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CHRONICLING PROCESS INDUSTRY INNOVATIONS SINCE 1966

CHEMICAL ENGINEERING WORLD APRIL 2016 VOL. 51 ISSUE 4 Mumbai ` 150

Mumbai 2017

14-17, February 2017 Mumbai, India

VOL.51 | ISSUE 4 | APRIL 2016 | TOTAL PAGES 76 | US $ 10 | ` 150

Chemical Engineering World

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VOL. 51 | ISSUE NO. 4 | APRIL 2016 | MUMBAI | ` 150 NEWS ► Industry News / 6 Technology News / 20

NEWS FEATURES ►

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MARKETING INSIGHT► Fuel Emulsification: An Unknown But Profitable Technology / 53

MARKETING INITIATIVE ► A Complete and Versatile Range of Vacuum Pumps… / 55 Extension to Qdos Range Offers Opportunities for Upscale to Higher Flow Rates… / 58 Top 3 Facts About Led Technology; Led: Long-Life, Efficient, Dynamic / 60

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4 • April 2016

Book Shelf / 71

Building Economies of Scope for Business Value Creation – Ajay Durrani, Managing Director, Covestro India Pvt Ltd

Disclaimer: The Editorial/Content team at Jasubhai Media Pvt Ltd has not contributed to writing or editing “Marketing Initiative.” Readers would do well to treat it as an advertisement.

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Chemical Engineering World

CEW Industry News LANXESS to Support the Cause of Education through Teach for India.

KEPL Shipped API BB4 Pumps to Mirfa International Power and Water Company

Thane, India: LANXESS India Private Limited, a subsidiary of leading global specialty chemicals company LANXESS, is continuing its association with Teach For India (TFI) as a part of its pledged five year commitment to support the not-for-profit organization’s effor ts towards providing quality education to children. The company has committed a sum of EUR 75000 (approx. INR 53 lakhs) per year for projects in India for the period 2014 - 2018.

Pune, India: Pune-headquartered Kirloskar Ebara Pumps Ltd (KEPL), a joint venture of Kirloskar Brothers Ltd (KBL) in India, has successfully completed the manufacturing and testing of High Pressure Ring Section type Boiler Feed Water Pump with 3.9 MW motor. These pumps are for 1400 MW greenfield combinedcycle power generation plant - Mirfa Independent Water & Power Company, Abu Dhabi (UAE).

Dr. Jacques Perez, Managing Director and Country Representative, LANXESS India Pvt. Ltd. handed over the cheque to Ms. Dimple Gujral, Chief Finance Officer, Teach For India (TFI) at LANXESS House in Thane. LANXESS has been contributing to TFI since 2010, starting with a sum of EUR 50,000 per year. LANXESS has supported 50 TFI Fellows (trained teachers on a 2 year full time paid commitment) and around 2275 students so far. This contribution helps TFI to sustain their current operations in Mumbai. On this occasion, Dr. Perez, said, “Education is one of the crucial tools towards securing the future of the next generation and by partnering with Teach for India, we would like to help spread the light of knowledge. We appreciate the work that Teach For India is doing and are happy to be a part of this noble cause.” M s. G u j ra l a d d e d , “ We fe e l p r o u d t o b e a s s o c i a t e d w i t h LANXESS for over 5 years and LANXESS has always been a strong supporter of our beliefs. For us at TFI, every single child matters. We believe that every child can and must attain an excellent education.” LANXESS believes in empowering education and has taken many initiatives in India, in the areas of education, skills training and preser ving cultural heritage. LANXESS has previously contributed to NGOs, technical institutions and schools to support education in every region that it operates in.

Storage Status of 91 Major Reservoirs New Delhi, India: The water storage available in 91 major reservoirs of the country for the week ending on April 07, 2016 was 37.92 BCM which is 24 per cent of total storage capacity of these reservoirs. This was 69 per cent of the storage of corresponding period of last year and 77 per cent of storage of average of last ten years. The total storage capacity of these 91 reservoirs is 157.799 BCM which is about 62 per cent of the total storage capacity of253.388 BCM which is estimated to have been created in the country. 37 Reservoirs out of these 91, have hydropower benefit with installed capacity of more than 60 MW. 6 • April 2016

The testing of high pressure Boiler Feed Pump took place at Kirloskarvadi, Maharashtra which was witnessed by officials from various users and EPCs of the power industry. KEPL pump model 250 X 200 KBDH is an 8 stage pump designed for high pressure Boiler Feed Water application.BB4 pump is a multistage between bearing, ring section and single casing pump designed for high pressure applications. This pump has a motor rating of 3900 kW having capacity of 740 m³/ hr and 1380 meter differential head achieved at a speed of 2974 revolutions per minute (RPM). The Mirfa Independent Water and Power Plant (IWPP) is a Power and Water Desalination Plant with a total combined net power capacity within the range of 1,400 and 1,600 MW of power generation and a total combined net water capacity of 52.5 million imperial gallons per day (MIGD), located on the Arabian Gulf coast, at Mirfa, approximately 160 km West of the city of Abu Dhabi in the Emirate of Abu Dhabi (UAE). This project will involve the acquisition of certain existing water and power facilities; the development, design, engineering and construction of new power and water facilities; as well as the operation of the plant.

Thirumalai Chemicals Mulls Business Expansion Mumbai, India: Thirumalai Chemicals Ltd (TCL) is studying options to significantly expand its Food Ingredients and Gas based Intermediates businesses. TCL is considering alternate manufacturing locations in the Asean, North America and the Middle East. The expansion will be in stages, and will also include sizeable capacity additions to its merchant Maleic Anhydride business. TCL presently manufactures Phthalic Anhydride, Food Ingredients & Specialty Chemicals in India, and Maleic Anhydride at its subsidiary in Malaysia, which brought on stream a major expansion during 2015. TCL markets its products in India, the EU and the Asean. The proposed growth will help TCL to serve its current markets and customers better, and to expand into new geographies. Chemical Engineering World

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CEW Industry News Saudi Aramco and LANXESS Complete JV Deal Mumbai, India: Specialty Chemicals Company LANXESS and Saudi Aramco have completed the formation of their 50-50 joint venture for synthetic rubber, ARLANXEO. The deal was first announced in September 2015, and all relevant antitrust authorities had cleared the transaction by February 2016. With the closing of the transaction, a 50 percent share in the joint venture ARLANXEO was transferred to Dutch Saudi Aramco subsidiary, Aramco Overseas Holdings Coöperatief U.A. In return, LANXESS received cash proceeds of around EUR 1.2 billion. LANXESS plans to invest around EUR 400 million of the proceeds from the transaction in organic growth. Another roughly EUR 400 million is earmarked for a further reduction of its financial debt position and around EUR 200 million are planned to be used for a share buyback program. W i t h t h e l a u n c h o f A R L A N X E O, t h e c o m p o s i t i o n o f t h e company’s Shareholders‘Committee was also announced. It is chaired by LANXESS’ Chairman of the Board of Management Matthias Zachert. Warren W. Wilder, Vice President Chemicals at Saudi Aramco, is Vice Chairman. The additional members of ARLANXEO’s Shareholders’ Committee are Michael Pontzen, LANXESS’ Chief Financial Officer, and Khalid H. Al-Dabbagh, Controller at Saudi Aramco.

Orange Renewable, SECI to Develop 100 MW Solar Power Project in Maharashtra Mumbai, India: Orange Renewable, a subsidiary of Singapore based AT Holdings Pte Ltd, has signed Power Purchase Agreement with Solar Energy Corporation of India Limited (SECI) onfor development of 100 MW solar power project in Maharashtra under JNNSM Phase- II, Batch – III Scheme. SECI has been designated as the nodal agency of GOI for implementation of MNRE schemes for developing grid connected solar power capacity. MNRE has revised the cumulative targets under National Solar Mission from 20 GW to 100 GW by 2021-22 which has given a big boost to the Indian Solar sector and has made India the preferred destination for investors. Orange Renewable has won this contract through a competitive bidding process followed by online live reverse auction conducted by SECI on TCIL platform. In the reverse auction processonly 8 bidders were able to bag the projects where Orange Renewable emerged as one of the largest capacity off taker in this bidding. Total tendered capacity was 450 MW and the projects fall under a Non-Solar Park Scheme. Orange Renewable will receive an average power tariff of INR 4.43 per kilowatt-hour for the next 25 years from commercial operation date of this project which is scheduled in 2017. 8 • April 2016

National Seminar on Multi-Purpose Development of Water Resources and Present Challenges Held New Delhi, India: Union Minister for Water Resources, River Development and Ganga Rejuvenation Sushri Uma Bharti has called for water revolution in the country. Addressing a seminar on Multi-purpose Development of Water Resources and Present Challenges in New Delhi, the Minister expressed concern over drought in certain parts of the country. She directed officials of Central Water Commission and other allied agencies in her Ministry to visit every block of drought affected areas in the country to chalk out a detailed plan to face this challenge. The Minister said we should have this kind of planning for every block of the country to effectively face drought in future. Sushri Bharti also announced that 100 villages dominated by SCs in the country will be selected under Jal Gram Scheme for water conservation. Jal Gram is a schemes under Jal Kranti Abhiyan of Ministry of Water Resources, River Development and Ganga Rejuvenation, in which two water starved villages will be selected from every district in the country for all round development of water resources. The Minister referred to little known contributions of Baba Saheb in water resources sector and announced that from next year her Ministry will celebrate Dr. Ambedkar’s birth anniversary as Jal Divas. The seminar was organised by Central Water Commission under Ministry of Water Resources, River Development and Ganga Rejuvenation as a part of 125th Birth Anniversary celebrations of Dr. BR Ambedkar to highlight Ambedkar’s contribution in water sector and discuss the way forward to realize his vision.

Centre Approves Fixation of NBS Rates for P&K Fertilizers for 2016-17 New Delhi, India: The Cabinet Committee on Economic Affairs, chaired by the Prime Minister Shri Narendra Modi has approved fixation of Nutrient Based Subsidy (NBS) rates for Phosphatic and Potassic (P&K) fertlizersfor the year 2016-17, due to decreasing trend in international prices of finished fertlizers and raw materials. At the same level of consumption of P&K fertilizers (about 310.44 LMT) during 2016-17 as in 2015-16, the total subsidy implication on P&K fertilizers for 2016-17 at proposed rates works out to be about Rs.21,274 crore. Government has been implementing Nutrient Based Subsidy (NBS) Policy for decontrolled P&K fertlizersw.e.f. 1stApril, 2010. Under this Policy, the subsidy onPhosphatic and Potassic (P&K) fertilizers is announced by the Government of annual basis for each nutrient i.e., Nitrogen (N), Phosphorous (P), Potash (K) and Sulphur (S) on per kg basis which is converted into subsidy per tonne depending upon the nutrient content in each grade of the fertilizers. These rates are determined taking into account the international and domestic prices of P&K fertilizers, exchange rate, inventory level in the country etc. Chemical Engineering World

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CEW Industry News LANXESS’ AII Unit Completes 3 Year Investment Plan in the Aromatics Network

Consultative Committee Meeting of Ministry of Chemicals and Fertilizers Held in Mumbai

Thane, India: The production of aromatic intermediates is a core competency of specialty chemicals company LANXESS, as demonstrated by a recently completed, three-year investment program totaling over EUR 20 million aimed at expanding the company’s aromatics network. The comprehensive modernization project focused mainly on facilities that manufacture nitrotoluenes, chlorobenzenes, and their downstream products.

Mumbai, India: The Consultative Committee meeting of the Department of Fertilizers, Ministry of Chemicals and Fertilizers was held in Mumbai. The subject for the meeting was Neem Coated Urea. The Union Minister for Chemicals and Fertilizers, Shri Ananth Kumar, chaired the meeting. It was attended by the Minister of State for Chemicals and Fertilizers, Shri Hansraj Gangaram Ahir, and Hon’ble Members Dr K C patel, Prof K V Thomas, Shri Rahul Ramesh Shelwale, Shri Sudheer Gupta, Shri Virendra Singh, Smt Kahkashan Perween, Shri Mohd. Ali Khan and Shri Ramnath Thakur. The officers of the Department of Fertilizers were also present.

Since 2013, LANXESS has modernized several production plants in the aromatics network operated by the Advanced Industrial Intermediates (AII) business unit at the German locations. Since the introduction of state-of-the-art automation systems, LANXESS also tapped into considerable capacity reserves, for example for nitrotoluene derivatives. At the same time the safety equipment was updated and significantly improved once again. Developed over decades, the LANXESS aromatics network is a complexly networked structure encompassing seven large production plants that manufacture over 60 synthesis components from petrochemical raw materials. Its name comes from the products themselves: aromatic compounds, mostly derivatives of benzene and toluene, of which chlorobenzenes, nitrotoluenes and their downstream products are among the most important. They are used by numerous industries to generate a wide range of final products.

Farrokh Bhathena Appointed as Sales and Marketing Director at KSB Pumps Mumbai, India: In a fierce competitive environment, when sustaining market leadership is one of the most important goals of KSB Pumps Limited in India; Farrokh Bhathena has been handed over the responsibilities of Director – Sales & Marketing from April 2016. With his over 25 years of experience in Sales and Marketing, Mr. Bhathena is all poised to strengthen the position of KSB in India. Bhathena is a graduate in mechanical engineering and a certified Marine Engineer. After a stint of 10 years in the Merchant Navy, he joined KSB India in 1990 as an Executive Officer and was a part of the team handling pumps for refinery, petrochemical and fertilizer industries. Before taking over as Director – Sales and Marketing, Bhathena held senior positions as Head of Product Management and as the Head of Energy Business. At the time Bhathena has taken over the responsibilities of Sales and Marketing of the Indian arm of KSB; he is all set to steering this over Rupees. 8000 Mio company today; to beyond Rupees 10000 Mio, in the next few years! Today, KSB in India offers solutions through Pumps; Valves and Services; to customers from Power; Oil and Refinery; General Process Industries; Construction; Water and Waste Water segments. 10 • April 2016

The members were apprised about the status of Neem Coated Urea production. The New Urea Policy, 2015 of Government of India is aimed at maximising indigenous urea production and promoting energy efficiency in existing plants. The Policy has led to an additional production of 20 Lakh Metric Tonnes (LMT) from the previous year and the total production of Urea during the year 2015-16 was 245 LMT ie the highest ever Urea production in the country. In May, 2015, Government had made mandatory the entire production of Urea with neem coating. The entire indigenous Urea and the imported Urea is being Neem coated wef 01.09.2015 and 01.12.2015 respectively. Neem coated Urea is expected to result in the reduction of consumption of Urea and will also curb diversion of Urea for non agricultural purposes. Hon’ble members were also apprised about the various other benefits of Neem Coated Urea.

Solvay to Increase its Hydroquinone and MEHQ Production Capacities New Delhi, India: Solvay Aroma Performance, the worldwide leader in diphenol and derivatives intermediates, announces its plan to build an additional production capacity of Hydroquinone (HQ) in China starting-up in 2018. This investment will be based on an innovative and environmental friendly technology. In addition, the Global Business Unit will extend its worldwide Methyl hydroquinone (MEHQ also referred as PMP – paramethoxyphenol) capacity. Both projects will support Solvay captive needs as well as the growth of HQ and MEHQ markets, particularly in Asia. “This decision will strengthen the company leading position in growing markets like Monomer inhibition with a full range of solutions including PTZ coming from Cytec acquisition, Specialty polymers and Coatings applications as well as Food & Feed antioxidants on which we are positioning ourselves” says Dominique Rage, President of the GBU. “This major capacity increase enhances our reliability towards our customers and will allow for new growth opportunities” he adds. Chemical Engineering World

CEW Industry News SRF to Set Up a Pilot Plant for New Generation HFO 1234yf Mumbai, India: The Board of Directors of SRF Ltd, an intermediate chemicals manufacturer and a leader in refrigerant gases, approved an investment proposal for setting up of a pilot plant to manufacture next generation refrigerant gas, HFO 1234yf. The breakthrough initiative will make SRF the first technology developer outside US and EUROPE for manufacture of HFO 1234yf, which is expected to find increasing use in car airconditioning systems globally in future. By venturing to develop its own process through strong and proven in-house R&D capabilities in refrigerant gases and high value fluorine based products, SRF Ltd has further reinforced its expertise and demonstrated its leadership in this niche domain. The in-house technology will also allow SRF to manufacture, brand and sell HFO 1234yf in India and in global markets and also develop other HFO refrigerants in future. The capex for setting up a pilot facility for HFO 1234yf is a milestone step in SRF’s journey towards becoming an R&D based chemical manufacturer at the world stage. The roots of SRF’s success in the space of R&D go back to the mid 90s when it became the first company in India to have indigenously developed the technology to manufacture HFC 134a and HFC 32. Till date, SRF remains the only producer of HFC 134a in India and has recently commissioned its HFC 32 plant, again with its own technology.

Green Biologics Partners with Acme-Hardesty Ashland, UK: Green Biologics, Inc, the US subsidiary of Green Biologics Ltd, a UK industrial biotechnology and renewable chemicals company, announced a distribution agreement with Acme-Hardesty, a division of Jacob Stern & Sons, Inc. and a leading U.S. supplier of bio-based chemicals. Acme-Hardesty will focus its efforts on marketing Green Biologics’ renewable n-butanol and acetone for high value applications in food ingredients, cleaning products and bio-lubricants. “We’re pleased to announce this partnership with Acme-Hardesty,” said Timothy G. Staub, Global Vice President of Business Development for Green Biologics. “Acme-Hardesty’s history in sustainable chemistry reaches back to the 1880s with Jacob Stern & Sons, and we’re delighted to align Green Biologics with this outstanding industry leader.” Using a proprietary fermentation platform, Green Biologics is able to produce higher quality chemicals that are molecularly identical to their petro-based counterparts without the associated contaminants produced through traditional routes. Compared to traditional fermentation platforms, the Green Biologics platform can significantly reduce both the production cost and the capital cost of implementation. 14 • April 2016

Indo German Agreement on Namami Gange Signed New Delhi, India: An Implementation Agreement for Ganga Rejuvenation under the Namami Gange Programme was signed in New Delhi today between the Ministry of Water Resources, River Development and Ganga Rejuvenation and German International Cooperation (GIZ) of Germany. The objective of the agreement is to enable responsible stakeholders at National and State level to apply integrated river basin management approach for the rejuvenation of the river Ganga. This will be based on Indo-German Knowledge exchange and practical experience on strategic river basin management issues, effective data management system and public engagement. The project will closely cooperate with other National and international initiatives including Indo-German bilateral projects like Support to National Urban Sanitation Policy (SNUSP) and ‘Sustainable Environment-friendly Industrial Production’ (SEIP). The project duration is three years i.e. from 2016 to 2018 and the German contribution in the project will be to the tune of Rs. 22.5 crore. Initial actions will focus on the State of Uttarakhand, with scope of expansion to other upstream Ganga States. The ultimate goal is to adopt the successful river basin management strategies used for Rhine and Danube and replicate the same, wherever possible for attaining the pristine status of river Ganga.

