzer housing. This new approach makes laser technology a real solution in industrial gas purity measurement for the first time.

While the new zero gap design has made laser technology viable for ethylene purity measurement, other advances have made it the preferred approach. QCL/TDL lasers are semiconductor instruments that produce light in the mid-IR range at a desired wavelength and use a laser chirp technique to scan a spectrum. To start the process, the laser is pulsed with electrical energy and heats up. The wavelength of the emitted light increases proportionally with the increase in temperature. A spectrum of one to three wavenumbers is scanned during the duration of a laser chirp, approximately one microsecond. Then the concentration of analytes can be calculated by converting the raw detector signal into a spectrum. Many thousands of spectra can be collected in just a few seconds since QCL/TDL lasers can be chirped at up to a 100 kHz frequency, and processing these spectra provides a strong signal with a good signal-to-noise ratio. The wavelength region that is scanned is selected to enable measurement of the desired analytes and it is often possible to detect more than one compound with a single device. An advanced signal processing procedure enables real-time validation of measurements and greatly reduces the need for calibrations. The results of this

Chemical Today Magazine | October 2017

multicomponent detection and real-time speeds means ethylene manufacturers can use laser gas analyzers for real-time process control and certify their product in real time by measuring all the components of interest in a single analyzer.

QCL/TDL systems can include up to six high-resolution lasers to measure both the near- and mid-infrared spectral regions for real-time, optimal gas measurement and analysis down to sub ppm concentrations.

The ability to combine multiple lasers/ detectors in a single analyzer, covering the mid- and near-IR ranges, gives a versatile and configurable analyzer the ability to meet the measurement requirements for a range of different applications, and the ability to replace multiple incumbent analyzers with a single compact system which can reduce costs for ethylene measurement by eliminating the upfront price of multiple analysis systems without compromising accuracy. In fact, it can be improved.

The significant improvement in response time is a function of the fact that in a QCL/TDL the sample flows through a measurement cell where laser beams analyze the gas continuously. As a result, the response time is generally less than 10 seconds to get to 90 percent of a step change, so the output is essentially real time and continuous, a capability not possible before in gas purity analysis.

One of the principal applications for the QCL/TDL is in the final purification step which is made in an ethylene fractionation tower, or splitter. To ensure that production is on-spec, itâ&#x20AC;&#x2122;s important that analysis is conducted for process control of the fractionator. It can be difficult to separate ethane and ethylene because they have similar physical properties.

Plants must maintain a very careful balance in their process control in order to keep ethane close to the specification limit without verging off-spec or recycling ethylene. Efficient operation of the tower minimizes energy consumption, avoids ethylene recycling, and decreases product giveaway, maximizing catalyst lifespan and performance to provide significant economic benefits. When plants measure the C1 and C2 molecules, as well as CO and CO2, as is possible with the QCL/TDL, the tower operation reaches optimum efficiency to ensure on-spec ethylene production.

Another application is the monitoring of the conversion in acetylene converters. In the acetylene converters, some molecules can be over-cracked and converted to acetylene during the cracking process. To maximize production, it is important to

convert this acetylene back into ethylene.

This can be accomplished by adding hydrogen in catalytic beds called acetylene converters. There are two acetylene converters used â&#x20AC;&#x201C; one in service and one on stand-by. To optimize acetylene conversion to ethylene and prevent process excursions, itâ&#x20AC;&#x2122;s important to collect analytical data at the inlet stream, mid-bed, and outlet streams. To ensure the maximum amount of ethylene is produced, extremely accurate and rapid control of the catalyst is absolutely critical. If the catalyst is too active, some ethylene could be converted back to ethane, but if the catalyst is not active enough, not all the acetylene will be converted to ethylene. To control catalyst activity, it is essential to measure CO, as well as monitoring the concentration of acetylene to prompt the change from the in-service to the standby unit. To prevent process excursions downstream, it is also key to look for acetylene breakthrough at the outlet of the converters. Measurement of the outlet must be fast and with a low detection limit, so QCL/TDL is an ideal solution for this application as well.

For ethylene manufacturers throughout Asia, the QCL/TDL technology promises the first real-time gas purity measurement that allows one system to be used where multiple devices were previously required, reducing costs and footprint in ethylene plants.