Dow Wins US Water Prize Minnesota, USA: The Dow Chemical Company has been awarded the prestigious US Water Prize by the US Water Alliance for its work in promoting and enabling more sustainable use and management of water by companies across the water value chain. The prize is awarded annually, and this year, Dow is being recognized for its leadership in developing new water management strategies, offering innovative products and technologies, and entering into effective collaboration models that make these solutions more attainable. Research estimates that if current water use trends continue, global demand for water will exceed viable resources by 40 per cent by 2030. With global water demand for manufacturing expected to increase by 400 percent by 2050, Dow contends that organizations seeking to remain in business must use this scarce resource more efficiently. Water demand trends are fueling an urgency to move from a linear economy model of “take, make and dispose” of raw materials to a circular approach in which raw materials are “reduced, reused and reclaimed.” Dow Water & Process Solutions (DW&PS) is the business unit of Dow that provides sustainable liquid purification and separation solutions, and it has been a vocal proponent of a circular economy model that emphasizes the need to reduce, reuse and reclaim the world’s limited water resource, sustained by advances in science and technology. Chemical Engineering World

CEW Industry News Pulsar Introduces MicroFlow Worcestershire, UK: UK measurement specialist Pulsar Process Measurement’s latest launch is MicroFlow, a microwave based non-contacting velocity sensor that mounts simply above a channel to provide maintenance-free, reliable, repeatable and accurate velocity measurement. For flow volume measurement, velocity x area provides a costeffective alternative to a channel restriction such as a flume, and a viable solution in situations where system hydraulics do not permit the installation of any primary measurement device. MicroFlow can be used as a stand-alone device, outputting velocity data via RS485 Modbus with a measurement accuracy of ±0.033m/s or 0.5%, whichever is greater. The industr ystandard data can be used for datalogging or alarm purposes, or processed further in a PLC. MicroFlow can also integrate with Pulsar’s FlowCERT ultrasonic flow measurement controller and a transducer such as Pulsar’s flow-dedicated dBMACH3 to create a complete open channel flow measurement system. MicroFlow consists of a compact, lightweight low-cost sensor, and is simply installed on a bracket above the flow at a 45º angle. Loop power and straightforward RS485 PC set up means that connection is simple and quick. Signal processing is via Pulsar’s well-proven digital algorithm and is a development from the system first seen in their award-winning FlowPulse device for measurement in closed pipes.

Bodal Chemicals Gets Govt Nod for Vadodara Unit Expansion Vadodara, India: Bodal Chemicals Ltd had applied for Environment Clearance (EC) from Ministr y Of Environment, Forests and Climate change, New Delhi for Expansion of its Dyes and Dyes Intermediates Manufacturing capacity (from 2,200 MTPM to 6,000 MTPM) and Co-generation Power Plant (SMW) at our Unit 7, Village Dudhwada, Tehsil Padra, District Vadodara, Gujarat. Bhavin S. Patel, Executive Director commented that with this approval in place, company is in a position to plan to enhance its dyestuff manufacturing capacity at very low capital cost compare to cost of green field proj ect or cost required for commencement of new plant in this sector. This is considering the ready civil structure, other infrastructure and utilities at our existing plant at the location. After complying the stringent norms and lengthy process it took more than 5 years for the company to get the said approval. It is also important to note that in the increasing trend of per unit power cost scenario, once 5MW power plant is commissioned, company will able to save significantly in power cost. 16 • April 2016

BASF Launches New Brand for the Construction Industry Mumbai, India: BASF started to roll out its Master Builders Solutions brand in Asia Pacific today as part of a phased launch process. The global brand is a sign for BASF’s commitment to the construction industry and represents a wide range of construction chemical solutions previously sold under a variety of specialty brands. The portfolio of products and services marketed under the Master Builders Solutions brand embraces chemical solutions for new construction, maintenance, repair and renovation of buildings and infrastructure: concrete admixtures, cement additives, chemical solutions for mining and tunneling, waterproofing, concrete protection and repair products, grouts and high-performance flooring products. ”Master Builders Solutions embodies our ability to collaborate across technologies and functions on a global scale. That way we create solutions geared to meet the individual construction chemical challenges of our customers,” said Dr Tilman Krauch, president of BASF’s Construction Chemicals division. “This one global brand draws on a number of successful specialty brands such as Master Builders, Glenium and Ucrete, and is based on a more than century-old tradition of innovations for the construction industry,” adds Dr Krauch BASF builds on that legacy with expertise, commitment and a customer-centered approach. In that manner, the Master Builders Solutions launch supports BASF’s strategy to intensify its focus on customer industries.

Godavari Biorefineries Increases Production Capacity Bangalore, India: Godavari Biorefineries Limited has commissioned its expanded facility for dehydrated ethanol (fuel grade) manufacturing at Sameerwadi in Karnataka. With this expansion, the company has the capacity to make 50 million litres per year of fuel grade ethanol, up from 15 million litres currently. The expansion of the fully automated plant using Molecular Sieve Dehydration Technology was completed in 5 Months. The facility will use byproducts of their sugar manufacturing process as raw material. Godavari Biorefineries Ltd. is a biorefining company producing sugar, biofuels, chemicals, power, compost, waxes, and related products, using sugarcane as the primary feedstock. The company has manufacturing plants at Sameerwadi, Bagalkot district in Karnataka and Sakarwadi, Ahmednagar district in Maharashtra. Samir Somaiya, Chairman and Managing Director said, “The expansion, is an extension of our strategy to create more value from our renewable stocks. The expansion will help our greater participation in the blending Programme of the Government of India that mandates target of 5 percent blending of bio fuel with petrol. Chemical Engineering World

CEW Industry News Aker Solutions Starts Pioneering CO2-Capture Project in Norway

GenNext Laser Based Solution for NOx Emission Monitoring

Oslo, Norway: The project is the first of its kind globally for a waste-to-energy plant and comes after Aker Solutions in December signed a contract with the city government. The project is funded by Gassnova, the state enterprise that supports the development and demonstration of technologies to capture carbon dioxide (CO 2 ).

Skedsmokorset, Norway: NEO Monitors introduces a new generation of the safest and most precise instrument to measure NH3 for any type of DeNOx system. NEO Monitors LaserGas III ammonia analyzer is designed to operate in hazardous areas to increase efficiency of the DeNOx-processes and minimize emissions.

“This is pioneering work with significant potential as the world focuses on finding ways to limit carbon emissions,” said Valborg Lundegaard, head of Aker Solutions’ engineering business. “As such, this pilot project is of international importance.” Carbon capture and storage (CCS) is an important tool in reducing CO 2 emissions and curtailing global warming. The test will be a key element in qualifying Aker Solutions’ amine-based CO 2 capture technology for commercial application at waste-to-energy plants globally. There are about 450 such plants in operation in Europe and about 700 globally. “We see potential in this mar ket across the wor ld,” said Lundegaard. The test will be conducted using the company’s mobile test unit for carbon capture. The gas released from Klemetsrud contains about 10 per cent CO 2 and is treated in several steps before it enters the mobile unit. Klemetsrud, which gets a majority of its feedstock from biomass, emits about 300,000 tons of CO 2 per year. “We expect to capture up to 90 per cent of the CO 2,” said Oscar Graff, Head of CCS at Aker Solutions. “The tests will verify important operating parameters such as energy consumption, solvent degradation, losses and required solvent make-up.”

Genomatica Expands Bioengineering Solutions Business California, USA: Genomatica announced they are expanding their Bioengineering Solutions business across the chemical, health (eg active pharmaceutical ingredients, natural products), wellness (eg nutraceuticals, personal care) and food and beverage industries. Genomatica’s offerings will now enable a broader range of customers to complement their in-house expertise and more rapidly and reliably deploy commercial biobased processes. The expansion of Genomatica’s Bioengineering Solutions group follows more than ten projects to their credit. These projects span the product development lifecycle, are spread out internationally, involve both bacteria and yeast, for both large and small companies. In addition, the company added two new customers in the last month focused on yeast fermentation processes for producing a food ingredient and a nutraceutical. 18 • April 2016

The instrument helps the industries achieve better processes control, increase the efficiency of emission reduction and decrease the use of costly consumables such as urea (ammonia). Customers in industries such as oil and gas, power, chemical, petrochemical and steel will benefit from lower operational cost as well as less NOx-emissions. The instrument has been tested in Asia, and 20 units have already been sold, following great feedback and impressive results from pilot installations. The Single path (SP) configuration is a transmitter/receiver solution for cross-duct/stack installation. The measuring principal is based on Tunable Diode Laser Absorption Spectroscopy (TDLAS). NEO Monitors is a global leader in laser-based solutions for measuring gases in a wide variety of industries. The company sells through a global distributor network and several of the world’s largest industrial players favor the gas analyzers. The company benefits from the groundbreaking research that takes place at its parent company, the research foundation Norsk Elektro Optikk (NEO). NEO is one of the world’s largest independent R&D organizations in electro optics.

Hydrogenics Chooses Intergraph SmartPlant P&ID for Enhanced Data Exchange Huntsville, USA: Hydrogenics Europe NV, a worldwide leader in designing, manufacturing, building and installing industrial and commercial hydrogen systems around the globe, has chosen Intergraph SmartPlant P&ID to improve efficiency and quality of their engineering data. The deal included an unprecedented customized interface between Intergraph SmartPlant P&ID and Hydrogenic’s existing ERP system. The customized interface allows all engineering data captured in SmartPlant P&ID to be stored in the ERP system, making it available for all departments in the company. The key benefits include improved efficiency and enhanced data quality, as the possibility of human error is removed by data automation. Efficiency is enhanced as the centralized access to engineering information reduces time needed for locating information in separate systems. Hydrogenics searched for a solution provider to enable the company to provide more reliable documentation to their customers in a standardized manner. Chemical Engineering World

CEW Technology News

MyDx - Electronic Nose to Measure Chemical Molecules in Vapor

Smarter Grid Solutions to Demonstrate LOTTE Chemical’S Flow Battery Testing

California, USA: In light of this year’s Flint, Michigan water crisis and massive methane leak in Porter Ranch, California, along with increasing awareness of manmade toxicities in our environment, consumers are looking for better tools to control their health and be better armed for knowing and controlling what goes into their bodies.

Glasgow, Scotland: Smarter Grid Solutions has announced they are working with LOTTE Chemical to test and demonstrate LOTTE’s Flow Battery Technology in the UK market. The two year project will demonstrate the controllability of a battery when it is paired with other technologies, such as renewables, to provide evidence of the types of ancillary services the pairing of these technologies could offer.

Enter MyDx — aka “My Diagnostic” — a portable analyzer that acts like an electronic nose to measure and detect chemical molecules in vapor. According to its website, the device “leverages the latest in electronic nose nanotechnology to accurately measure chemicals of interest in nearly any solid, liquid, or gas sample, anywhere, anytime.”

The project is funded by the South Korean government and overseen by the Korea Battery Industry Association (KBIA). Innovation in energy storage is also a big driver for the UK, with the UK government recently allocating a £50m budget to encourage innovation in energy storage, demand-side response, and other smart technologies. The role of Active Network Management in Energy Storage

MyDx was founded by Daniel Yazbeck, a former Pfizer scientist and Panasonictechnology and market developer, with a mission to “empower you to live a healthier life by revealing the purity of what you eat, drink & inhale in the palm of your hands and in real time.”

GreenCentre Partner with Maratek Environmental for Solvent Recycling Technology Kingston, Canada: Recycling solvents conver ts them to pure form so they can be reused — thus sending less waste to landfills — but has its own challenges, such as removing water from solvents.

LOTTE Chemical is currently working on testing a small-scale flow battery at the Power Network Demonstration Centre (PNDC), based in the UK. Smarter Grid Solutions will work with LOTTE Chemical to demonstrate the use of a flow battery within an Active Network Management (ANM) scheme. Energy storage is not a new concept to Smarter Grid Solutions. The company’s ANM technology is used to manage and control different energy storage technologies, such as Lead Acid grid scale storage, Lithium Ion grid scale storage, and grid-to-gas electrolysers.

Scientists Create Graphene-Based Sensor that Detects Air Pollution in Your Home

M a ra t e k E nv i r o n m e n t a l a n d G r e e n C e n t r e C a n a d a h ave teamed up to commercialize a solvent recovery technology that addresses this and other challenges, making the process more energy efficiency and cost effective, the companies say.

Kanazawa, Japan: A graphene-based sensor that can incredibly detect harmful air pollution at home, has been developed by scientists from the University of Southampton and the Japan Advanced Institute of Science and Technology (JAIST).

Maratek Environmental is a Bolton, Ontario-based solvent recovery and wastewater recycling company. GreenCentre Canada provides chemistr y technology development and services to businesses and other organizations.

This sensor could prove helpful in combating sick building syndrome (SBS), a condition typically marked by headaches and respiratory problems. Polluted air that is contained within a space can give rise to these health issues.

Under the agreement, GreenCentre will provide chemistry expertise and access to technologies developed at Canadian academic institutions while Maratek will design, engineer, m a n u fa c t u r e a n d d i s t r i bu t e e q u i p m e n t b a s e d o n t h e s e technologies. Maratek will also provide insight into existing challenges faced by industrial companies in their efforts to recycle solvents, which are used in the chemical industry to produce a variety of products, including paints, printing inks, coatings, and plastics.

The team of researchers, including Professors Hiroshi Mizuta, Manoharan Muruganathan and Jian Sun, came together to develop this revolutionary graphene-based sensor.

20 • April 2016

Graphene can be described as an extremely thin layer of pure carbon - a single, tightly packed layer of carbon atoms bonded together in a hexagonal honeycomb lattice. It is the thinnest and lightest known material and highly sensitive in terms of detecting chemical gases. Chemical Engineering World

CEW Technology News

High-Tech Biological Systems Show Promise in Treating Leachate New York, USA: While some of the more innovative methods of leachate treatment still combine biological and physical-chemical methods to meet effluent requirements, high-tech biological systems that use specialized bacteria are promising candidates for leachate treatment, according to industry experts. Membrane biological reactors (MBRs) are fairly new innovations that are an improvement of classic biological treatment, says Frank DeOrio, technical manager for O’Brien and Gere based in Syracuse, N.Y. “MBRs provide an advantage in allowing for longer solids retention times than traditional biological systems,” DeOrio says. “It is this extra solids retention that allows the bacterial mass to acclimate to the leachate and select for bacteria more resilient and efficient in treating the biodegradable constituents.” Membrane technology also plays a role and has made major advances in recent years regarding physical-chemical methods, he says. “The ability to manufacture precise occlusion limits in membrane systems has made ultrafiltration and reverses osmosis (RO) a more common treatment approach in modern leachate treatment systems,” he adds. Up to 99 percent rejection rates for dissolved solids are possible with current membrane technology.

SA Forges Ahead with Hydrogen, Fuel Cell Technology Cape Town, South Africa: South Africa is forging ahead with hydrogen and fuel cell technology. This as the country’s first hydrogen refuelling station has been opened on Gauteng’s East Rand. The project is a collaboration between the Science and Technology Department, Impala Platinum, Hydrogen South Africa and the University of the Western Cape. It’s another endeavour to make our carbon footprint smaller. Science and Technology Minister, Naledi Pandor says: “A fuel cell converts chemical energy into electricity through a chemical reaction with oxygen or another oxidising agent. Fuel cells require fuel and oxygen/air to sustain the chemical reaction (unlike a battery). They have an anode, a cathode and an electrolyte that allows charges to move between the two sides of the cell and electrons flow from the anode to the cathode through an external circuit, producing a DC current.” Pandor adds: “South Africa has started to make a number of bold moves that could well see it leapfrog into the leading countries in hydrogen and fuel cell technologies installations in the short to medium term.” 22 • April 2016

A Greener Way of Producing Ethylene Providence, USA: The researchers developed a new composite catalyst using nitrogen-rich graphene dotted with copper nanoparticles. A study, published in the journal Nano Energy, showed that the new catalyst can efficiently and selectively convert carbon dioxide to ethylene, one of the world’s most important commodity chemicals. Ethylene is used to make plastics, construction materials and other products. Chemical companies produce it by the millions of tons each year using processes that usually involve fossil fuels. If excess carbon dioxide can be used to make ethylene, it could help make the chemical industry more sustainable and eco-friendly. “We hope that this new catalyst could be a step toward a greener way to produce ethylene,” said Shouheng Sun, a professor of chemistry and engineering at Brown, whose research team developed the catalyst. “There is much more work to be done to bring such a process to an industrial scale, but this is a start.”

Ministry of Science & Technology Initiative to Promote Women in Science Bangalore, India: Concerned over the low representation of women in Science & Technology (S&T) in planning and policy making in the country, the Union ministry of science & technology has constituted a Standing Committee for promoting women in science. Prof. HS Savithri, Indian Institute of Science, Bangalore, is the chairperson of Committee which will make endeavours for creating gender enabling environment in S&T institutions in the country. Senior officials in the ministry said that in recent years though there has been significant increase in enrollment of women in S&T at all levels, yet women are still not getting enough opportunities in academic institutions, R&D laboratories and S&T organisations. A low representation of women in S&T in planning and policy making is a matter of concern, officials said. Officials further said that the department of science and technology (DST) has been making concerted efforts to identify issues facing women in science and to address them in order to bring greater representation of women in science. Adoption and execution of Women Component Plan, formulation of gender specific schemes, constitution of Task Force, gender budgeting, etc are various efforts made by DST in this direction. The Standing Committee would take proactive measures to identify and correct any imbalances that still persist and hinder women in S&T. The Committee will also make endeavours for creating gender enabling environment in S&T institutions; recommend special measures to ensure growth of women in science; recommend programmes designed specifically for fostering utilising and supporting women in science; and monitor periodically implementation of its various recommendations. Chemical Engineering World

CEW News Features

Modern Trends in Water Purification and Waste Water Treatment The article emphasises on water wastage reduction, water re-usage and conservation process and implies that the need for water purification and treatment will be on the rise.

ater, besides being the most essential source of life, is also a natural resource that is multiutilitarian in nature and function. The irony about water, however, is that it is the most abundant yet the scarcest resource in nature. The current trends of human water consumption and disposal indicate that by 2030, 47 per cent of the world population will be living in areas of high water stress. Most population growth will occur in developing countries and primarily in regions that are already experiencing water stress and in areas with limited access to safe drinking water and adequate sanitation facilities. Sensing these needs of the years to come, methods of water purification and waste water treatment in domestic, commercial and institutional spaces, geared towards conservation and sustainability have been constantly evolving. With respect to the water purification space, the traditional method was installing a Point of Use (POU) purification filter for each unit or household. However, a smart water management solution that has been developed is integrating the Point of Entry (POE) purification system for water treatment. The POE water treatment system, also called as the ‘whole house water filter’ system, delivers treated water to all sinks, baths, dishwashers and toilets, since it is installed at the main water line where water first enters the home or commercial set-up. This is an effective onestop solution to the purification needs of an institutional space, since it avoids the need for water purifiers at each faucet and also eliminates the need for water storage or procurement through 20 litre jars or bottles.

26 • April 2016

This two-pronged solution resolves two key challenges to sustainability.

Treatment Processes (STP) and Effluent Treatment Processes (ETP).

Firstly, it eliminates need for plastic containers of water and secondly, it reduces wastage of water. Traditional POU purifiers waste 70-75 per cent of the water and have a recovery rate of only 25 per cent. Thus a major chunk of water entering the system is drained and lost. The modern POE purification, on the other hand, is a robust system and has a higher recovery rate.

Some companies in the waste water treatment area have successfully developed Packaged STP solutions for residential, commercial and industrial set-ups. With respect to their installation and space requirement, these STPs are decentralised and comparatively compact sewage water treatment systems, thereby allowing for modularity, ease of installation and recycling and re-usage of waste water, and thus providing an ideal waste water treatment solution for institutional spaces. The processing and reuse of the waste water rather than draining it off will help industries, commercial and domestic units meet their non-potable water needs in a more sustainable manner. This is thus a robust and efficient approach to water conservation for a better and sustainable tomorrow.

Smart, compact, durable water treatment products (WTPs) of capacity up to 20 m 3 per hour that are Packaged, Plus and Play (PPP) have been developed for light industrial, commercial, housing and urban spaces. These modern tools are both – cost and space effective and thereby help manage water and the water purification process in the most sustainable manner. The problem of waste water treatment has also been the priority for innovators in the water management space. This is primarily because a vast quantum of water is currently being used for manufacturing and industrial purposes and this water is then processed and disposed or drained off into water bodies. There is a scope for this water to be reused post processing for secondar y, non-potable pur poses like gardening, household chores, other manufacturing processes etc. Thus efforts h ave r evo l ve d a r o u n d s ewa g e Wa t e r

Another important issue is making potable water available to all segments of the society at affordable prices. Potable water problem is thus also the issue that needs to be addressed with utmost urgency. Currently, 1 in 9 people worldwide do not have access to safe and clean drinking water. This implies that safe, conveniently available water is a luxury many still can’t afford. To resolve this problem of availability o f p o t a bl e a f fo r d a bl e wa t e r, s eve ra l companies are promoting the concept of Water ATMs. Water ATM dispenses up to

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India’s refining sector has come a long way from capacity of 62 MMTPA in 1998 to current capacity of 254 MMTPA, projected to increase to 330 MMTPA by end of this decade. Refining industry in India has significantly evolved over the last two decades as the refiners have set up new capacities with higher complexities, upgraded existing capacities through revamps and carried out value addition through integrated the petrochemical manufacturing. Major oil and gas companies and petrochemical manufacturers in India have announced their plans to expand and/or revamp their manufacturing facilities. India is set to witness a huge development.

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CEW News Features

Storage Status of 91 Major Reservoirs of the Country as on April 13, 2016 According to the Ministry of Water Resources, the water storage available in 91 major reservoirs of the country for the week ending on April 13, 2016 was 35.839 BCM which is 23 per cent of total storage capacity of these reservoirs. This was 67 per cent of the storage of corresponding period of last year and 77 per cent of storage of average of last ten years. The total storage capacity of these 91 reservoirs is 157.799 BCM which is about 62 per cent of the total storage capacity of 253.388 BCM which is estimated to have been created in the country. 37 Reservoirs out of these 91, have hydropower benefit with installed capacity of more than 60 MW. The Eastern region includes States of Jharkhand, Odisha, West Bengal and Tripura. There are 15 reservoirs under CWC monitoring having total live storage capacity of 18.83 BCM. The total live storage available in these reservoirs is 6.40 BCM which is 34 per cent of total live storage capacity of these reservoirs. The Western region includes States of Gujarat and Maharashtra. There are 27 reservoirs under CWC monitoring having total live storage capacity of 27.07 BCM. The total live storage available in these reservoirs is 4.79 BCM which is 18 per cent of total live storage capacity of these reservoirs.

200 litres per hour at the cost of 20 paisa per litre. Water ATMs have high application in rural areas and areas with high drinking water stress. Thus the ATM has efficiently addressed the common man’s thirst for water. The technological advances are also allowing for equipping such water treatment and water dispensing systems to be enabled with Smart Monitoring. Smart monitoring is a feature that allows the user to stay connected and analyse their water treatment system at all times and also allows them to control the systems from the comfort of their home or office space through smart app or web access. This allows mapping water usage and reducing water wastage by conscious and constant analysis of the systems. Thus the ergonomical nature of the smart monitoring feature is integrating man and machine for better sustainability and efficient management of water resources. Such innovations in the water purification and water treatment space are helping conserve water, recycle and reuse waste water and help us move towards a better sustainable water consumption and water management model. The focus of most modern day ‘Green Companies’ in the Water treatment space is to provide clean water to all and to reuse and recycle waste water. Their modern methods of usage and disposal of water are aimed at achieving the synergy between smart science and smart engineering to attain a stable sustainable world with balanced water demand and water supply needs. We can thus hope for a better future with smarter cities and industrial spaces using green innovation aimed at providing clean with water for all! Courtesy: Voltas Water Solutions

The Central region includes States of Uttar Pradesh, Uttarakhand, Madhya Pradesh and Chhattisgarh. There are 12 reservoirs under CWC monitoring having total live storage capacity of 42.30 BCM. The total live storage available in these reservoirs is 12.95 BCM which is 31 per cent of total live storage capacity of these reservoirs.

References: • http://www.unwater.org/statistics/ es/?page=2andipp=10andtx_dynalist_pi1%5Bpar%5D=YTox OntzOjE6IkwiO3M6MToiMiI7fQ • https://thewaterproject.org/water_stats

The Southern region includes States of Andhra Pradesh, Telangana, AP&TG (Two combined projects in both states) Karnataka, Kerala and Tamil Nadu. There are 31 reservoirs under CWC monitoring having total live storage capacity of 51.59 BCM. The total live storage available in these reservoirs is 7.55 BCM which is 15 per cent of total live storage capacity of these reservoirs.

Chemical Engineering World will bring out a dedicated special issue on Water and Waste Water Treatment & Solid Waste Management in the month of SEPTEMBER 2016.

28 • April 2016

Water Special Issue

Write to us (harshal_desai@jasubhai.com) if you would like to contibute technical articles/case studies and guest column in this issue. Chemical Engineering World

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CEW Features Guest Column

Efficient, Successful and Sustainable – Wacker’s Integrated Production System Saving resources, using renewable energy and making processes efficient and sustainable have been an integral part of Wacker’s mindset long before terms like ‘green’ or ‘sustainable’ entered public awareness, says Anand Gopaladesikan, MD, Wacker Chemie India and Dr Sascha Büchel, ED, Wacker Metroark Chemicals. In this article, the authors discuss how the company has been practicing ‘Green Engineering’ in its plants.

n its website, the United States Environmental Protection Agency EPA defines green engineering as ‘the design, commercialisation, and use of processes and products in a way that minimises pollution, promotes sustainability, and protects human health without sacrificing economic viability and efficiency’. According to the officials, such engineering methods ‘embrace the concept that decisions to protect human health and the environment can have the greatest impact and cost-effectiveness when applied early in the design and development phase of a process or product.’

Wacker’s Burghausen plant ever since. Over the years, the organisation has evolved into a globally active chemical company. Today, the group operates production sites in Europe, the Americas and in Asia, generating more than 80 percent of its sales outside of Germany.

emulsions and silicone rubber for the textile and personal care industry since 1998. Through a wholly owned entity, Wacker Chemie India Private Limited, headquartered in Mumbai, Wacker also addresses the business requirements of its divisions Wacker Polymers, Wacker Biosolutions and Wacker Polysilicon.

Since the 1970s, Wacker has also been supplying chemical products to India. With offices in Delhi, Mumbai, Kolkata and Chennai, as well as in Dhaka in Bangladesh, the group now operates in the most important commercial centres on the Indian subcontinent. Our Kolkata based silicones joint venture with Metroark, Wacker Metroark Chemicals, has been manufacturing silicone fluids,

Despite our global footprint, a large portion of our products are still manufactured in Germany, a country noted for its energy and labour costs. What makes us, nevertheless, globally competitive is our ability to maximise the quality of our products while keeping production costs to a minimum. The key levers are our integrated production systems. They give us a competitive edge, even though our

The vision of using sustainable hydroelectric power to produce chemicals dates right back to the company’s origins in the early 20th century, when, in 1913, the company founder Dr Alexander Wacker had been looking for a suitable location for a new chemical site. His decision to construct the plant on the outskirts of Burghausen, a town in Southern Germany close to the Austrian border, was strongly supported by the permission to build a canal and a power plant right next to the plot. The facility, which still is one of the largest privately owned hydroelectric power stations in Germany, went on stream in 1922. It has been supplying inexpensive and environmentally friendly electric power to 30 • April 2016

Figure 1: WACKER’s Kolkata based silicone joint venture Wacker Metroark Chemicals currently produces around 300 different silicone products. A thorough energy and water management play a vital role in the production units. (Photo: Wacker Chemie AG)

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CEW Features energy and personnel costs in Germany are high compared to those of other international players. At all major production sites, we operate highly integrated material loops. Basically, this involves using and recycling the byproducts from one stage as a starting material for other processes and products. For example, in our integrated ethylene production system, we use ethylene to obtain organic intermediates, which we then turn into polymer dispersions and dispersible polymer powders. Our integrated silicon production system operates along similar lines. Although comprising only a small number of raw materials – basically silicon, methanol and sodium chloride – this system enables us to manufacture over 2,800 different silicone products including pyrogenic silica. All loops are designed by engineers at our plants. In addition to silicones, Wacker also produces crystalline silicon for subsequent use in solar cells and computer chips. The starting material for both silicones and silicon is the same: silicon metal. We pulverise the material upon delivery to produce different grain sizes for different needs. That way we can utilise virtually 100 percent of the raw material. It would be extremely difficult, if not impossible, to achieve that with only one product line.

Figure 2: One of the major industries WACKER caters to in India is textile. Silicone ﬂuids and emulsions impart softness and moisture absorption to terry goods or other high-quality functional textiles. Their innovative structure combines the superb softness of silicones with the excellent wettability of hydrophilic molecules. (Photo: Wacker Chemie AG)

Our integrated production system also minimises the consumption of important auxiliaries. Hydrogen chloride is an essential auxiliary deployed in the production of reactive intermediates from energy-poor natural materials. We use these intermediates to make our end products. Unfortunately, the production of hydrogen chloride requires a lot of energy. We therefore recover both hydrogen chloride and energy during the conversion of the chlorine-containing intermediates to chlorine free end products such as hyperpure silicon or pyrogenic silica. We then return the recovered hydrogen chloride to the production loop and reuse it. This closed material loop reduces emissions and, due to lower raw-material consumption, shipment journeys. Currently, the company recycles almost 95 percent of the hydrogen chloride used in the production loops at our German sites in Burghausen and in Nünchritz. In 2014, our integrated production system in Burghausen prevented the emission

Figure 3: Together with customers, WACKER developed highly sophisticated specialty silicone compounds which cut down foaming and thus enable signiﬁcant water savings in detergent applications. Photo: Wacker Chemie AG)

32 • April 2016

of more than 883,000 metric tons of CO 2 equivalents. Due to this high reutilisation rate, less fresh hydrogen chloride needs to be generated and, consequently, there are savings in the transportation of raw materials and in energy consumption. Wacker’s engineers are constantly developing new possibilities to make processes more sustainable. For over twelve years, we have been using a chloralkali membrane process to supply chlorine, hydrogen, caustic soda and hydrogen chloride as starting materials at our Burghausen site. Since 2000, this membrane electrolysis has enabled us to stop using mercury-based chlorine electrolysis and simultaneously cut energy consumption by around 25 per cent per year. Thus WACKER has fulfilled the chemical industry’s voluntary commitment to phase out mercury-based processes by 2020 well ahead of schedule. Many chemical reactions generate heat that can be put to use in other production processes. Here, too, Wacker’s integrated

Wacker recycles almost 95 percent of the hydrogen chloride used in the production loops at our German sites in Burghausen and in Nünchritz. In 2014, our integrated production system in Burghausen prevented the emission of more than 883,000 metric tons of CO2 equivalents. Chemical Engineering World

Features CEW production system with its closed material and energy loops is a tremendous advantage: We can take the waste heat from one process and use it for later production steps.

of around 85 per cent. Thus, it bridges the gap to renewable energy systems, since it contributes to CO 2 savings, unlike uncoupled electricity and steam generation.

our customers, we develop highly sophisticated specialty silicone compounds which enable significant water savings when used in detergent applications.

At our sites in Burghausen and Nünchritz, we use integrated heat-recovery systems which significantly reduce the amount of primary energy – as a rule natural gas – that our power plants consume. For example, our polysilicon production minimized its specific energy consumption by a third between 2005 and 2013 – despite increased volumes. This enables us to remain globally competitive and to support climate protection. The chemical industry is known to be one of the most energy-intensive sectors. In Germany alone, it uses around 20 per cent of all the electricity consumed by the industry. At our Burghausen site, we operate a combined heat and power plant to cover the site’s electricity and steam needs. The facility has a fuel efficiency

At all of its productions sites, Wacker attaches particular importance to environmental protection, safety and health.

Today, companies around the world can only be profitable in the long term if they assume responsibility for the environment and for society.

Our measures often surpass statutory requirements. This is also true for our Kolkata plant in India, where we offer more than 200 full time employees work with state-of-the art technology and production facilities and where we currently produce around 300 different silicone products.

At Wacker, the awareness for sustainability has been firmly rooted in our business processes and institutionalised for many years. Our integrated production system with its closed material and energy loops will continue to be a major pillar of our success – in economical as well as in ecological terms.

Due to local climate conditions and the range of custom-made products, a thorough energy and water management play a vital role in our Indian production units. Furthermore, together with

(The authors cab be contacted at anand. gopaladesikan@wacker.com and sascha. buechel@wacker.com)

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Jasubhai Media Pvt. Ltd. Taj Building, 3rd Floor, 210 Dr D N Road, Fort, Mumbai - 400 001 Tel: 022-4037 3636, Fax: 022-4037 3635 Email: industrialmags@jasubhai.com Chemical Engineering World

April 2016 • 33

CEW Features Technical Article

Improving Energy Efficiency of the Ammonia Production Process Linde has developed a novel modified concept of its existing ammonia concept for light hydrocarbon feedstocks that specifically addresses world scale capacities and the economic production of urea. The existing process (LAC.L1) has already proven its incomparable benefits in operating plants where full conversion of ammonia into urea was not required due to customer’s integrated complex requirements. And now the newly developed process (LAC.L2), which is an advance in the design philosophy of ammonia plants, is a novel concept of proven process steps extending the capability and flexibility of the Linde Ammonia Concepts (LAC) product family.

ue to the unique set-up of the syngas generation section a high flexibility in the NH 3 /CO 2 ratio in the syngas is achieved. This feature is ideally suited for different operational scenarios e.g. for constant urea demand resulting in constant CO 2 demand and varying export NH 3 . The new concept was developed to improve the energy efficiency of the ammonia production process as well as to improve reliability, availability and flexibility requirements and will provide substantial savings in high energy cost scenario like in India. The LAC product family also incorporates solutions for utilising low cost feed stocks such as heavy residue, petcoke and coal (LAC.H) for production

of ammonia and conversion to urea in countries like India facing constraints in supply and pricing of NG. The author will also demonstrate how easily it is possible to produce ammonia from hydrogen rich offgas streams (LAC.L3) originating from e.g. methanol plant, PDH and ethylene plants applying some of the core process blocks of the LAC product family and consequently achieving the lowest cost of ammonia production. Introduction of LAC Commercial synthetic ammonia process has started in 1913 and has become a large industry. All of the conventional ammonia technologies are based on the original process developed

by Haber and Bosch more than 100 years ago. In commercial ammonia plants hydrocarbons are the source for hydrogen and air is the source for nitrogen. With LAC, Linde didn’t change the sources but the process to produce hydrogen and nitrogen to get an ammonia plant with low investment and high in efficiency and reliability. The concepts provide: • Processes for the production of an inert-free ammonia synthesis gas in the right H 2 /N 2 -ratio • Polygeneration capable process schemes, which allow diversity and stability to ammonia plants during market swings Introduction of Linde’s Existing Process (LAC.L1) A new process scheme was introduced to the fertiliser industry for the production of ammonia from lower hydrocarbon

Figure 1: Linde Ammonia Concept (LAC.L1) and a plant desinged on this concept

34 • April 2016

Chemical Engineering World

CEW Features in a reduced pressure drop • The process is a much more direct route to ammonia resulting in a reduced start-up time and important savings in lifecycle costs • Gas flow rate downstream of the primary reformer is 30-80 per cent lower compared to conventional processes

Figure 2: Fuel oil based Ammonia Process Configuration

Figure 3: A plant designed with LAC.H scheme

feedstocks ranging from natural gas to naphtha. The LAC.L1 (Figure 1) consists essentially of a modern hydrogen plant combined with a standard air separation unit producing inert free synthesis gas in the right H 2 to N 2 ratio for the downstream ammonia synthesis. The first plant went into operation in 1998 for GSFC, Vadodara with a design capacity of 1350 MTPD, currently operating at 1450 MTPD. Today, it is one of the most energy efficient ammonia plants in India with an energy consumption of @ 7.2 Gcal/MT of ammonia including utilities and energy required for nitrogen generation unit. Convincing Advantages Compared with the conventional ammonia process route, the abovementioned process has the following important features: 38 • April 2016

• Elimination of the CO 2 -removal system for stand-alone ammonia production providing significant benefits to clients in terms of total cost of ownership • Elimination of three catalytic process steps (Secondary reforming, HT shift conversion and methanation), reducing the total catalyst volume to approx. 50 per cent of that in a conventional plant • Elimination of a syngas drying system (ASU and PSA deliver dry products) • The generation of inert free synthesis gas, giving important savings in the synthesis loop and eliminates a purge gas purification step • The process condensate treatment is eliminated by routing the condensate directly back to the isothermal shift reactor producing process steam • The simplified flow sheet also results

Introduction of LAC.H In 1981 GNFC, Bharuch started up an ammonia/urea complex utilising heavy hydrocarbons as feedstock. The scheme below (Figure 2) shows the process configuration of the ammonia section of the heavy fuel oil based plant. The process mainly follows gasification, soot extraction and recycle, CO conversion by sour gas shift, heat recovery and gas cooling followed by gas cleaning through Rectisol wash to remove CO 2, H2 S, COS, HCN and ammonia. Final purification of synthesis gas is carried out by liquid nitrogen wash. Finally ammonia synthesis is carried out by employing modern converter loops. Based on this concept several plants were built globally. This plant has been operated up to a capacity of 1750 MTPD NH 3. This plant (Figure 3) is designed with the highest gasification pressure thereby reducing the synthesis gas compression requirement for ammonia production. The plant also serves as syngas supplier for downstream Methanol and CO production. Integrating the Nitrogen Wash System as final purification step allows the generation of an inert free synthesis gas in the right H 2 to N 2 Ratio with consequential advantages in the downstream ammonia loop. An Actual Subject Nowadays India’s fertiliser industry is facing constraints in supply and pricing of natural gas, coal or petcoke is seen as an alternative to produce ammonia or urea. The majority of plants based on Chemical Engineering World

Features CEW The modified process has incorporated well proven process steps where in each process step has been operating successfully at GNFC, GSFC in India and other ammonia, hydrogen and methanol projects worldwide and of much larger size. Successful references for higher capacities are also available for all process modules.