1

IHS Chemical, http://media.corporate-ir. net/media_files/IROL/11/110877/05_Global_ Ethylene_Market_ Outlook_Eramo.pdf

Author: YeeTiong Koh is Business Development Director, Analyzers & Solutions, Asia Pacific at Emerson Automation Solutions.

71

EQUIPMENT AIR QUALITY MONITORING

REDUCE YOUR

ENVIRONMENTAL IMPACT keeping the machines running smoothly & continuously. With a proactive approach & implemented Good Maintenance Practices, a majority of unscheduled failures can be stopped or avoided. These practices, along with the outlook of the management towards maintenance as a value-adding department, than otherwise would help in moving towards a ‘Zero Surprises” process.

The range of technological solutions available today can help the chemical manufacturing companies move towards this goal and eventually help in saving huge costs for the company.

This is where the ACOEM Group with its Proactive Maintenance Solutions plays a vital role in helping the chemical manufacturers turn their production processes into efficient & controlled operations.

The ACOEM solutions – OneProd, Fixturlaser, 01dB & Ecotech, are designed for Machinery health & Environmental monitoring to help the process industry keep a tab on the health of their rotating machinery & further on, the environmental impact due to the process.

BY SAMIR SABNIS

U

nscheduled breakdown is a manufacturer’s nightmare!! More specifically, if it happens to be a continuous process for manufacturing setup like a chemical, dyes or related company. With the manufacturers under more pressure now, for meeting the production targets, a very important and critical aspect of the process is often neglected. It is the health of machinery, equipment, and other ancillary production tools that are often overlooked in order to achieve the production output.

This, in turn, reflects in the net plant efficiency and at times, also the quality of the final product.

Operating a machine with unplanned or no maintenance is a huge risk to take. More so if you are following the same old traditional maintenance methods, you not only end up risking unwanted surprises in the plant but more importantly, it also would end up becoming a safety hazard endangering lives of those operating the machines and

72

Chemical Today Magazine | October 2017

also creating a bad environmental impact.

An improperly maintained machine poses a threat both to human and environment, apart from the operation profitability.

Chemical manufacturers cannot take this risk with the kind of investment made in plant and machinery and the expectation of a continuous process. A single day of unscheduled shutdown means loss of money, power, resources, and output. The chemical industry is often criticized for its negative impact on the environment. Do you know that there is a way out to reduce this impact considerably?

As per many industry experts, the efficiency of process equipment directly impacts the environment, quite similar to the health of a vehicle on the road.

The need of the hour is to implement a proactive maintenance plan. Companies need to move away from traditional maintenance methodology and adopt methods and instruments that can aid in

Other than keeping a periodic or continuous check on the condition of their rotating machinery, the solutions help to identify the onset of a fault developed within the specific component of the machine and generate accurate analysis with recommended corrective measures.

One of the major constraints, especially in India, is the effective implementation of a Reliability Based Maintenance Program in a plant. A plant manager today feels the need to have a robust Reliability Program, which would then bring him in control of the plant process - at any given point.

Nowadays, even wireless solutions are fast becoming the norm. At the plant level, this helps to monitor and cater to hazardous and inaccessible places with ease – ensuring that even such equipment are monitored regularly and the user is in control of the situation, even for critical & inaccessible or hazardous locations in the plant. The early diagnosis of these conditions is all the more helpful.

As the next step for an effective Proactive Maintenance program would be the corrective actions on the identified fault – which is an important step to close the loop and ensure that the fault identified doesn’t aggravate further to also cause any collateral damages.

The other critical issue faced by plants and one of the biggest causes of machinery breakdowns is Misalignment. In industry after industry, critical machines in the production process require precise alignment to perform to specs. As per the international studies, it has been proven that more than 50 percent of the plant machinery failures happen due to improper alignment of the driver and the driven. This makes misalignment the single largest cause of unscheduled machinery breakdown. More vital is to note that a machine running with even a small amount of misalignment can over the period of time, result in considerable damage to direct & indirect components, financial losses due to higher power consumption & lower MTBF. So an investment towards achieving precision machine alignment – whether through latest alignment tools, better alignment practices or better training of the skilled manpower– it can be justified in uptime increases, and make the payback time short. This will ultimately make the chemical industry more profitable and due to the better efficiency- our environment more sustainable.