Figure 4: Typical process configuration of coal/petcoke based fertiliser project

higher hydrocarbon feedstock ranging from fuel oil to coal are based on this process scheme installed in the GNFC complex and operated for more than 35 years. We call this process scheme LAC.H.

LAC.L1 to create a process scheme which allows full conversion of ammonia to urea and even shows design and operating flexibility with regard to the CO 2 to NH 3 ratio with improved energy efficiency called LAC.L2.

Economical justification of these feedstocks needs a thorough opex and capex analysis considering e.g. feedstock cost, plant location, and polygeneration requirement. Figure 4 gives typical configuration of such project.

The Modifications • The Air Separation Unit is converted from pure nitrogen service to oxygen and nitrogen production • The Steam Reformer is combined with a non-catalytic/catalytic partial oxidation using the oxygen from the modified air separation unit • The CO 2 -Removal is fully integrated into the synthesis gas train • The PSA H 2 Purification system is replaced by a nitrogen wash system, still ensuring inert free synthesis to the ammonia loop

Combining to Fill the Gap Linde Ammonia Concept has already proven its incomparable benefits in operating plants where full conversion of Ammonia into Urea was not required due to customers’ integrated complex requirements. Further the Natural Gas supply is becoming lean which has forced many ammonia plants operating on conventional technology to produce higher quantity of synthesis gas to meet the CO 2 requirement for full conversion to urea. As this mode of operation is cost prohibitive, many ammonia urea producers have installed CO 2 Recovery Unit (CDR) for recovery from flue gas. To overcome this deficiency and to be prepared for large sized ammonia/urea complexes the LAC.L1 was modified combining features from the LAC.H and Chemical Engineering World

Energy Advantage With high energy cost, scarcity of NG and rising subsidy burden for procurement in India; Linde believes that energy efficient solution is required for ammonia urea project to be viable. This modified process enables better energy consumption figures. The typical energy consumption for this concept is in the range of 6.7 to 6.9 Gcal/MT of ammonia or respectively 4.5 to 4.6 Gcal/MT of prilled urea. Spin-Off LACTM.L3 is a spin-off of the L1 and L2 scheme, capable using hydrogen rich offgas streams like Methanol Purge gas, off gases from PDH or ethylene plants to purify them and convert them to ammonia. From an economical point of view this is the cheapest way to produce ammonia. Depending on feed gas composition, H2 yield and CO 2 by-product requirements two principal schemes (Figure 5) are available as shown below. Many methanol plants based on conventional technology without oxygen

Figure 5: Ammonia from OFF Gas

April 2016 • 39

CEW Features blown auto thermal reformer also generates huge volume of purge gas rich in hydrogen. Under such condition a significant investment cost for ammonia production can be saved as investment in synthesis gas generation is not required. Conclusion LAC has several remarkable features such as generation of inert free ammonia synthesis gas in the right H 2 to N 2 ratio, adjustable CO 2 /NH 3 product ratio. The plant can be designed to process different feed stocks from light hydrocarbon to heavy hydrocarbons.

VOL. 49 NO. 3 March 2014 US $ 10

         ` 

` 150

 

Successful operation of fuel oil based1750 MTPD ammonia plant of GNFC, India over three decades and energy efficient NG based 1350 MTPD ammonia plant of GSFC, India show case the capability of LAC technology. With less number of processing steps it has lower cost of installation and production. It provides flexibility for extension, integration and therefore well suited for phosphatic fertilizers, ammonium nitrate and chemical producers. It also provides opportunity for coproduction of ammonia in conventional methanol plants.

EPCM Special ChemTECH World Expo 2015 28-31 January rry 2015, Mumbai, India

28-31 January 2015, Mumbai, India

With development in ammonia process, experience in scaling up of individual process blocks, modern technology provides lower energy consumption and capital cost. Fertilizer industry can be benefitted by adopting such forward technology to bring in lower cost of ammonia urea in future. This can be achieved through selection of the technology, process steps based on the feed stock, utility integration and the ability to combine the best possible technologies of main process blocks by licensors.

Author’s Details Nilesh Mangukia Head - Conceptual Design - Hydrogen & Synthesis Gas Plants (HSD) & Process & Environmental Safety (ENS) Linde Engineering India Pvt Ltd E: Nilesh.Mangukia@Linde-LE.com 40 • April 2016

Chemical Engineering World

Features CEW Technical Article

Unlocking Profitable Biofuel Opportunities with Process Simulation Biofuel market has witnessed significant growth in recent years on account of rising environmental awareness and strong demand from automotive sector. Stringent government regulations resulted into growing demand for biofuel. This is anticipated to boost the demand for bioethanol, states a recent report. The increasing demand for biofuel will certainly need profitable processes. Following article discusses these opportunities and challenges associated with the biofuel production processes.

s the demand for lower carbon emission fuels increases, resourceful design of biofuel processes, such as biodiesel, bioethanol, syngas, and biogas derived from biomass feedstocks such as corn, sugarcane, algae, and cellulosic sources etc. is unlocking opportunities for more attractive and profitable endeavours. Combustible biofuels offer a nearly carbon neutral alternative within the existing oil and gas energy infrastructure and for these reasons among others, they are attracting continuing investment interest. Recently, an influx of low cost natural gas and tight shale oil in the US has altered the economic benchmark for biofuels, putting pressure on process engineers to arrive at optimised designs. Designing biofuel processing plant configurations with an advanced flowsheet simulator that incorporates economic, energy, and heat exchanger design analyses, to optimise processes for energy use and cost, can not only produce better designs but also in shorter period of time. Several design challenges arise with the development of biofuel processing plants, the foremost being the proof of technofeasibility and profitability, prior to detailed design, to attract capital investment. Other challenges include the rapid pace of process innovations, resulting from the exploration of alternative crops and cellulosic ethanol, and the pressure to optimise feedstock selection and ensure flexibility in plant design to accommodate change. To further secure profitability, many processes must also incorporate the production of profit-making by-products including animal feeds and chemicals. Chemical Engineering World

Process simulation is used to design entire biofuel processes

From processing the feed and controlling the final product to equipment selection and costing, process simulation is used to design entire biofuel processes from research and development to conceptual design to engineering and procurement. By designing a fully developed process model in a process simulator, users can compare and screen solutions that support more profitable and flexible biofuel plant designs. Advancements in biofuel processing, such as those seen in feedstock pretreatment, transformation (i.e. hydrolysisis, saccharification, and fermentation), ethanol dehydration, gasification of biomass, and transesterification of triglycerides, can be conceptually designed in a flowsheet simulator. Users can benefit from visualising and optimising the entire

process, rather than the individual steps. The design can be modularised, to explore impact of substitution of different units and technologies in the overall process schema. Using consistent and reliable property data from a database, such as the comprehensive and always advancing NIST database available in select simulators, increases model validity. Furthermore, process simulation allows for optimisation studies to find the optimal operating conditions while considering process constraints like product water content or vessel temperature. Users also have the opportunity to test different feedstocks and feedstock blends in the same plant configuration. With these options, higher quality models, that can forecast scale-up and economics, can be developed, dismissing fears of solutions lacking techno-feasibility. April 2016 â&#x20AC;˘ 41

CEW Features Process simulation has been used to model chemical processes for the last 30 years and has been providing model-centric integrated solutions for many process industry sectors. To date, users have used models for cornstarch plants, dry and wet mill cornto-ethanol processes, cellulose-toethanol processes, as well as biomass gasification processes. Additionally, process simulation is widely used for designing important ethanol activities such as hydrolysis, saccharification, fermentation, distillation and dehydration, co-products recovery, and pH control. With the integration of solids modelling capabilities into flowsheet simulators, users can now more rigorously model equipment used to process solids feeds, such as crushers and mills, and the equipment used to model liquid/solid separation, such as centrifugation and drying. There are many process simulators on the market today, and depending on the vendor, the user may be able to take advantage of integrated process engineering tools when designing biofuel processes. These integrated tools bring energy optimisation, rigorous exchanger design and rating, and cost estimation tools into process simulation environment. With integrated energy optimisation software, users can increase heat recovery by evaluating exchanger networks and minimise operating costs by effectively

evaluating the different utility types by cost effectiveness. With rigorous exchanger design and rating tools integrated into the process simulator, users can size and rate an exchanger from the flowsheet, utilise the design to increase flowsheet accuracy, and also check the exchanger for operational risks and warnings such as vibration, fouling, and excessive operating temperature and pressure. With integrated economic evaluation tools, users can compare alternative process designs in less time and also view the impact of operational decisions on the overall operating cost the process. The unique opportunity to use these types of analyses earlier in the design process can translate to more profitable design. Pan Pacific Technologies, a sustainable energy consultancy run by Dr Eric Dunlop, used Aspen Plus to develop various models for biological processes to evaluate the technical and commercial feasibility of carbon-to-algal-biomass conversion integrated with downstream biodiesel production1. Through innovative use of aspenONE solutions, Pan Pacific Technologies was able to accurately solve the biological physical properties challenge, and successfully produce an Aspen Plus model with results matching laboratory and industry data. With this baseline case, they further used the model, the energy balance, and the link to AspenTech’s estimating system to understand scale-up constraints and the key economics of the process. The

resulting model was validated and accepted by the DOE’s NAABB Consortium. The Brazilian Bioethanol Science and Technology Laboratory (CTBE), a research centre based out of Brazil, used Aspen Plus to design and scale up a sugarcane refinery to assess different routes for biofuel production 2. CTBE considered first and second generation ethanol plants, sweet sorghum as a feed, and butanol as a product, and compared economics, social, and environmental factors. Using aspenONE Engineering, CTBE was able to find the best configuration for return on investment. In addition to the number of biofuel models developed by experts at Aspen Technology, the National Renewable Energy Laboratory (NREL) has a collection of biofuel processing models developed in Aspen Plus that are available to the public 3. With this existing know-how as to modelling all of the processes involved in biofuel production, users can have a starting point when designing new processes. By using innovative software simulation, organisations that are even in the early R&D stage or technology demonstration phase, can develop innovative biofuel process designs that are not only more technofeasible, but also in a shorter amount of time, with rigorous process results that demonstrate both the engineering viability and the economic opportunity of a new process or feedstock. References 1. Dr. Eric Dunlop, Pan Pacific Technologies, 3rd International Conference on Algal Biomass, Biofuels and Bioproducts, Toronto, 2013. 2. Tassia L. Junqueira, CTBE, AspenTech OPTIMIZE, Boston, MA, May 2013 3. National Renewable Energy Laboratory, NREL Biorefinery Analysis Process Models. Author’s Details

The resourceful design of biofuel processes unlocks opportunities for more proﬁtable endeavours

42 • April 2016

Sunil Patil Business Consulting Director APAC, AspenTech E: sunil.patil@aspentech.com Chemical Engineering World

Features CEW Technical Article

The Proof is in the Pump This white paper presents the results of head-to-head comparisons between the top AODD pumps and the final data acquired during those tests. The results will help illustrate the impact differing ADS technologies have on air consumption, energy use and overall flow rate.

ir-operated Double-diaphragm (AODD) pumps have played a profound role in the modern global manufacturing and fluid-handling operations of many companies for more than 50 years. The original pump concept has changed little over the decades and works through its sheer simplicity of operation and construction. With operating efficiency and cost reductions being a major focus of businesses today, AODD pump manufacturers have introduced new technologies in Air Distribution Systems (ADS) to increase pump efficiency and meet these demands. The new ADS technologies utilised range from electronic controls to mechanical innovations. However, the resulting savings in compressed air usage and increase in pump efficiency varies considerably by system.

The Challenge In AODD pump operations, energy use is directly related to the rate of consumption of air used to drive each stroke of the pump during the pumping cycle. With increasingly high energy costs, facility operators understand that the initial purchase and installation of a new pumping system is but a small part of the total cost of ownership and operation during the pump’s life cycle. Routine costs of energy and maintenance remain the primary cost drivers in the total cost of ownership. Much like cars, pumps can be rated according to efficiency. The goal is to utilise the least amount of air to pump the greatest amount of product. The ultimate objective is to reduce the rate of air consumption in relation to the product flow rate while also minimizing the overall amount of air that is not producing product yield (wasted energy) during the pumping cycle. If attained, this combination will directly impact an operation’s bottom line - the profitability being determined by something as simple as the volume of air being consumed and the energy required to compress it. In addition to wasted energy, air overfilling stretches the diaphragm unnecessarily. This stretching produces excessive diaphragm wear and tear resulting in more frequent replacement and downtime, while also increasing operating costs.

Figure 1: The race is on for AODD pumps to move volume faster and more cost effectively. In head-to-head comparisons with the competition, the Wilden® Pro-Flo® SHIFT Air Distribution System proved it is not just an incremental improvement in ADS technology, but an entirely new way of looking at how pneumatic pumps operate.

Chemical Engineering World

Although the technology is more than 50 years old, AODD pumps can be made more efficient by recent ADS

developments that better control the air flow and prevent wasteful air overfilling, which will reduce air consumption, and operating and maintenance costs. Two primary methods have been introduced to control air flow and prevent overfilling by cutting off the air supply to the air chamber before the end of the pump cycle: electronically controlled and mechanically actuated ADSs. Electronic control has two shortcomings. First, the electronics raise an entirely different set of maintenance and operational concerns, including prohibition of use in explosive environments like mines and an inability to be submerged. Second, this electronic ADS technology requires a ‘learning period’ of 30 to 40 seconds where it monitors the operation of the pump before it can estimate when to cut off the air supply prior to the end of the stroke. This can result in erratic and sometimes wasteful flow rates during this learning period. During the time period from the end of each stroke to the completed shift of the valve, the air is allowed to ‘overfill’ the air chamber without any corresponding displacement of fluid. This volume of compressed air is entirely wasted. The mechanically actuated method is a simple yet extremely effective way to control the air with each stroke and prevent wasteful overfilling. The air is mechanically controlled on a constant basis to maximise efficiency, minimise complexity and maintenance April 2016 • 43

CEW Features considerations, and allow for operation in explosive and submerged pumping environments. The Controlled Comparisons To create real-world conditions to measure the effectiveness of various ADS technologies industry-wide, a controlled, objective head-to-head test was arranged comparing the industry’s top AODD pumps that have been fitted with traditional, electronically controlled and mechanically actuated ADSs. Common conditions of service that are seen in the field were replicated in the laboratory. This simulated application required each pump to produce a flow of 320 litters per minute (L/min) (85 gpm) against a head pressure of 2.1 bar (30 psi). To achieve a fair comparison between these competing pumps, each pump was run at the inlet air pressure needed to meet the common condition of service. Air-consumption data was then recorded. The Solution The data gathered in the objective AODD testing shows conclusively that Pump D (Wilden Pro-Flo SHIFT) beats the competition in all three key points of measurement with the lowest air consumption in SCFM, the lowest strokes per minute and the highest volume of fluid pumped per SCFM. Pump D averages an overall 30 per cent reduction in air consumption compared to Pumps A, B and C. It also manages the largest reduction in air consumption among the four pumps while still managing the best overall volume of fluid moved per stroke, requiring the lowest strokes-per-minute.

the air flow into the filling air chamber at the end of the pump’s stroke to minimise the compressed air that is wasted. The revolutionary air control spool of the Pro-Flo SHIFT meters the air to prevent overfilling with no reduction in product yield. The result is reduced air consumption while still maintaining maximum operational efficiency and

flow rates. Compared to the electronic ADS solution, which requires an electrical power source and the delayed ‘learning’ period after each start-up, the Pro-Flo SHIFT, with no electrical power requirement or delay needed to achieve peak operation, clearly makes choosing the best AODD pump an easy decision.

Chart 1: In a controlled head-to-head test comparing eight of the industry’s top AODD pumps, where common operating parameters seen in the field were mimicked in the laboratory, this sample of four illustrates the dominance of Pump D and the wide range of energy and strokes required to achieve similar fluid output.