The Chemical industry manufacturers today face an important compliance issue – that is the tightening of pollution control norms. The chemical industry is drawing a lot of flak on the negative impact its production causes on the environment. As a natural progression on the above production efficiency, chemical manufacturers should aim at partnering with equipment manufacturing companies that will help to curb the impact on the environment both in terms of direct & indirect pollution. These can be air, water, noise, pollution and many others.

Chemical Today Magazine | October 2017

Chemical companies, jointly with monitoring instrumentation manufactures can aim to be more productive while simultaneously ensuring that the environment does not get impacted negatively due to any unchecked emissions.

The pioneering Vibration based Condition Monitoring Solutions and Laser Alignment tools from brands like OneProd, France, and Fixturlaser, Sweden make it possible to monitor & maintain the machinery health.

01dB, France can keep a check on the Noise Monitoring while the Ecotech Ambient Air Quality Monitoring Stations help monitor the plant emissions in real time, helping Chemical Industries to be compliant with the specified regulations and while also contributing to sustainable development strategies.

In today’s time when being sensitive towards the environment has become more of a necessity than an option, it is imperative that manufacturers adopt greener production procedures. A way to achieve this for chemical manufacturing companies is also by increasing the efficiency of the production process.

Coming to the last challenge that companies face in the chemical industry is lack of qualified and skilled technical experts for vibration analysis or implementation of condition monitoring programs.

We at ACOEM aim to be your solution partner and help companies achieve exceptional excellence in machinery health management. Apart from offering equipment, we offer a range of consultancy, mentoring and training services to strengthen technical channels of your maintenance team.

It is important to remember that an optimally and efficient running machine will always have a lower environmental footprint. And at the ACOEM Group, we are committed to “Reduce your Environmental Impact” Author: Samir Sabnis is Managing Director of ACOEM India.

73

EQUIPMENT MIXING/DISPERSING MACHINE

ANSWER IS IN THE AIR

MIXING AND DISPERSING MACHINE USES VACUUM EXPANSION METHOD.

BY DR ING HANS-JOACHIM JACOB

O

nly after being mixed into liquids do powders fulfil their real and final purpose – as colour pigments, thickeners, flavours, matting agents, fillers, reinforcing fibres, catalysts, et cetera. The quality of the final product depends essentially on how well or how badly the powder is decomposed, in other words how effectively every single particle has been wetted and dispersed. If your yoghurt tastes better and your paint is applied more evenly, your photo prints are sharper or your suncream protects your skin much better, then a powerful dispersing machine such as the Conti-TDS was very probably involved.

Whenever paint manufacturing costs are reduced to one tenth, a resin takes only seconds to dissolve rather than hours, a million dollar paper coating machine runs at twice the speed or the batteries of an aging tank can be dispensed with in an ice cream production process, the reason is always the same: a well engineered technology for powder dispersion. This technology separates each particle in the powder using a specific vacuum expansion method. The particles are wetted completely and instantaneously, and dispersed on first contact with the liquid. They are also distributed homogeneously at the same time.

With traditional methods of powder addition, either on top of the liquid surface or possibly below it in vacuum vessels, such as common in-line blenders or injectors, the powder always comes into contact with the liquid as a bulk. The powder particles touch each other. The liquid only wets the compact, and often agglomerated, product from the outside. Local, over-concentrated clusters and wet lumps are created.

All these agglomerates have to be destroyed, resulting in a long mixing time and extensive additional dispersing. This in turn has many negative side-effects and is anything but helpful in most cases: • With yoghurt or desserts the texture is partially destroyed and more proteins and stabilisers are required

74

Chemical Today Magazine | October 2017

Picture 1:

Processing system with Conti-TDS, two processing vessels and one powder hopper

•

With shampoos and gels the viscosity is reduced and more thickener is needed

•

With paints and coatings the binder is stressed and the quality is lower

•

With polymer dispersions unacceptable heating takes place, so that efficient external cooling is a must

•

Additional dispersing requires time, energy and extra tank capacity

Always in motion To avoid agglomerates during wetting and create sufficient space between the particles to allow unhindered penetration of the liquid, these particles have to be separated. Enough distance has to be ensured between each one. Yet how can this best be achieved? Vacuum expansion of the air in a streaming powder is the answer. No additional air is needed. Any powder contains air – quite a lot, in fact. The air content can be easily calculated from the ratio of bulk density to true density of the solids. Even heavy powders such as titanium dioxide still contain 75 % air. Light powders contain much more.