The Wilden Pro-Flo SHIFT Air Distribution System in Pump D is not just an incremental improvement in ADS technology, but an entirely new way of looking at how pneumatic pumps operate. (See Chart 2 on next page) To combat the phenomenon of overfilling, the Pro-Flo SHIFT restricts 44 • April 2016

Chart 2: Saving Air Consumption, Saving Energy

Chemical Engineering World

Features CEW

Chemical Engineering World

The Pro-Flo SHIFT ADS addresses the overfilling waste of traditional AODD pumps, providing considerable savings by decreasing air consumption while still maintaining the same fluid-volume output to provide savings and output efficiencies when compared to other systems. The Wilden Pro-Flo SHIFT does not require electrical power, allowing it to be submersible and ATEX-compliant. While competing pumps may offer ATEX compliance and increased efficiency ADS options, these come with additional costs that contribute to the front-end expense. In addition to its dramatic reduction in strokes per minute compared to the competition, the Pro-Flo SHIFT also delivers extraordinary maintenance advantages with its minimization of wear and tear during every minute of operation through the optimisation of every pump stroke. To view the video documenting the laboratory pump demonstration of the Wilden Pro-Flo SHIFT versus the industry’s top competitors, visit www.profloshift.com/proof. Author’s Details Ravi Prasad Director - Sales PSG India E: sales.psgindia@psgdover.com

Pumps & Valves Special August 2016

Because the Pro-Flo SHIFT does not require an additional electronically controlled ADS or a ‘learning period’ before it can begin operating at its highest efficiency, it can be configured as ATEX-compliant right out of the box, it is submersible and it offers an annual cost savings over the closest competitor of USD 1,135 per pump. More productivity, less energy, reduced air consumption and a rapid ROI per pump means immediate cost savings and better long-term bottom-line results.

Valves Pumps & Special 16 August 20

When you analyse the need for higher energy consumption, more strokes with subsequent wear and tear for maintenance, and less overall fluid volume moved per SCFM of air flow, it is impressive to find that, while Pump B’s ADS is electronically monitored and controlled, it still requires more air for less fluid flow rate and therefore delivers a less productive yield than the mechanically actuated Pro-Flo SHIFT.

While manufacturers understand that AODD pumps featuring new ADS technologies can deliver the results that support their ever-shrinking budgets and operating margins, Wilden’s Pro-Flo SHIFT exhibits the innovation and results that set it apart from the competition.

Contact our representative to book your advertisement in Pumps and Valves special issue of Chemical Engineering World magazine.

• 16% more air and strokes • 30 additional strokes per minute • 6.9 SCFM more air consumption

2017 Mumbai

Even the most efficient competing AODD pump was significantly less efficient when compared to the Wilden Pro-Flo SHIFT during side-by-side testing. The electronically - controlled Pump B in the white paper comparison required the following to maintain the same condition of service as the Wilden Pro-Flo SHIFT:

Conclusion Although reliably utilised in a host of applications for more than 50 years, AODD pumps can be enhanced to deliver greater efficiency and cost savings through improved ADS technology that prevents air overfilling.

ry 2017 14-17, FebruaIndia Mumbai,

The Next Best Pump Still Cannot Compare

April 2016 • 45

CEW Features Technical Article

Precious Metal Catalyst Recovery in Chemical Processing One common unit operation is filtration in the Hydrogenation reactions in API, chemical, petrochemical and fine chemical industry, which uses precious metal catalysts. An efficient filtration system helps in reducing bottlenecks, downtimes and losses of precious metal catalyst in chemical processing. This paper illustrates the choices, parameters to choose and current trends in selection of systems for catalyst filtration in process industry. The Catalyst to be recovered from processes can be from a few gms to many kgs per batch. The high rising prices of these catalysts as well as environmental and work place regulations have forced companies to have good and efficient catalyst recovery systems. The innovative design asymmetric metallic sintered membrane filters show distinct advantages over the conventional porous filter media.

atalyst filtration is common activity in a chemical processing plant. Typical applications include polishing filter applications to recover metal catalysts Pt/C, Pd/C, Raney Nickel, inorganic bromide salts, copper chromites, etc. API & Bulk Drug use Precious metal catalysts. The catalyst is either re-cycled back or sent to the spent catalyst section for recovery. Aromatic compounds require Hydrogenation and have extensive use of catalyst. Petroleum Industry - Hydrogenation reactions in the API or hot hydrocarbon streams, such as FCCU slurry oil, often require removal of catalysts and other particulate. Fluid Catalytic Cracking uses catalyst to assist separation. Separation is carried out in fractionators and the gas produced is taken out from overhead, the middle cuts are heavier and the bottom is slurry oil that contains the catalyst fines. PRESENT SYSTEMS USED IN THE INDUSTRY Conventionally the industry has been using filter presses, nutsche or such batch filters. These filters though very efficient have raised many concerns and

46 â&#x20AC;˘ April 2016

continuous search has been on to develop new systems for these applications. These concerns are loss of precious metal in fluid stream, Long down-time and assembling, by-pass of black particles in the process stream and fire hazards due to some catalyst being pyrophoric in nature. However, the industry needs completely closed system, effective filtration, no bypass and safety from fire hazards.

NUTSCHE FILTERS - SINGLE OR DOUBLE DOME DESIGN Nutsche filter is the industrial version of the well-known laboratory scale Buchner Funnel except that it is designed to operate under either on vacuum or pressure. These operate usually under pressure or full vacuum, in batch oriented industries such as fine chemicals, dyes, pharmaceutics and pesticides.

TECHNOLOGIES AND SYSTEMS AVAILABLE Filter Press These conventional filter assemblies have plate and frame design. These systems are prone to usual problems of drip losses, manual handling and loss of catalyst. Very few installations are seen in the industry now, often due to capital budget constraints. A complete analysis of ROI, considering the losses and maintenance costs, regularly indicate that these are very expensive piece of equipment to buy for these applications

Nutsche filters are constructed to perform a multitude of tasks including reaction, filtration, cake washing and thermal drying on a single unit. These filters are well suited for handling flammable, toxic, corrosive and odour-noxious materials since they are closed systems and designed for use in hazardous and explosion-proof environments when extremely safe operation is necessary. But there is a lot of manual operation involved in the end of the cycle and also there is a hold up of the catalyst in the system.

Advantages: Dry filter cakes and work under pressure or vacuum Disadvantages: Batch operation, large floor space, drip losses, manual handling â&#x20AC;&#x201C; product loss, opening and closing difficult and washing of catalyst a problem due to channelling.

Advantages: Closed systems, work under pressure of vacuum and washing of catalyst effective Disadvantages: Batch operation, large floor space, manual handling, opening and closing difficult and hold up of catalyst particle FUNDABAC/FABRIC CANDLE FILTERS Fundabac from DrM or any such fabric Chemical Engineering World

Features CEW candle filters have also been used. These are very effective for bulk solids handling. The design to filter the Heel volumes and unique candle design of 5 tubes assisted in cake dislodging in various chemical applications.

Disadvantages: Relatively high capital cost FLOW CONFIGURATIONS The filter manufacturers suggest two configurations – ‘In-to-Out’ flow through

candles and second alternate ‘Out-to-In’ flow in the candle. For large catalyst loads in a reaction mixture the ‘In-to-Out’ flow poses a problem of cake discharge and makes the systems very large. Generally

Advantages: Closed systems, work under pressure, washing of catalyst effective and heel volume filtration possible Disadvantages: Semi-batch operation, by-pass of catalyst in beginning, cake dislodging problem causing haze, tearing of fabric frequent and micron retention of 3-5 microns – catalyst passes initially. CONTINUOUS TUBULAR FILTERS (CONTUFILT-M) (Refer Figure 1) The most recent amongst the above are the Continuous Tubular Filters (e.g. Contufilt-M) which offer an outsidein filtration using vertical candles in a closed pressure vessel for polishing in hydrogenation slurry catalyst recovery and filtration. The systems are back washable, easy to use and maintain. The Zero-Hold up design ensures that all the pharmaceutical or API products are recovered completely. Continuous Tubular filters like Contufilt –M have the following distinct advantages over their predecessors: Closed System: Helps reduce operator exposure to hazardous materials Accessibility: Easy access to elements from top

Figure 1:Continuous Tubular Filters (Contufilt-M)

Compact Design: Element bundle is removable as an assembly Coded Vessels: Filter areas up to 200 m 2, withstands differential pressure as high as 30 kg/cm 2. Designed generally in accordance with ASME section VIII Advantages: Continuous/semicontinuous operation, closed systems, work under pressure or vacuum, no hazy product, no product re-cycle, no problem of cake dislodging, washing of catalyst effective, low lifetime cost/low maintenance and compact size. Chemical Engineering World

Figure 2: In to Out Flow vs. Out to In Flow – a pictorial representation

April 2016 • 47

CEW Features it is preferable to use ‘Out-to-In’ flow for these continuous tubular filters. Contufilt uses ‘Out-to-In’ flow configuration. FILTER MEDIA Industry has tried using both fabric both woven/non-woven and sintered metal filters in catalyst recovery and filtration. Fabric sleeves (e.g. Fundabac equivalent) are no doubt cheaper alternates, but have their inherent problems. Fabric sleeves use cake filtration to filter the catalyst particles. The liquid is re-circulated for sometime allowing formation of a cake which enhances filtration. When the clear liquid starts the cake is allowed to build under controlled conditions – i.e., without disturbing the cake. It is critical to maintain the cake formation and in case of failure during the filtration cycle the catalyst passage starts again disrupting the filtration process. Design of the vessels and the flow characteristics have to be studied well before selecting these filters. To overcome the above problem newer filter media are being developed and more recently sintered steel rolled or iso-statically pressed media have proved to be very successful. The process of making these filter-media is very energy intensive and the technology is closely held by a few companies in the world thereby increasing their initial cost. Now further development has introduced SS membrane layer which is applied on the on top of the sintered media. This asymmetric structure of the SS membrane is proving to be very beneficial as this type of filter media overcomes the problem of the rolled sintered filters - which were welded on the seams (weak joints) and also could not take very high pressures. Asymmetric metallic membranes use a coarse support

Figure 3: SEM of an AS-SS Membrane Media (mm wall thickness)

48 • April 2016

structure for support and due to iso-static construction of the base core can handle very high operating pressures. (See Figure 3) Comparison Rolled versus Iso-Statically pressed Sintered Media Rolled Sintered: Sintered and then rolled and welded longitudinal seam welded, In to Out Flow, In to Out pressure: up to 4 Bar, Out to In pressure: up to 2 bar (causes buckling beyond) and micron rating available up to 1 micron Iso-Statically Pressed (Asymmetric Membrane): Pressed and then sintered, seamless tubes, Out to In flow, In to Out pressure: 12 Bar, Out to In pressure: 8 bar and sub-micron Advantages of the New Membrane Design • Single pass system – no re-circulation for cake build-up, no by-pass of black particles • 100 per cent regeneration of the candle surface – giving clean filter and clear filtrate after every cycle • Can be used as a Trap filter during the initial start-up – so no need of re-cycling the liquid in the fabric candle (e.g., Fundabac) before the cake built up is there initially and also hazy liquid flows • No fear of the cake falling during batch

operation as in the fabric candle (e.g., Fundabac) causing problem of catalyst by-pass. New membrane design does not allowing by-pass due to surface filtration. HEEL VOLUME FILTRATION The design incorporates Zero-Holdup where the heel volume in the process is filtered using the ZLH Filter system. After filtration of the complete batch, you have an option of recycling the catalyst back to the reactor or collect it for the regeneration. The driving force is nitrogen/ compressed gas pressure and no PUMPS are employed (pumps disintegrate the catalyst and also bring in handling losses). However, in applications where pumping is used these systems can be efficiently used Whatever the type of filter candle used the basic principle remains the same. At the end of each filter cycle, solids are backwashed off the inside or outside of the elements and discharged as a concentrated slurry or wet cake. These systems offer ultimate particle retention, back-washability, solids capacity and strength and can be used in combination with filter aids for difficult filtration applications. OPERATION The system consists of a number of equally sized pressure vessels each containing

Figure 4: Contufilt – M – Backwashing and Pulsing System

Chemical Engineering World

Features CEW an equal area of porous metal cartridges arranged in multi-cylindrical form. The vessels perform the specific functions of filtration, in-situ reverse flow, gas assisted discharge of collected catalyst and when required, an in-situ soak to re-slurry the catalyst if required. The mechanism of filtration is a direct interception of catalyst particles on the surface of the Porous metal filter down to the micron rating of the filter media. This initial capture starts and enhances the capture of all other particles 1 micrometer and lowers (ASTM F795-88). This ongoing formation of a surface cake continues to build- up to a depth of 10-15 mm or greater. BACKWASH Backpulsing is used during process to increase flow rate. The backwash system should provide efficient separation of fine particles from a fluid stream by collecting the particles on the surface of a composite stainless steel, sintered metal filter. The filters are then cleaned, in-situ, by backwashing in the reverse direction, dislodging the solids from the filter and flushing the filter vessel. The filter system should function with no loss in collection efficiency or suffer from physical degradation due to chemical attack. Since powdered sintered metal and felt metal

have depth, these small catalyst particles will pass through the surface pores and become lodged within the depth of the sintered powder metal where they cannot be dislodged by simply reversing the flow of liquid. AS membrane – two layer designs have shown phenomenal results in terms of catalyst particle capture and cleanability. (See Figure 5)

TESTING Testing consists of non-destructive testing like radiography, liquid penetrant inspection, magnetic particle inspection, leak testing, etc.

GOOD SYSTEM ENGINEERING & HOUSING DESIGN The housing is designed for: • the specified pressure at the temperature given in the technical specifications • even flow distribution • specified element spacing for cake build up • easy access for change-out (i.e., a solids collection vessel catalyst recovery) • The filter housing can be made of SS 316 or compatible MOC with nozzles for inlet, outlet, drain, backwash fluid, vent, and pressure taps with suitable connection size and type for proper operation as per the flow parameters specified.

A filter element integrity test is performed on all filter elements using a nondestructive ‘Bubble Point Test’ 1 that has been correlated to a destructive challenge with test contaminant to certify it meets the rated efficiency.

The housing is designed and fabricated generally in accordance with the DIN/ ASME Boiler Pressure Vessel Code, Section VIII, Division 1.

The entire filter is hydrostatically tested in accordance with ASME Code, Section VIII, Division 1.

CONCLUSION Closed loop systems for precious metal catalysts using AS membranes and ZLHZero Hold-up designs are very effective in catalyst recovery and recycle. References: I. Permeable Sintered Metal Materials Determination of Bubble Test Pore Size -DIN- ISO 4003) II. Liquid filtration , Cheremisinoff, Nicholas P, Azbel, David S., 1983 III. Fil’trovanie teoriia i pratika....(Filtration; theory and practice for .suspended matter)- Zhuzhikov, V.A., 1961 IV. Filtration : equipment selection, modelling and process simulation , Wakeman, R.J., Tarleton, E.S, 1999 V. ASTM F795-88(1993)Standard Practice for Determining the Performance of a Filter Medium Employing a Single-Pass, ConstantRate, Liquid Test

Authors’ Details Lalit Vashishta Diva Envitec Pvt Ltd E: lalit@aboutfilter.com

Figure 5: The graph alongside depicts how back pulsing helps improve the ﬂow rate in a Contufilt system –The two shades show how the iso-static non-asymmetric candle ﬂow rate drops with time and slowly the candle chokes Courtesy : GKN Germany

Chemical Engineering World

Dirk Stoecker GKN Sintermetal, Germany E: dirk.Stoecker@gknsintermetals.com April 2016 • 49

CEW Features Technical Article

Role of Decision Support System in Managing Reject Water and Source Sustainability A significant progress is achieved by India in access to improved source of drinking water as per the joint monitoring program (JMP) of WHO and Unicef. It is reported 97 per cent population in urban areas and 93 per cent in rural have access to improved sources of drinking water1. The access to improved sources of drinking water is a quantitative indicator adopted under JMP to measure the progress globally against the unimproved sources like unprotected dug and springs, surface water like stream, river, pond and canal irrigation water. The improved water sources could be piped water into dwelling, plot or yard, public tap/stand post, tubewell/borewell, protected dug well, protected spring and rainwater collected2. It is well established mere access to improved water sources cannot ensure that the water is safe for human health. The water quality standards (BIS 10500) determine whether the water is within the acceptable limit of drinking water or not. The acceptable limit has been relaxed in difficult areas for the certain chemical contaminants with permissible limit. The information about the source water quality and monitoring of availability play significant role decision making.

emand of water in each sector is increasing to maintain selfsufficiency and economic growth. More than 60 per cent of irrigated agriculture is dependent on groundwater. Similarly, the significance of groundwater for domestic water supplies is high, over 85 percent rural water supply depends on groundwater sources 3. Irrational and non-regulated use of water resources has impact like drying of surface water sources, increasing distance of sources from habitations and higher dependency on ground water also resulting drinking water shortage. Competing water demand in each sector along with other factors like geo-hydrology, agro-climatic, socioeconomic and water governance have influence on slippage of water supply in service levels below prescribed norms. These results in large number of drinking water sources either become dysfunctional or seasonal variations in quantity of water supply to the habitations. It is reported that slippage in rural water supply is more than 30 per cent at all India levels, which is substantial by any standards 4. The slippage in service levels is posing serious challenge to sustainability of rural water supply and risk to water security if water resources are not managed by adopting integrated approach.

50 • April 2016

Quality and Health Impact • The contaminated water is posing much serious health risks. Around 46 million people in India—or the size of the population of Spain—are exposed every day to contaminated water, leading to health issues such as crippling skeletal damage, kidney degeneration, cirrhosis of the liver and cardiac arrest 5. • Over dependence on ground water is one of the causes for inorganic contaminants like Fluoride, Arsenic, and Iron etc. as these are geogenic. Arsenic poisons the water nearly 10 million people have health risks and fluoride affected areas pose risks to another 66 million people. Many coastal districts in India suffer from excess salinity in groundwater. • The bacteriological contamination is affecting large part of the country, especially faecal coliform. Mostly in groundwater the coliforms come from the leaching of solid (human and animal excreta) and liquid wastes estimated about 21 per cent of communicable diseases in India is water related6 like diarrhoea, gastroenteritis, jaundice, hepatitis, cholera, typhoid and polio.