Air expands under vacuum to a multiple of its initial volume. This is exactly what happens when powder is inducted by vacuum. In the streaming powder the distance between particles increases in line with the vacuum due to the expansion of the air. Even compact and dense powders become remarkably fluidised without any additional fluidising air.

It is important that the powder keeps moving under vacuum. It is conveyed at high speed in the inducted powder stream all the way into the dispersing zone and finally into the dispersed liquid. This expansion effect would not work in a vacuum vessel or a rotary feeder, where the powder would settle or retain its bulk density even under vacuum.

Principle of the dispersing unit The Ystral Conti-TDS uses the volume expansion effect to induct and disperse powders into liquids. Its particular feature is a specially designed wetting chamber which creates a maximum vacuum in its dispersing zone, allowing the powder to be directly inducted into the liquid phase.

The powder and the liquid reach this zone by completely separate routes. They cannot mix in an uncontrolled manner and do not build up agglomerates â&#x20AC;&#x201C; only in the wetting zone and under maximum vacuum they are able to come into contact with each other. Since the maximum vacuum occurs at this point, it is here where the distance between the particles is greatest. The particles

are separated as they pass the rotor-stator system and completely wetted by the liquid due to the intensive dispersing at maximum turbulence.

Once the powder has been completely dispersed into the liquid, another question arises: what happens to the air that was present in the powder? It cannot simply disappear. The answer is very simple: because of the centrifugal effect of the high-speed rotor, the air is separated from the significantly heavier liquid dispersion and coagulates to form large air bubbles, which deaerate easily in the downstream process vessel.

With the Conti-TDS, the powder is not added to a tank on the surface of a liquid and there is therefore no dust above this surface inside the tank. Dust above the liquid level always results in powder crusts and contamination on the tank wall, lid, mixer shaft and all sensors or other internals. Such contamination is difficult to clean and very often crumbles away, polluting the product. Owing to the external in-line addition principle of the Conti-TDS, this problem is now a thing of the past. Product quality, cleanliness and reliability are significantly improved.

The Conti-TDS can be used very flexibly. The machine inducts the powder directly from a paper bag, sack tip or big bag station, hopper or container. It can be connected to more than one processing vessel or used at several different sites as a mobile version on casters. It also integrates very easily into existing processing systems.

Graphics 1:

A larger distance between particles enables complete wetting and dispersing in the rotorstator system

Graphics 2:

With the Conti-TDS, even difficult powders can be easily inducted and dispersed directly from a paper bag, big bag, container or silo

Author: Dr - Ing. Hans-Joachim Jacob, Process - and Application Engineering at ystral gmbh.

Chemical Today Magazine | October 2017

75

EQUIPMENT Heat Exchangers with many benefits

A

lfa Laval’s T35/TS35 plate heat exchanger which is widely used in the chemical industries offers many benefits compared to other heat exchangers. The features are it has increased uptime, lower maintenance costs, energy savings, reduced investment costs, easy capacity expansion and lastly, maximum reliability. Based on the M30 range, new features include: New, unique distribution area – less fouling, better heat transfer; ClipGrip gaskets – totally glue free attachment; Gaskets available with two different profiles – maximum lifetime and reliability;Swing Foot – makes opening the unit easy.

Contact: Alfa Laval (India) Limited Office No. 301, Global Port Building, Survey No. 45/1-10, Mumbai Bangalore Highway, Baner, 411 045 Pune, India Tel: +91 206 734 11 00 Fax:+91 206 734 11 15 Email: india.info@alfalaval.com Web:http://www.alfalaval.in

Magnetic Belt Separator to eliminate ferrous particles

G

alaxy Sivtek launched magnetic belt separator to eliminate ferrous particles from final product. It is a new capacity enhancement system to remove iron particles while conveying the material in process industries. The presence of ferrous (iron) particles in the final product such as dry food powder or pharmaceutical API & excipient is one of the major factor leading to low to bad product quality among major process industry. To eliminate ferrous impurities, the company has launched Magnetic Separator - A Magnetic Belt to Eliminate Ferrous Impurities while Conveying the Material.

Contact: Galaxy Sivtek Pvt. Ltd. Plot No. 1406, GIDC, Waghodia 391760, Vadodara, Gujarat, India Tel: +91-2668-262970/+91-2668-263170 Email:inq@galaxysivtek.com Web:http://www.galaxysivtek.com

New air cooled dry pumps for scientific instruments

E

dwards launched the new air cooled nXLi dry vacuum pump range, ideal for applications where consistent performance, reliability and control are required. The nXLi provides a small footprint with quiet operation, making it a convenient and high performing yet compact vacuum pump. There is a choice of control options, with either manual, simple remote or serial communications control as standard, allowing more flexible control options for the system builder. During the initial chamber pump down the intelligent transient overload protection allows a higher power draw for a short period of time. This new single phase pump is available in two options, nXL110i and nXL200i, both optimised for LCMS (liquid chromatography – mass spectrometry) and ICPMS (inductively coupled plasma mass spectrometry) duties, and capable of handling gas loads of up to 25 slm.

Contact: Edwards Innovation Drive, Burgess Hill, West Sussex, RH15 9TW, UK Tel: +44 (0) 8459 212223 Fax:+44 (0) 1444 253001 Email:info@edwardsvacuum.com Web:https://www.edwardsvacuum.com https://www.edwardsvacuum.com/media/

Multichannel pipetting to reduce adverse effects

I

ntegra offers a wide range of multichannel pipettes, both manual and electronic, which do not suffer any of the adverse effects. The use of microplates is now standard in most laboratories, making multichannel pipettes the perfect tools to increase productivity and reproducibility.

Working with eight-, 12- or 16-channel pipettes dramatically reduces the number of pipetting steps compared to single channel pipetting.

Some of the great frustrations when working with multichannel pipettes are misaligned pipette tips, tips that leak or, worst case, tips that fall off, resulting in wasted reagents or work that has to be redone. These issues are due to the widespread use of unfavourable pipette tip and tip fitting designs that requires excessive force to load tips across all channels.

76

Chemical Today Magazine | October 2017

Contact: Integra Biosciences AG Tardisstrasse 201, CH-7205 Zizers, Switzerland Tel: +41 81 286 95 55 Email:info-ch@integra-biosciences.com Web:https://www.integra-biosciences.com

Flow Monitor for enhanced data logging, remote access

B

adger Meter introduced Blancett® B3100 Series flow monitor, a flexible, durable, easy-to-use digital signal processing platform for demanding flow metering applications. The B3100 flow monitor incorporates advanced options with user-friendly full operation through the glass. Data logging, and remote data access and programming are available without opening the enclosure. The B3100’s remote programming capability is a key product feature, which allows for full configuration of the flow monitor. Enhanced functionality is ideal for use with automated systems in remote locations, such as monitoring of meters in oil fields. Other typical applications include secondary oil recovery, remediation and reclamation, fracture/ refracture, coal bed methane, regulatory compliance and environmental accountability, chemical processing, semiconductor manufacturing, fertilizer production and dispensing, pesticide manufacturing, and liquid batching and water-cooling.

Contact: Badger Meter 4545 W Brown Deer RD, PO Box 245036, Milwaukee, WI 53224-9536 USA Tel:800-876-3837 Email:infocentral@badgermeter.com Web:https://www.badgermeter.com

Process analyzers to monitor critical chemical parameters

M

etrohm Process Analytics introduced the new family of economical online process analyzers: the 2026 Titrolyzer and 2029 Process Photometer. These powerful, compact process analyzers are integrated solutions for 24/7 online analysis of critical chemical parameters in industrial processes and wastewater streams. A 7” full-color touchscreen shows trend graphs and allows easy access to customer data. These process analyzers are especially suitable for analysis in the chemical, petrochemical, semiconductor, food and beverage, potable water, and environmental branches.

Contact: Metrohm USA, Inc. 6555 Pelican Creek Circle, Riverview, FL 33578, USA Tel: 866-638-7646 Email: info@metrohmusa.com Web:https://www.metrohm.com

Innovative flow meter uses SAW waves

T

he food & beverage, pharmaceutical and cosmetics industries require flow meters that not only operate with high precision, but also meet strict standards and legal requirements with regard to hygiene and cleaning. With FLOWave Type 8098, Burkert offers a practical solution for this purpose. The flow meter operates according to the patented SAW process (Surface Acoustic Waves), which uses surface waves to perform measurements. The primary advantage of this process is that there are no installed fittings or constrictions, which also means there are no empty spaces in the measurement tube. Measurements can be taken in standing liquids in fast-flowing liquids or in liquid flows that change direction. In addition, no maintenance work is required, which can significantly reduce the operating costs.