The Gaps The above section indicate that the water availability and quality are the two serious issues; the Ministry of Drinking Water supply and Sanitation reported around 30.8 per cent households have piped connection and only 17.6 per cent receives treated water. There is huge gap in treated water supply; the dependency of people on untreated water supply in both rural and urban areas is very high. It offers a large market waiting to be addressed by both governments and market operators. Unfortunately, till now the focus of government is mainly to improve the access to drinking water, the quality is completely neglected. The private sector companies and entrepreneurs are attempting to fill-up this gap by offering various technological options for water treatment. Some of them are able to demonstrate the success and profitably solve this issue by offering point-of-use water filters, popular in urban areas and few demonstrated success of centralised community size water treatment plants adopted both in urban and rural areas. The Indian cities largely depend on surface water sources like reservoir, dam, river, lake etc. for domestic water Chemical Engineering World

Features CEW supply. Even though the distance of water sources is increasing due to drying of sources, but no other options are explored. The sources supply low TDS water through distribution network of piped connection. Most water from taps in India needs some sort of treatment before it is consumed. While tap water is often, but not always, treated at centralised facilities, it has a high risk of recontamination before it reaches homes due to old and badly maintained pipes. While this is a problem faced in urban India, it is also the crux of India’s rural drinking water problem. Owing to gradual increase of awareness about water borne diseases and health risks due to contaminated, people have no choice but to depend on market for the treatment solutions. Market Intervention and Efficacy of Popular Option The technological options available to treat water have long range like reverse osmosis, electrolyser, coagulation, ultra-filtration, UV disinfection, activated alumina, chlorination etc. these are well-known technologies and available across India. The treatment process vary from traditional methods to complex membrane-based systems such as reverse osmosis (popularly known RO) which is perhaps the most effective in removing all kinds of contaminants. The private sector has best made use of media as an instrument to create awareness about the need of treated water and bombarded with ads by showing RO filter systems are only giving pure water. However, while RO provides sparkling clean drinking water, it has environmental concerns. It generates reject water which ranges between 40 and 80 percent of the input water. The percentage of reject depends on quality of input water. Higher the total dissolve solid (TDS) more is the reject. Normally, point-of-use household water filters discharge much higher reject water if compared with centralised RO water treatment plants. Systems are energy dependent, require Chemical Engineering World

reliable and significant electricity supply. Filters and membranes need to be changed frequently, higher dependency on external service support and supplies which adds to the cost. During the treatment process the naturally available beneficial minerals are also removed – requires balancing through addition if carefully designed. Overall, RO is too expensive and wasteful to be used in cities which are supplying water from surface sources. It is even wasteful to be used in absence of information about the concentration of contaminants. In spite of environmental concerns, the RO is the go-to technology and registered on top in the consumers’ mind. It has a close-nit ecosystem with a number of operators and equipment vendors serving everyone from middle-income and up consumers to governments to NGOs to public-private partnerships and media. Point-of-use household water filters have gained more popularity especially in urban areas over community size centralised water treatment plants. The factors responsible for such popularity are; • Increased awareness for the clean drinking water and the health benefits of treated water • Non-reliable public water supply, old pipe lines and many a times these runs along the public waste water disposal drains • Convenience to manage point-of-use filters at household • Cost-economic and service support provided by vendors The above listed factors are the main reasons behind deriving the growth of water treatment systems. According to the international study conducted by MarketsandMarkets 7 the projected growth of reverse osmosis systems is going to witness highest among the other technological options between 2015 and 2020. The study has further segmented on the basis of the device; the table top pitcher segment is projected to grow

at the highest rate. The point-of-use water treatment systems which holds the highest share among others is projected to register a compounded annual growth rate of 9.8% from 2015 to 2020. The point-of-use water treatment systems market is estimated to reach USD 24.5 Billion by 2020. Decision Support System to Address Environmental Concerns The drinking water sector is facing two key challenges; 1. Source Sustainability and 2. Expanding Water Quality affected areas with multiple contaminants. Both these challenges can be addressed by adopting systematic information collection and adopting analytical approach of decision making. Below given examples provides scope to adopt such approaches in managing the environmental concerns at local level. 1. Source Sustainability: A systematic study of water resources in a given areas is required to understand the groundwater dynamics and source sustainability challenge in a given area. The study involves assessment of water utilisation practices within the hydrological unit (watershed) and recoding periodic water level fluctuation, estimation of crop, domestic and other water requirement. Ultimately water balance is worked out. 2. WQ Test for Technology Selection: The reject water is serious environmental concern with reverse osmosis technology of water treatment. It can be managed by conducting systematic water quality test of raw water and selecting the technological option based on test results. Many a times reverse osmosis technology is selected by the people under the influence of market and without conducting water quality tests of raw water. This practice is more common especially in the case of point-of-use treatment systems. Even the water is well within the limit of inorganic contaminants only microbial treatment is required, still household April 2016 • 51

CEW Features select RO systems. A simple water quality test of raw water and proper advisory to the users can drastically reduce the wastage of raw water from point-of-use water treatment systems. Similarly, selection of technology for community size water treatment plants requires prudence towards water use. The areas those have TDS below 500 ppm should strictly abide the norms and do not setup the RO plants. 3. Blending of Reject Water: The community size water treatment plants using reverse osmosis technology can also minimise the reject water by conducting systematic water quality tests of raw water, treated water and reject water. The information of quality test helps in decision to plan recirculation of reject water by mixing with raw water. The recirculation process tested in villages Wadlakjonda, Parvathagiri Mandal, District Warangal. In this village raw water TDS was 230 ppm, by adopting blending of reject water about 30 per cent more recovery of water was achieved. Presently this treatment plant is discharging only 21% of reject water with 780ppm TDS. Based on this test a study of 77 plants in Telegana conducted by Safe Water Network India, it is found that 41 plants have TDS < 1500ppm, in these plants recirculation can be planned to minimise the reject water. Conclusion • The community size treatment plant operator to adopt ecosystem approach to address source sustainability. – Monitor ground water fluctuation in the watershed and take appropriate decision for optimisation of usages – Engage with user groups to educate for improving water use efficiency – Work toward water augmentation for achieving water safety and security at local level. • Water quality test supported with advisory are essential to select right water treatment system, specially point-of-use filters, to avoid huge 52 • April 2016

A study carried out by Safe Water Network India in a micro-watershed of 1650 square kilometre in which three community size water treatment plants are operating, serving to more than 7500 population. The study reveals that the groundwater use for water treatment plants is only 0.03 per cent of the total water use in the village. The water use for agriculture purpose is more than 98% in this watershed and only 0.19 per cent of the groundwater recharge is used by the water treatment plants. Such study can also contribute in decision to adopt water harvesting measures and improve water use efficiency in irrigation to offset the effect of ground water depletion. (Source: Solving for Water Security in a Micro-watershed, field insight series, September 2015, Subhash Jain, Ravi Sewak, Christopher McGahey, Safe Water Network India)

water losses due to selection of reverse osmosis technology where it is not needed • Systematic water quality monitoring of Raw water, Reject water and Treated water on periodic interval are essential to decide the adoption of Reject Water Blending for minimising wastage of water. References: 1. 25 year Progress on Sanitation and Drinking Water, 2015 update and MGD Assessment Annex 3 Country, Regional and Global Estimates on Water and Sanitation page 65 (India). 2. Twelfth five year plan – 2012-2017, report of the working group on rural domestic water and sanitation, Chapter 2, 3.6.1 – Joint Monitoring Programme 3. Deep well and prudence: Towards pragmatic action for addressing groundwater overexploitation in India, World Bank report. 4. “Slippage”: The Bane of Rural Drinking Water Sector, a study by extent and causes in Andhra Pradesh by Centre for Economic and Social Studies by V. Ratna Reddy, M S Rammohan Rao, M Venkataswamy, year 2010 5. h t t p s : / / i n . f i n a n c e . y a h o o . c o m / s / 4 6millionindiansbeingslowlypoison ed000000921.html 6. Combating diarrhoeal disease

in India through safe drinking water, Justin DeNormandie and Janette Sunita, Population Services International (PSI) Delhi, India http://www.marketsandmarkets. com/Market-Reports/point-ofuse-water-treatment-systemsmarket-131277828.html

Author’s Details Subhash Jain, Development Consultant, worked as Program Head with Action for Food Production, Program Leader with Safe Water Network, Program Leader and Regional Council Member, Global Water Partnership-SA Chemical Engineering World

Market Insights CEW

Fuel Emulsification: An Unknown But Profitable Technology

he main advantages of using emulsified fuels instead of the fuel itself are environmental and economic benefits. Addition of water to the diesel process decreases combustion temperatures and lowers NOx emissions. Initially, the ‘acceptance’ of using water mixed fuel was a challenge, but with increasing awareness about environment coupled with interesting marketing strategies of different companies, emulsified fuel is being accepted. What is the need for the Emulsified Fuel? Hardly a day goes by without one seeing a headline about climate change, tighter automobile emission norms, the need to clean-up the environment and yet, industrial pollution keeps on going on unabated. Concurrently, often in the same month - if not the day - there might be another news item about fuel being adulterated. Mostly people don’t correlate the these two stories until they learn that fuel adulteration is a `40,000-crore business in India with about `10,000 crores pertaining to industrial fuels alone. Industrial fuels like furnace oil (heavy fuel oil) leave the refineries and often reach the end consumer adulterated to the tune of 25 per cent with substances like used engine oil, sludge, water and miscellaneous acid and chemical waste. This oil is later fired in furnaces and boilers where the impurities show up in the guise of black smoke, noxious fumes and tank sludge, all of which are major air and ground water contaminants. The Technology It was in this environment that a Delhi-based entrepreneur – Darshan Bhat, having no prior experience in the fuel industry or trade, decided to create Creatnet Technologies Pvt Ltd (CTPL)

to usher in a revolution in cleaning up industrial emissions and improving fuel combustion characteristics of heavy fuels using a long existing but little known technology - Fuel Emulsification. His search for the most effective solution in greening industrial fuel initially took him to St. Petersburg Technical University in Russia. When the equipment order from Russia reached India, he encountered challenges in every step - commissioning, technical trials, start production and most of all figuring out how to market a product that any lay man would consider either sophisticated adulteration or plain insanity. As mentioned earlier, the ‘acceptance’ of using water and oil mixed fuel was a challenge He realised that technology was a lot more than equipment and required constant innovations in process, chemistry and the business model. The solution to the technical impasse came in the form Ravi Deka - a maverick innovator, pioneering evangelist and system integrator of fuel emulsification technology with over eight years in this field. Deka was saddled with the responsibility of finding ways to make the technology work, start emulsified fuel production and its commercialisation. Featuring on the government who’s-who list of innovators and a serial guest speaker in UNDP-GEF seminars on energy efficiency, today Ravi Deka leads CTPL as its CEO. The company and the technology were later promoted by another team member Eeshwar Chopraa, who is responsible for articulating the company’s path going forward. Fast forward one year, today Creatnet Technology Pvt Ltd is the sole fuel supplier to Lead recycling giant Gravitas India and aluminium sheet manufacturer Metnere Ltd, and currently engaged in consultations for emulsification and customised eco-friendly fuel solutions to several MNC FMCG and pharma companies. The Process What are fuel emulsions? How does mixing oil and water in adulterated oil turns it into an eco-friendly and economical alternative to normal and usually adulterated Industrial fuels? Well, for starters, emulsified fuels consist of hydrocarbon oil like diesel or furnace oil, uniformly embedded with 5-10

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April 2016 • 53

CEW Market Insights microns water droplets turning its appearance into a sponge-like substance under microscope. When ignited in a boiler or furnace burner, the high flame temperatures flash these water droplets into steam causing micro-explosions which rupture the fuel droplets into a nano-fuel mist causing a phenomenon known as ‘Secondary Atomisation’ which causes complete combustion of fuel simultaneously enriching it by releasing traces of highly combustible hydrogen. The end result is improved combustion and fuel efficiency, with significantly cleaner flue gas emissions. Environmentally, emulsified HFO (Heavy Fuel Oil) combustion uses 15-20 per cent less oxygen than normal fuel in the same furnace or boiler due to increased combustion efficiency and lower requirement of excess air, due to which it also produces almost 20 per cent less waste-heat in the chimney. There is also about 30 per cent less NOx, 20 per cent less SOx and particulate matter in the flue

gases when compared with stock HFO. Challenges Potential clients are at first intensely sceptical that anything as far-fetched as a mixture of oil and water would even burn, let alone provide any economical or ecological benefits. And secondly, even after seeing the positive results, the only factor in which they are ever interested is a direct price discount vis-à-vis their normal fuel; better ecology and improved efficiency not warranting as much as a raised eyebrow. The deeply entranced corruption amongst many company’s personnel long habituated in receiving hefty pay-offs from unscrupulous dealers and transporters for accepting heavily adulterated and substandard fuel had been another recurring stumbling block in penetrating the market. Meanwhile, the government agencies on their part along with the officials of most oil company officials both seem to suffer a selective myopia when

addressing the rampant fuel adulteration of fuel and its resulting pollution. The Future Today, the Creatnet technical team is working on formulating several key solutions on the request of sectors as diverse as biscuit manufacturers, pharmaceutical companies to copper smelters in providing them an economical but more importantly a cleanly burning emulsified fuel tailor made for their specific requirements. The team is also finalising various other fuel solutions such as Oil-Coke-Colloidal Fuel, Carbon Slurry Fuel etc., for which the patenting process has been initiated. In the end it’s all about ushering in hope of greener fuels, cleaner are and hopefully blue skies. Interestingly, this technology can very easily be exported by Creatnet to various parts of the continent. Courtesy: Creatnet Technologies Pvt Ltd (www.creatnettechnology.com)

ADVERTISE TO EXPAND your reach through

For Details Contact

Jasubhai Media Pvt. Ltd. Taj Building, 3rd Floor, 210 Dr D N Road, Fort, Mumbai - 400 001 Tel: 022-4037 3636, Fax: 022-4037 3635 Email: industrialmags@jasubhai.com 54 • April 2016

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Marketing Initiative

A Complete and Versatile Range of Vacuum Pumps & Cutting-edge Vacuum Dryers Include the Best of Italvacuum Experience Serving Chemical and Pharmaceutical Industry

hanks to over 75 years of experience, Italvacuum is one of the leading manufacturers of vacuum pumps, as well as a worldwide reference point in the design and manufacture of vacuum dryers, which ensure top-tier performances for the processing of wet feed from filtering and centrifuging processes. Considering the impor tance of the use of Italvacuum installations, that are quite often exploited in the production of API, fine chemicals and inter mediates, the company mission has always been to provide the customers with the utmost in quality, safety and innovation, with a special care for sustainability and total respect for the environment. Italvacuum Workshop -Vacuum Pumps

To d a y I t a l v a c u u m ' s m a n u f a c t u r i n g capabilities include a wide range of original and patented products, which comply with the main European regulations (EC, ATEX and PED) and with the ever more severe FDA rules and cGMP norms, including: • Saurus939, vacuum pump unique in reliability and performances • Planex ® System, multi-patented paddle v a c u u m d r y e r w i t h Z e r o Fr i c t i o n ® planetary movement eccentric agitator • CRIOX System, rotary vacuum dryer/ p u l ve r i ze r w i t h m o t o r - d r i ve n l u m p breaker units • MULTISPRAY ® Cabinet Dryer, vacuum tray dryer with MULTISPRAY automatic washing system for fast cleaning of all internal parts • CosmoDry ® System, paddle vacuum dryer with concentric agitator, fitted with a shaft that can be disassembled in sections, for maximum ease of cleaning and inspection. Chemical Engineering World

Italvacuum is able to provide turn-key installations and also to realize customized systems, which are built according t o c u s t o m e r ’s p r o c e s s r e q u i r e m e n t s. Italvacuum’s presence all over the world, with a continually growing number of installations in both consolidated markets and emerging areas, is a tangible sign of the company’s reliability. SAURUS939, fit and forget A vacuum pump that guarantees unrivalled performances, ensuring total recover y of extracted solvents, even in severe operating conditions. A simply designed machine, that combines traditional robustness and reliability with the most evolved technology. Resistance, strength and consumption of oil virtually eliminated t h a n k s t o t h e i n n o va t i ve L u b r i Z e r o ® system. A solution which guarantees perfect operation and optimum results with total respect for the environment.

Saurus939 has no fear of aggressive and corrosive solvents, powders and condensates, nor distillation by-products. But above all it does not fear confrontation because it is designed and manufactured to work 24 hours a day with a constant ex c e l l e n t p e r fo r m a n c e a n d m i n i mu m operating costs, thanks to a low-energy motor, negligible oil consumption and easy, immediate maintenance. Powerful, efficient, but absolutely safe: Saurus939 guarantees optimum safety through the whole process and complete purity of the final product. In other words, ensures an uncontaminated vacuum. Saurus939 has a wide range of use and could be employed in different sectors: chemicals, pharmaceutical, cosmetics, Oil & gas, plastics & rubber, bio-science, waste management. The processes are those of the process industry: vacuum dr ying, reaction, distillation, April 2016 • 55

Marketing Initiative ideal for drying small batches. CRIOX System, powdering while drying An international great success patent, which consists of a rotary vacuum dryer/ pulverizer, counting more than 400 units installed in more than 30 countries.