Contact: Christian Bürkert GmbH & Co. KG Christian-Bürkert-Strabe 13 – 17, 74653 Ingelfingen, Germany Tel: +49 7940 10 0 Fax: +49 7940 10 91204 Email:info@burkert.com Web:http://www.burkert.com

New solution for walkaway LC-MS sample preparation

T

ecan has unveiled its latest innovation, the automated RESOLVEX™ A200 positive pressure workstation for LC-MS sample prep.

This walkaway system further expands Tecan’s portfolio of MS sample preparation workstations and smart consumables, uniquely allowing the company to provide complete solutions to match any workflow, from manual processing to semi-automated high throughput systems based on a Freedom EVO® or Fluent® platform. The RESOLVEX A200 offers unattended positive pressure solid phase extraction, providing increased walkaway times for LC-MS sample preparation workflows. Lighter and smaller than previous systems, it has been carefully designed to offer greater ease of use and enhanced performance. The intuitive touchscreen control enables straightforward integration into laboratory protocols for immediate productivity.

Chemical Today Magazine | October 2017

Contact: Tecan Trading AG Antonietta Allocca, Seestrasse 103 CH-8708 Mannedorf, Switzerland Tel: +41 (0)44 922 81 11 Fax: +41 (0)44 922 81 12 Email:info@tecan.com Web:www.tecan.com

77

ADVERTISING INDEX 03

Ystral India Pvt. Ltd. India Tel: +91 80 49528787 E-Mail: ranjan@ystralindia.com www.ystral.com

Sharplex Filters (India) Pvt. Ltd.

15

India Tel: +912269409850/60 E-Mail: sales@sharplexfilters.com www.sharplex.com

Kimberlite Chemicals (India) Pvt. Ltd. Front Inside

Xobber

India Tel: +91 80 42487300 Email: info@kimberliteindia.com www.kimberliteindia.com

India Tel: +91 80 42487301 Email: sales@xobber.com www.xobber.com

Back Cover

GLOSSARY PAGE NO

PAGE NO

Accenture

05

FICCI

06, 40

Pfizer

ACOEM India

73

Future Market Insights

45, 52

pkm construction & srp chemicals

48

Agrium

47

Galaxy Sivtek

76

Plaintiffs

09

Gassnova

11

PMFAI

Geofin Comtrade

05

Resil Chemicals

25

Rutgers University

56

Aimco Pesticides

78

PAGE NO

34, 40

Air Liquide

09

AkzoNobel

08, 30, 64

Grand View Research Inc

47, 49

64

34, 40

Alexfert

05

Henkel Adhesive

27

Sanofi

64

Alfa Laval

76

Honeywell

32

Shell

11

Badger Meter

77

Huntsman

64

SICPA

05

BASF

17, 41, 47, 55

Indian Express

06

Society for Science & the Public

62

Bayer

41, 47

Indian Oil Corp

07

Solvay

64

Beaulieu Fibres International

18

Infosys

41

SONGWON

29

Bielefeld University

54

Integra Biosciences

76

Statoil

11

Bureau of Indian Standards

06

Jowat Corporation

66

Swinburne University of Technology

60

Cabot

10

Kehdem Media

50

Syngenta

09

Chennai Petroleum Corp

07

Kemira

Tecan Trading

77

Chevron

12

Lanxess

67

Tianjin University

58

Christian BĂźrkert

77

Lonza

64

Total

11

Dow

10

Lubrizol

10

Trinseo

10

DowDuPont

10

Maruti Suzuki

05

TSMG

40

DuPont

47

Metrohm USA

77

University of Bath

37

Eastman

64

Michelman

67

University of Birmingham

36

Edwards

76

Monsanto

47

University of Boras

38

Emerson Automation

71

National Iranian Oil

07

University of Delaware

Endress+Hauser

68

Nissan

09

University of Illinois

Equate

12

Nobel Prize in Chemistry

13

University of Western Australia

55

Evonik

64

ONGC

12

Volkswagen

05

Expanded Polymer Systems Pvt

05

Panacol-Elosol

66

Wacker

08

FCI

05

Persistence Market Research

51

ystral gmbh

75

Chemical Today Magazine | October 2017

24, 64

56 36, 39

October Issue

Sector Focus Chemicals Section Agro Chemicals

• Fertilizers • Pesticides • Insecticides • Fungicides • Herbicides • Bactericides

Pulp and Paper

• Pulping Chemicals • Bleaching Chemicals • Sizing Agent • Wet Strength Additives • Dry Strength Additives • De-Inking Agents • Slime Control Agents • Defoamers & Deareators • Water Repellents • Pulp Flocculants • Retention Agents • Dispersing Agents • Binding Agents • Wax Emulsifiers • Wood Preservation • Wood Treatment

Mining

• Emulsifiers • Flotation Reagents • Coagulants • Collectors • Depressants • Dewatering • Dispersants • Dust Control Suppressants • Flotation Frothers • Heat Transfer Fluids • Flocculants

Resins

• Chemical Resins • Plastic Resins • Acrylic Resins • Polypropylene Resins • Melamine Resins • Epoxy Resins • Vinylester Resins • Polyester Resins • Aliphatic Resins • Aromatic Resins • Terpene Resins

Equipment Section Chemical Process Equipment

• Agglomerators • Agitators • Air Strippers • Blenders • Blowers • Chillers • Compressors • Condensers • Cooling towers • Crushers • Crystallisers • Distillation Equipment • Drivers • Dryers • Dust Collection Equipment • Evaporators • Feeders • Filtration Equipment • Fractionators • Granulators • Heat Exchangers • Incinerators • Industrial Ovens • Mixing Equipment • Mills • Pipes • Precipitators • Pressure vessels • Pumps • Reactors • Shredders • Screening Equipment • Scrubbers • Sedimentation Equipment • Seperation Equipment • Storage Tanks •Valves • ventilators • Air Handlers • Autoclaves • Bioreactors • Blow Molding

November Issue

Sector Focus Chemicals Section: • • •

Pharmaceutical Bulk Drugs Lab Chemicals

Equipment Section: •

Lab & Analytical Instruments

Augu

s

t 2017

r 2017

mbe Septe

Send your queries to

Email: media@worldofchemicals.com Chemical Today Magazine | October 2017

79

78 94 80

Chemical Today Magazine | January October 2017

TELL US YOUR

CHEMICAL

REQUIREMENTS Plastics & Polymers Speciality Chemicals Basic Chemicals Emulsion Health Cosmetics & Personal Care Surfactants Paint & Coatings Aerosols Gas Treatment Cleaning & Sanitation Textile Pigments Oil & Petroleum Fluids Electroplating Construction Electronic Pulp & Paper Resins Bulk Drugs Water Treatment

Rubber Fine Chemicals Food Additives Sugar Dairy Soaps & Detergents Enzymes & Hormones Propellants Industrial Chemicals Flavours & Fragrances Biocides Inks & Dyes Glass & Ceramics Fuels & Lubricants Adhesives & Sealants Metal Treatment Leather Agrochemicals Mining Pharmaceuticals Lab Chemicals Silicones

TELL US YOUR EQUIPMENT

REQUIREMENTS Chemical Process Equipment Lab & Analytical Chemical Storage Equipment MRO Equipment Plant Utilities

Chemical Resistant Equipment Safety Equipment Transport Equipment Material Handling Equipment Chemical Industrial Automation

Send your enquiries to:

Email: info@worldofchemicals.com

"

Chemical Today Magazine | October 2017

79 81

Kimberlite Softwares Pvt Ltd #10, Pampa Extension, Kempapura Bangalore-560024 Tel: +91 80 23621441

Postage Stamp

Please complete the following & get a quick effective response from suppliers: Your line of business Name: Designation: Company Name: Address: City: Tel: Email:

Pin

editorial@worldofchemicals.com

RNI: KARENG/2016/71454 REGISTERED/KRNA/BGE-1148/2017-2019 POSTED AT BANGALORE PSO 560026 ON 7TH OR 11TH OR 13TH EVERY MONTH TOTAL NO OF PAGES 86 DATE OF PUBLICATION: 7TH OF EVERY MONTH.

Xobber

Where Business Needs are Cognized

Get Ready to

Make Smart Decisions for Your Chemical Business Now An elegant business tool with abundant number of handy features; lets you do bigger than your vision, regardless the size of your enterprise.

Contact us for free DEMO

Mob: 9620220027 | Phone: +91 80 42487301 | Email: sales@xobber.com

Visit: www.xobber.com Xobber

Chemical Today Magazine | May 2017