Italvacuum Workshop -Vacuum Dryers

crystallization, filtration, evaporation and polymerization. PLANEX ® System, a revolutionary drying philosophy A multi-patented machine which is conquering the most demanding operators from all around the world, by guaranteeing results that were unthinkable till now with conventional systems, both horizontal and vertical. Planex ® System is a special horizontal vacuum paddle dryer with an eccentric agitator featur ing two independent movements, allowing it to simultaneously revolve around its own axis and to rotate tangentially to the drying chamber, ideal for the production of APIs. The combined rotations of the agitator and its small size compared to the dr ying chamber diameter, ensures the perfect mixing of the entire batch, and allows consuming at least three times less energy than c o nve n t i o n a l d r ye r s w i t h c o n c e n t r i c agitators. This means a threefold reduction in mechanical and thermal stresses on the batch being dried (analysis by Politecnico d i To r i n o ’s D e p a r t m e n t o f M a t e r i a l s S c i e n c e a n d C h e m i c a l E n g i n e e r i n g ) . As a result, even the most delicate and temperature-sensitive products are treated with maximum care. But there is more. Planex ® System, thanks to its agitator’s Z e r o Fr i c t i o n ® p l a n e t a r y m o v e m e n t , 56 • April 2016

prevents the product from being rubbed against the dr ying chamber walls and thus heating up due to friction, a typical problem in conventional paddle systems. In addition, the rotation of the paddles tangentially to the chamber walls, conveys the product into the small clearance between the agitator and the chamber surface, preventing lumps formation and guaranteeing an even more effective drying and a controlled final particle size distribution, which is impossible to achieve with conventional dryers. Thanks to the agitator movement controlled by the “Stop & Swing” program, it is also

The central body is made of a double cone chamber, characterized by smooth surfaces without edges and sharp corners. During the rotation, this structure helps the total and continuous revolution of the mass to be dried and allows a homogenous and delicate mixing. The double cone shape of the rotary chamber would not be effective in itself if it did not contain inside the two powerful electric lump breaker units – which are a peculiar characteristic of the CRIOX System – allowing for the increase of the product surface exposed to the evaporation and to enhance the agitation efficacy of the system. The lump-breaker units not only breaks down the eventual pre-existing agglomerates in the wet powders thus preventing the forming of lumps, but they also allow for grinding and powdering during the last drying phase, limiting the use of the mill. This helps having bulk products ready for bagging or powders

Saurus939

Chemical Engineering World

Marketing Initiative Italvacuum services: from pilot trials to project engineering right through to a comprehensive After Sales Service Customer care, for Italvacuum, means supporting the customer from the very first contact. Italvacuum offers the opportunity to conduct pilot drying trials and involves the customer in system design and manufacturing.

with checked final particle size distribution, where the next operation is often limited to a sifting phase. CRIOX is versatile and profitable: specific s o l u t i o n s h ave b e e n s t u d i e d fo r t h e products automatic loading and unloading and also in order to wash, to clean through and to inspect the plant before changing the batch. This means the opportunity to pass quickly from one product campaign to another, as production demands. M U LT I S P R AY ® C a b i n e t D r y e r , a consolidated ever evolving technology Best results, ergonomics, safety and flexibility for any product batch. These are the qualities that have always characterised MULTISPRAY ® vacuum tray dryers, result of Italvacuum's consolidated experience in the cosmetic, pharmaceutical and chemical industry process applications. But that’s not all, because the important added value that differentiates MULTISPRAY ® innovative dr yers from conventional systems is that it guarantees total cleanliness of the inner chamber and all heating plates, in compliance with the increasingly restr ictive FDA standards and the cGMP standards of good manufacturing. In fact, thanks to the C.I.P. MULTISPRAY ® patented fast washing system, the equipment can be completely c l e a n e d i n j u s t a few m i n u t e s , i n a repeatable and certifiable way, minimizing washing liquid consumption. The MULTISPRAY ® vacuum tray dryers can be used in any type of application as there are two versions available, fixed plate and removable plate, the latter particularly indicated for multiproduct usage. Also, fo r t h e p r o d u c t i o n o f h i g h l y a c t i v e pharmaceutical ingredients (high potency API) and for R&D activity, Italvacuum has developed the laboratory version LaboDry. CosmoDry ® System, the evolution of the species An innovative horizontal paddle vacuum Chemical Engineering World

Planex System

O nc e the s y s tem is up a n d r u n n in g , Italvacuum also provides all the technical support the customer may need to ensure year after year of fault-free operation. Pilot trials The Italvacuum facility comprehends a full range of pilot systems for carrying out semi-industrial and laboratory scale drying tests on customer’s products.

Criox System

d r ye r, t h e r e s u l t o f h i g h l y a d va n c e d research by Italvacuum and of a careful analysis of the production requirements of the most demanding customers. Power, load flexibility, drying speed, easy unloading, maximum quality of dr ied product. All important and fundamental values, but Italvacuum went even further. T h e g r e a t i n n o va t i o n o f C o s m o D r y ® System as opposed to traditional dryers, in fact, is in the par ticular str ucture of the agitator: the inner par ts can be dismantled in different par ts, quickly a n d e a s i l y. W h i c h m e a n s ve r y e a s y internal cleaning, maintenance and inspection: a mix of qualities that ensure the machine is always kept in perfect working order and optimize the production processes, making CosmoDry ® System also the perfect solution for multi-product applications.

Engineering Outstanding technical know-how and a thorough knowledge of the needs of the chemical and pharmaceutical industries have enabled Italvacuum’s engineering services to build up unparalleled expertise in vacuum processes. After sales service With highly qualified personnel, Italvacuum’s After Sales Service provides the following assistance: 1) Scheduled preventive maintenance; 2) Technical assistance; 3) Service parts; 4) System upgrading and overhaul. Italvacuum in India Concerning sales strategy, Italvacuum can count on a worldwide network of highly qualified agents. For vacuum pump promotion in India Italvacuum cooperates with Vac Enterprises India LLP, which is based in Mumbai. With a very competent staff, Vac Enterprises India LLP is able to understand every client requirements. This is also due to the training provided to all the salesmen and technicians, which are constantly updated with regular courses in Italvacuum. For more info: www.italvacuum.com April 2016 • 57

Marketing Initiative

Extension to Qdos Range Offers Opportunities for Upscale to Higher Flow Rates - and Opens up New, Powerful Opportunities for Process Engineers

atson-Marlow Fluid Technology Group is proud to release the new Qdos 120, offering flows up to 120 l/hr at a maximum pressure of 4 bar, double the flow of existing models in the Qdos range of peristaltic metering pumps. This latest addition to the product range builds upon the core foundations of the Wa t s o n - M a r l ow ’s d e s i g n - t h i n k i n g fo r the widely deployed Qdos suite of highaccuracy chemical metering technology. Qdos 120 - not only offers double the flow of other models (in comparison with Qdos 60), it delivers a step-change in

performance and usability compared to conventional solenoid or stepper-driven diaphragm metering pumps. All models i n t h e Q d o s fa m i l y a r e d e s i g n e d t o eliminate the need for ancillaries, boost productivity, and cut chemical wastage due to its highly accurate, linear and repeatable metering. Powerful combination of features This powerful combination of core features offers significant benefits to process engineers in the water/ wastewater, industrial and agri-chemical s e c t o r s. I t i s e a s y fo r c u s t o m e r s t o upscale to the higher flow rate of the

Qdos 120 as it maintains the same c o m m o n i n t e r fa c e , c o n n e c t i v i t y a n d functionality of the existing Qdos models. Driven by market demand for pumps that offer low total cost of ownership (TCO) without compromise to performance or process quality, the Qdos 120 allows engineers, as well as skid manufacturers and packaged-plant designers, to overcome a host of issues associated with diaphragm pump technology, such as poor suction lift and the downtime resulting from blocked valves and gaslocking. The per istaltic operating pr incipal of the Qdos 120 has been designed to d e l i ve r c o n t i n u o u s , s m o o t h f l o w fo r optimal fluid mixing, while high accuracy provides chemical savings and increased process quality. Safe, One-minute maintenance The combination of high reliability and low maintenance ensures minimal operational expenses. There are no valves or seals to clog, leak, gas-lock or corrode. Moreover, process uptime is maximised with notools maintenance and quick and easy pumphead replacement. In fact, there is only one consumable part on Qdos 120 pumps, the ReNu pumphead, which can be replaced in 60 seconds to return the pump to its as-new state. What’s more, the fully contained pumphead ensures no spillage or exposure to chemicals.

Qdos 120

58 • April 2016

Increased flow capability at development partner sites Among the many success stories emerging

Chemical Engineering World

Marketing Initiative

Qdos 120 • New Qdos 120 offers greater flow – and has no valves, ancillaries or gas-lock issues, thus reducing installation and maintenance costs • Reduced chemical costs through accurate, linear and repeatable flow • Provides extended operating life from customers involved in the validation of Qdos 120s product development, is a seed treatment company, which since a d o p t i n g t h e Q d o s 1 2 0 h a s e n j oye d improved flow capability and accuracy at a higher viscosity. Previously, the company was limited to the chemical types it could r un on its existing Qdos 60. In contrast, the 120 allows a single pump to cover all flow ranges, providing users greater flexibility with a single spare part inventory. Additional benefits include the n e e d t o s t o ck o n l y o n e p u m p a n d a s i n g l e c o m p o n e n t s p a r e s i nve n t o r y. Furthermore, the company’s customers are now afforded more flexibility to apply material at higher-than-design rates if needed, while another positive comment made by the user alluded to fluid recovery on the Qdos 120, which was said to be simpler than on competing peristaltic pump models. The application at the seed treatment p l a n t i nvo l ve d p u m p i n g v i s c o u s a n d shear-sensitive polymer chemicals from 11 litre packaged containers to a 1200 litre tote (via a 3-metre pipe run) ready for seed coating. Here, any pulsation would affect consistency because the pump is feeding an air-powered atomiser. The flow range of the Qdos 120 is ideal for Chemical Engineering World

The application at the seed treatment plant involved pumping viscous and shear-sensitive polymer chemicals from 11 litre packaged containers to a 1200 litre tote (via a 3-metre pipe run) ready for seed coating. this application because different seed is treated with different levels of chemical, on demand. The company does not want to make up large batches of treatment which would then go to waste. Here the self-priming and dry running capabilities of the Qdos pump play a vital role in facilitating this requirement. High accuracy metering At another customer site – an electroplating business - the use of a Qdos 120 pump proved highly successful when metering various chemicals that included sodium hydroxide (NaOH) at 50% and calcium fluoride. Features of the pump praised by the company included high accuracy along with low pulsation and reduced maintenance requirements. The facility targets a “set and forget” approach to its plant requirements, which is fulfilled with a pump such as the Qdos 120. Further benefits available to all users of Qdos pumps include reduced installation costs as there is no need for the pulsation dampener, strainers, de-gassing, back pressure or foot valves required with diaphragm metering pumps. In addition, system design can be simplified thanks to high suction lift and viscous handling, eliminating the need for flooded suction, day tanks and specialist piping schemes.

speed control models, through universal+ (manual, 4-20mA input/output, pulse), to remote and Profibus control options. Watson-Marlow Fluid Technology Group is an international operation based i n Fa l m o u t h , C o r n wa l l , U K . Wa t s o n Mar low Fluid |Technology Group has offices in Argentina, Australia, Austria, Belgium, Brazil, Chile, China, Canada, D e n m a r k , Fr a n c e , G e r m a n y, I n d i a , Italy, Japan, South Korea, Malaysia, Mexico, the Netherlands, New Zealand, Poland, Russia, Singapore, South Africa, Sweden, Switzerland, Taiwan, USA and Vietnam. is the world leader in niche peristaltic and sinusoidal pumps and associated fluid path technologies. Founded on nearly 60 years of supplying engineering and process expertise and with over one million pumps installed worldwide, our pumps are tried, tested and proven to deliver. www.wmftg.com

Logistics costs are also minimised due to the inherent accuracy of Qdos pumps, which enable higher concentrations to be used. Control options The Qdos 120 range includes a number o f m o d e l s o f fe r i n g d i f fe r e n t c o n t r o l functionality depending on customer requirements, extending from manual April 2016 • 59

Marketing Initiative

Top 3 Facts About Led Technology; Led: Long-Life, Efficient, Dynamic LONG-LIFE The service life of LEDs exceeds that of conventional light sources by far. Thus the maintenance-free time increases as well. The LED technology is particularly well suited for use in extreme temperatures. Especially in combination with maintenancefree luminaire designs, the operating and maintenance costs are reduced to a minimum. EFFICIENT Continuously improved high-performance LEDs offer an excellent luminous efficacy. Furthermore, LEDs are champions with regard to saving energy. They require less current and have a longer service life. So the higher procurement costs will be amortized after only a few years. This not only saves money but also protects the environment. At the same time, reduced CO2 emissions contribute to climate protection. DYNAMIC LED luminaires improve safety – because they leave no one suddenly in the dark. They do not suddenly fail completely, but only gradually lose their luminous intensity. LEDs furthermore feature a high vibration resistance. Thus they are par ticularly s u i t a bl e fo r u s e i n r o u g h i n d u s t r i a l environments. Especially in areas that are hard to access, compact lighting solutions may be realized with such luminaires. In addition, there is the possibility to adjust the luminous intensity to the surrounding brightness. WHAT ARE THE DIFFERENCES... …between LEDs and incandescent lamps? The main difference between the two light 60 • April 2016

sources is the lighting efficiency; with lumen output of up to 180 lm/W, the LED is almost 10 times more efficient than a conventional halogen lamp. Instead of converting 5 % of the input energy to light, the LED converts up to 35 % of the energy into visible radiation. A d d i t i o n a l l y, t h e s e r v i c e l i fe o f a n incandescent or a halogen lamp is shorter, often resulting in a broken filament. An LED performs differently, as luminous flux and output decrease gradually; the user can identify the point at which the fitting is approaching the end of its lifetime. Industry standards define a minimum of 70 % of the initial luminous flux as a failure criterion; this decrease however, cannot be identified by the naked eye and subsequently requires the use of a luminous flux meter. Furthermore, an electronic controller is required for the LED, this ensures that the mains fluctuations in the power supply system will not compromise the LED's service life; so the specified service life is guaranteed. … between LEDs and gas discharge lamps? Every high-pressure discharge lamp uses mercury to generate visible light, which places a heavy burden on the environment; the new LED technology does not require this polluting element. Furthermore, the service life of LEDs is more than 50,000 hours and thus exceeds the service life of gas discharge lamps by a factor of 2. As the LEDs generate less heat, ambient temperatures of up to +70 °C are possible for safe operation whereas with gas discharge lamps, the limit is +40 °C or +50 °C.

Another big difference is the start behavior; while discharge lamps require up to 10 minutes run-up time to emit 100 % light, the LED emits its full visible light output after a few micro seconds. Moreover, it is possible to switch the LED off and to start it again instantly; when discharge lamps are switched off, they can only be re-ignited after a specified cooling phase; with this feature, LEDs actively increase safety and efficiency in the workplace. … b e t w e e n L E D s a n d c o nv e n t i o n a l fluorescent lamps? The fluorescent lamp is a discharge lamp as well - however, with a lower internal lamp pressure. So mercury is also required for fluorescent lamps to generate visible light. However, the low filling pressure of the lamp results in a rapid decline in efficiency as soon as it gets cold. At temperatures below -25°C, the lamp does not emit any light at all any more. Here, LEDs can help. The LED will operate at temperatures down to -55°C. Frequently, the service life of the fluorescent lamp ends prematurely, as the lamp is switched on and off too often. Especially the combination of cold ambient temperatures and frequent switching cycles leads to a nominal service life of only 30 %. Here, the LED shows its advantages as well.

Contact Details R. STAHL (P) Limited Plot No. 5 Malrosapuram Main Rd | Sengundram Ind. Area Malrosapuram Post | Singaperumal Koil Kanchipuram Dist. | PIN 603 204 Ph +91 (0) 44 30600600 F +91 (0) 44 30600700 E: ashwini.bondale@rstahl.net E: www.rstahl.net Chemical Engineering World

Products CEW Inline Analytical Technology For reliable online bath monitoring the LiquiSonic analytical technology from SensoTech is used, monitoring continuously and in real time processes in degreasing, preservatives or quenching baths. The LiquiSonic sensors are installed directly into baths or pipes of any size and measure precisely the concentration of, eg, cleaning, anti-corrosive or quenching agents. This makes an immediate and exact replenishment possible to ensure an optimum process performance and product quality. Furthermore, costs savings can be realized by avoiding over- and underdosing. In addition to the concentration measurement, the LiquiSonic sensors determine the contamination degree in cleaning baths. This enables the efficient control of bath changes, optimizing the component cleanliness while saving resources. The LiquiSonic technology is based on sonic velocity measurement providing accurate and every second updated measurement results. Due to the robust design, the sensors are maintenance-free with long-term stability. The measurement is inline and the real-time results are provided online to PCs and control systems. For details contact: SensoTech GmbH Steinfeldstr 1 D-39179 Magdeburg–Barleben, Germany Tel: +49 39203 514100 | Fax: +49 39203 514109 E-mail: info@sensotech.com or Circle Readers’ Service Card 4

High Output Electronic Cooling Fan AMETEK Rotron offers a high output version of its MIL-XTM tubeaxial fan that is optimized for heat sink and heat exchanger electronic cooling applications. This addition to the Extreme Performance Series delivers best-in-class airflow capacity of 450 cfm at 1” iwg or 350 cfm at 2” iwg. It is designed for long life in harsh military, aerospace and industrial environments. The new fans can be used to cool electronic devices and equipment racks in mission and personnel critical airborne, land-based and sea-borne applications. Multiple fans can be stacked to meet high-flow requirements. Standard efficiency and reliability features include advanced composite propeller material, shock-proof construction (meeting Mil-S-901), reverse polarity protection and over-voltage protection, Optional features allow the fans to be used in a wide range of situations and configurations. These include round or flat case, mounting options, EMI filter, immersion protection, fan performance sensor, analog speed control, custom finishes and more. It finds application in military and commercial electronics cooling; satellite/ aviation communications; rack cooling; telecom; heat exchangers; heat sink; chemical processing; fuel cells; etc. For details contact: AMETEK Instruments India Pvt Ltd 148, EPIP Phase, 1st Floor, Prestige Featherlite Tech Park Whitefield, Bengaluru, Karnataka 560 066 Tel: 080-67823259 | Fax: 91-080-67823232 E-mail: ananth.h@ametek.com or Circle Readers’ Service Card 5

Chemical Engineering World

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CEW Products Energy Storage

Wiped Film Molecular Distillation Plants

The energy storage market is constantly looking to increase capacity for applications such as electric vehicles. Ashland addresses this need with its new Soteras MSi binder. The new anode binder is based on breakthrough technology specifically for use with silicon to increase the capacity of lithium-ion batteries by as much as 30 per cent. This stepchange in battery capacity could prove significant for cell developers supplying the electric vehicle market.

Molecular distillation process is characterised by short residence time at the operating temperature, high heat transfer coefficient, absence of hotspots, possibility of continuous operation, and low working pressures of the order of 0.001 mbar. The feed material is fed to the wiped film molecular distillation plant; a unique roller-wiper system wipes this liquid on the heated evaporator. The centrally located condenser condenses the vapour, to get the required fraction condensed. Material handled in the WFMD: Monoglycerides, insecticides, pharmaceuticals, silicone oils, perfumery and flavours, essential oils, petroleum industry including waste lube oil rerefining, etc.

Soteras MSi binder is a unique water-based binder that can easily be processed using standard industry practices. Soteras MSi binder controls swelling, resulting in superior cycle performance at capacities greater than 400 mAh/g when used with silicon oxide (SiO), silicon composite (SiC), silicon oxide composite (SiOC), or silicon graphene (Si-Gr) technologies. For details contact: Ashland Inc PO Box 2219, Columbus, OH 43216, U.S.A. Tel: +86 (21) 2402 4863 E-mail: bpei@ashland.com or Circle Readers’ Service Card 1

For details contact: Atomic Vacuum Co (Exports) Bungalow C-6, “BANGANGA” Opp: US Vitamins Govandi Station Road Mumbai 400 088 Tel: 022-25563525 Fax: 91-022-25563525 E-mail: atovac@vsnl.com or Circle Readers’ Service Card 2

Gas Analyser The FTIR instrument, a Gasmet DX4040, has been purchased by North Shore Environmental Construction (NSEC), a specialist in the management of hazardous materials response and clean-up and field-based environmental construction. As a portable FTIR gas analyser, the DX4040 effectively enables laboratory grade analysis onsite which dramatically increases the speed with which contamination can be assessed, and avoids the problems, costs and delays associated with transporting samples to a laboratory. The DX4040 is able to measure up to 25 individual compounds simultaneously. It achieves this by producing a spectrum for the measured compounds, which means that the instrument can be set to display almost live readings for the compounds of potential interest.A major advantage of Gasmet’s FTIR analyzers, however, is their ability to identify unknown compounds. Calcmet software facilitates the identification of unknown peaks in a spectrum by comparison with Gasmet’s vast library of stored spectra. GZA GeoEnvironmental has developed a strong working relationship with NSEC; NSEC providing emergency response, and GZA delivering clean-up monitoring and site clearance. Portable FTIR, in the right hands, is a very powerful tool, helping to define the composition of gaseous contamination, which reduces risk and builds assurance in remediation activities. For details contact: Gasmet Technologies Oy Pulttitie 8 A FI-00880 Helsinki, Finland Tel: +358 9 7590 0400 E-mail: contact@gasmet.fi or Circle Readers’ Service Card 3

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Chemical Engineering World

Products CEW Falling Film Evaporator A falling film evaporator is used for concentration and evaporation of relatively low viscosity liquids. Steam, hot water or hot oil is used as the heating media and the process is carried out under atmospheric or vacuum condition. The evaporator is used for volume reduction where dilute products are concentrated to a medium concentration. The process is continuous. The liquid to be concentrated is fed from the top and a distributor ensures proper feed distribution in each of the tubes. The distributor also ensures that all tubes are wetted and that the liquid flows in a film. The liquid and vapour both travel vertically downward. Due to a relatively thin film, the heat transfer coefficient is better than that obtained in reactors and simple shell and tube evaporators. If further concentration is required, the concentrated product can then be fed to the WFE. For details contact: Dalal Engg Pvt Ltd 36/37, Jolly Maker Chambers No: 2 Nariman Point, Mumbai 400 021 Tel. 022-22024046 Fax: 91-022-22029278 E-mail: deplmum@vsnl.com or Circle Readers’ Service Card 9

Gasketing Products Today’s environmental concerns demand positive seals. Garlock gaskets provide that assurance and perform with proven reliability. Gasketing is offered in wide range of non-asbestos materials including GYLON restructured PTFE gaskets, an industry standard for resistance to aggressive chemicals and its extreme grade gasketing with flange free anti-stick coating. A patented heat welding process enables the production of one-piece gasket instead of separate segments spliced together. Garlock’s gasketing products include engineered low-load styles available in either sheet form or as discreet gaskets as well as materials to effectively seal metallic piping. Compressed fiber sheet gasket material has been reformulated and upgraded and the high-pressure sheet (HPS) manufacturing process now uses an environmentally-friendly non-VOC solvent. In addition, Garlock’s environmental controls now include a solvent recovery system that captures emissions and recycles them into the production process. Solvent recovery is used in the production of both HPS and GYLON. For details contact: Garlock India Pvt Ltd Plot No: 21, “S” Block, MIDC Bhosari, Pune, Maharashtra 411 026 Tel: 020-30616608 | Fax: 91-020-30616699 E-mail: sales.india@garlock.com or Circle Readers’ Service Card 10

Chemical Engineering World

April 2016 • 63

CEW Products Borewell Submersible Pumps

Delivery Pump Units

CRI 175 mm (7”) 200 mm (8”) and 250 mm (10”) borewell submersible pumpsets are powered by water filled, rewindable submersible motor which is suitable for continuous duty. The stator is wound with special waterproof synthetic film insulated copper winding wires and made up of low watt loss silicon steel laminations assembled under pressure and rigidly locked in SS stator shell. Specially designed thrust bearings (SS AISI-420 with graphite carbon) are used to withstand axial and down thrust loads with minimum wear and tear. This 175 mm and 200 mm submersible pumpsets are supplied with 150 mm (6”) motor combination and for 250 mm (10”) submersible pumpsets supplied with 200 mm (8”) motor combination only.

Beinlich self-priming delivery pump units consist of external gear pumps which are made from standard materials 0.7050 (housing) / 1.8550 (shafts and gears) and FKM (static seals). They are especially suitable for the low-pressure range and can convey almost every low viscosity media as well as uncritical media without fillers, which are compatible to the materials used. The engine power of the 4 pole asynchronous three-phase motor is sufficiently assessed for achieving differential pressures of up to 40 bar. Additionally, delivery pump units are available within a short delivery time, thanks to standardised units. It finds application in filling plants, printing machines, paint industry, filter technology, generator construction, cooling machine, mechanical engineering, hydraulics, oil processing, tank facility construction, compressors, vacuum plants and machine tools

For details contact: CRI Pumps Pvt Ltd 7/46-1 Keeranatham Road Saravanampatty Coimbatore, Tamil Nadu 641 035 Tel: 0422-3027000 | Fax: 91-0422-3027005 E-mail: corp@cripumps.com or Circle Readers’ Service Card 6

For details contact: Bedaflow Systems Pvt Ltd W-7, Sector-11, Noida, Uttar Pradesh 201 301 Tel: 0120-43299 - 90 | Fax: 91-0120-43299 - 20 E-mail: info@bedaflow.com or Circle Readers’ Service Card 7

Cooling Towers Smallest of the Paharpur intermediate range of cooling towers, the Series 9 is available in single-flow design and thereby uniquely suited for limited space installations. The inert material used in structural and functional components is specifically designed for cooling tower application. A low silhouette and minimum plan area together with high capacity per cubic foot are major design advantages. These towers are ideal for use in intermediate size AC systems and industrial duty. The Series 10 DF tower is available in16 low profile models. Widespread use of inert fibreglass components. The highly versatile Series 15 and 18 DF or SF is adaptable for intermediate process cooling, large AC applications and specialised cooling requirements. As with all other models, fans, gear reducers and other components are manufactured specially for cooling tower use. Splash fill enables the Series 15 and 18 to cope with poor water quality which would kill film fill. Series S-100, 120 and 160 wood is designed for AC and intermediate industrial cooling applications where a low profile is desirable. The Series was developed to offer greater cooling capacity in smaller space with lower operating costs. Features more efficient PVC fill; double hot water distribution system; lower overall profile and pumping head; SS full support system; no framing obstruction in fill area; and industrial duty mechanical equipment. For details contact: Paharpur Cooling Towers Ltd Paharpur House, 8/1/B Diamond Harbour Road Kolkata 700 027 Tel: 033-40133000 Fax: 91-033-40133499 E-mail: pctccu@paharpur.com or Circle Readers’ Service Card 8

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Chemical Engineering World

Products CEW Liquid Ring Vacuum Pumps Liquid Ring Vacuum Pumps from Toshniwal offer optimum performance and reliability. The product offers minimal water consumption and has got an innovative impeller design that assures extremely quite operation. It extends its life even under harsh condition. It also reduces manufacturing times further shortening delivery times. Specifications: Hydro twin: PLC Controlled roots + LRVP package for high vacuum application with total liquid recirculation capacity to 3900 m3/hr; Max Vacuum 2 mbar Hydro sys: Centralised package and vacuum units with total or partial water recirculation capacity to 3500 m3/hr; Max Vacuum 33 mbar Typical Application: Distillation, Drying/Material Transfer/Power and Steel/Food Processing/Paper/General Vacuum /Textile For details contact: TOSHNIWAL INSTRUMENTS (MADRAS) PVT LTD 267 Kilpauk Garden Road Chennai, 600 010, India T: +91(0)44 26448983 / 8558 E: sales@toshniwal.net W: www.toshniwal.net or Circle Readers’ Service Card 9

Inline Rotor Stator Mixers The Inline Model high shear rotor-stator mixer design consists of a single, dual or four stage rotor that turns at high speed within a stationary stator. As the rotating blades pass the stator, they mechanically shear the contents. The Inline Model is a good choice for process lines that require frequent changeover from one product to another. A simple valve can divert finished product downstream or switch instantly from one vessel to another. Interchangeable rotor-stator combinations provide unlimited flexibility to adopt to a variety of product formulations. The Inline Models are supplied in many sizes and materials of construction from 1/2 through 150 horsepower. (Their inline high shear mixers are 3A approved). For details contact: Ross Process Equipment Pvt Ltd Plot No: D-233/3, Chakan Indl Area Phase II, Village: Bhamboli, Tal: Khed Dist: Pune, Maharashtra 410 501 Tel: 02135-628400, 628401, 628402, 628403 E-mail: mail@rossmixers or Circle Readers’ Service Card 10

Chemical Engineering World

April 2016 • 65

CEW Products Pumps

Roots Pumping Systems

The ability to carry out two, sometimes three unit operations makes the SUPERTOR extremely versatile and useful. It sizes, reduces, grinds, delumps, chops, disperses, separates, macerates and even pumps and has been installed for various slurry handling applications.

Roots Pumping Systems are manufactured using finest quality material. The range of products offered by the company is in adherence with international quality standards. Available in a spectrum of specifications, these systems are used in distillation process, food processing, drying of powder and solids and transformer evacuation.

The SUPERTOR is an all-round machine developed from a centrifugal pump with an inclined disc which is at an angle to the shaft instead of a normal impeller. This creates strong turbulent flows which simultaneously aid in pumping and intense mixing of the medium. Since the rotor and the housing are equipped with teeth, the SUPERTOR can also be used for disintegration or crushing. For details contact: Dalal Engg Pvt Ltd 36/37, Jolly Maker Chambers No: 2 Nariman Point, Mumbai 400 021 Tel. 022-22024046 | Fax: 91-022-22029278 E-mail: deplmum@vsnl.com or Circle Readers’ Service Card 11

Features • Longer functional life • High efficiency • Compact design For details contact: Toshniwal Instruments (Madras) Pvt Ltd 267, Kilpauk Garden Road Chennai - 600010 Tel: +91 44 26445626 /8983 Email: sales@toshwnial.net Web: www.toshniwal.net or Circle Readers’ Service Card 12

Sheet Metal Structured Packing EVERPACK SM column packing is the sheet metal version of the popular EVERPACK WM (wire mesh) and HYFLUX (knitted wire mesh) packing. EVERPACK SM is supplied in modules, which consists of parallel layers of uniquely designed embossed sheet metal strips which are corrugated and arranged vertically. These modules are then stacked with an alternating 90 degree orientation of every other layer which gives a good lateral distribution of liquid. The embossed metal strips help to draw the liquid in all directions into a thin film and provides a marked improvement in uniform wetting of the packing bed. With the improved internal liquid distribution, high volumetric mass transfer efficiency is achieved and low pressure drop is maintained. Also because liquid is evenly distributed through the packing as a thin film, the total liquid hold-up in the packing is substantially reduced. The standard packing version has specific surface area of 250 m 2/m 3 (EVERPACK SMY 250). However, other variants with specific surface areas of 125 m 2/m 3 (SMY 125), 175 m 2/m 3 (SMY 175), 350 m 2/m 3 (SMY 350), 500 m 2/m 3 (SMY 500),750 m 2/m 3 (SMY 750) and X crimp (60 degree crimp alignment) are also in addition to the column packing, Evergreen Technologies also design and manufacture high efficiency column internals (distributors, collectors, support grids, etc). Good initial distribution together with systematic redistribution is critical to optimum tower performance. It finds application in vacuum distillation; atmospheric operations; debottlenecking energy reduction programs and increase product purity. For details contact: Evergreen Technologies Pvt Ltd 3-D, Maker Bhavan-2 18 New Marine Lines Mumbai 400 020 Tel: 022-22012461, 22012706, 61566969 | Fax: 91-022-22010024 E-mail: info@evergreenindia.com or Circle Readers’ Service Card 13

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Chemical Engineering World

Products CEW High Vacuum Pump (Oil immersed) The GL Series pump is an Oil sealed belt driven pump operating according to the rotary vane principle with gas ballast valve. Oil, which is injected into the pump chamber, is used for sealing lubrication and cooling purpose. Single stage and Double stage models from 36 m3/hr to 300 m3/hr are available to meet wide range of vacuum needs. Features • Highly Reliable • Guaranteed Ultimate Vacuum • Effective Gas Ballast • Quieter Operation • Advanced Lubricating System • Easy Maintenance • Compact and Sturdy design For Details contact: Toshniwal Instruments (Madras) Pvt. Ltd. 267 Kilpauk Garden Road, Chennai - 600 010. India Tel:+91(0)44 26448983 / 8558 Email: sales@toshniwal.net | Web : www.toshniwal.net or Circle Readers’ Service Card 9

Easy User Interface

Hydraulic Components

Conformancee to nuclear industry QA/QC - NRC Hydraulic components include heavy-duty seals to meet the demanding requirements of today’s reciprocating equipment. Key hydraulic component products include CHEVRON V-ring packing, GARTHANE urethane seals and SLUDGE-PAK for vertical sludge pumps. Also offered are polytop sets and turbine runner blade packing for hydroelectric applications.

Garlock Palmyra developed its Chevron packing using standard duck and rubber tubing, which was subsequently expanded from its original use in steam engines to applications in the off road equipment, power generation and automotive industries. The global growth of Chevron hydraulic packing has continued in the oil and gas and nuclear industries. For details contact: Garlock India Pvt Ltd Plot No: 21, “S” Block, MIDC Bhosari, Pune Maharashtra 411 026 Tel: 020-30616608 | Fax: 91-020-30616699 E-mail: sales.india@garlock.com

Integration with smartPlant 3D / Tekla / STAAD.Pro Validation & veri�cation for more than 5000+test problems Base plate modeling & analysis Linear and Non linear Static-Dynamic analysis Steel Frame & reinforced concreate design CIS/2 analysis data interface Comprehensive & detailed user documentation Offshore structure analysis & deisgn

Email: sales@iges.in

or Circle Readers’ Service Card 10

Chemical Engineering World

It is time to Migrate to an advanced Structural Analysis Software

www.iges.in TOLL FREE : 1800 102 4437 April 2016 • 67

Oil & Gas World Expo 2016 Concurrent Events: SMP World Expo, EnerTECH World Expo Dates: 3 – 5 March 2016 Venue: BC&EC Mumbai, India Details: Platform to showcase services, technologies, innovations and current & future trends of entire value chain of hydrocarbon industry. Contact: +91 22 40373636 Email: sales@jasubhai.com Website: www.chemtech-online.com Watertech India 2016 Dates: 15 – 16 September 2016 Venue: New Delhi Details: An event for water, wastewater and solid waste management products/ technologies/services Organiser: Messe Frankfurt Trade Fairs India Pvt. Ltd. Contact: +91-22-6144 5900 Email: prashant.lade@india. messefrankfurt.com Website: www.watertechindia.com

Understanding the Global Petrochemical Industry Dates: Sep 30-Oct 02, 2014 Venue: London, UK Details: The conference will cover impact of shifting feedstock slates: shale gas and oil, coal, and bio-based feeds are expanding feedstock options worldwide Organiser: IHS Inc Contact: 000 8000 016 775 (Toll Free) Website: www.ihs.com

AchemAsia 2016 Dates: 9 – 12 May 2016 Venue: China National Convention Center, Beijing Details: A four-day event for entire process industry Organiser: DECHEMA eV Contact: 69 75 64-277 Email: ruebberdt@dechema.de Website: www.achema.de/en

India Chem 2016

ORPEC 2017

Dates: 1 – 3 September, 2016 Venue: Bombay Exhibition Centre, Mumbai Details: Event of chemicals and petrochemicals industry in India in its 9th edition Organiser: FICCI Contact: +91 22 2496 8000 Email: vishal.ganju@ficci.com Website: www.indiachem.com

Dates: 13 – 15 May 2017 Venue: Muscat, Oman Details: Designed to deliver key buyers to Oman’s growing refining and petrochemical industries creating a forum aligned with the government’s growth plans Organiser: OMANEXPO LLC Contact: Mr Ebrahim Taher Email: info@omanexpo.com Website: www.omanexpo.com

Automation 2016

The 2016 Automation Summit

Dates: 22 – 25 August 2016 Venue: Bombay Exhibition Center, Mumbai Details: Automation 2016, a four day automation event is set to introduce new and upcoming technology this year Organiser: IED Communications Ltd Contact: 91 22 22079567 Email: jyothi@iedcommunications.com Website: www.iedcommunications.com

Dates: 27 – 30 June, 2016 Venue: Las Vegas, USA Details: Siemens Automation Summit – A User Conference. All areas of industrial automation will be covered including factory, process, motion, and drives. Organiser: Siemens Industry, Inc Contact: +1 800 241 4453 Email: rich.chmielewski@siemens.com Website: usa.siemens.com/summit

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AD INDEX

Chemcon Europe

Atomic Vacuum Company (Exports)

Inside Cover I

CRI Pumps Pvt Ltd

Economy 9 Refrigeration Pvt Ltd

Hi-tech Applicator

ID Technologies

ImageGrafix Engineering Services Pvt Ltd

61, 63, 65, 67

Impart 7 International Pvt Ltd/ Munsch Chemie

Kirloskar Brothers Ltd

Inside Cover II

KSB Pumps

10 Mist Ressonance Engineering Pvt Ltd

11 National Reseasrch Development Corporation

12 Paharpur Cooling Tower

13 Ross Process Equipment Pvt Ltd

14 Suraj ltd

15 Uni Klinger Ltd

16 Watson Marlow India Pvt Ltd

Chemical Engineering World

Project Update CEW New Contracts/Expansions/Revamps The following list is a brief insight into the latest new projects by various companies in India. • CHEMICALS Panoli Intermediates (India) proposes an expansion of its specialty chemicals manufacturing unit and a new 10-MW coal-based captive power project in Unit-III, GIDC Nandesari, district: Vadodara, Gujarat. The estimated cost of the project is ` 100-million. The current status of the project could not be ascertained. According to MoEF sources, the total plot area is 15,480-sq m. The capacity of isomers and DNCB such as 2:4 DCNB, 2:6 DCNB, 2:5 DCNB is to be augmented from 200-TPM to 2,200-TPM, ortho anisidine/para anisidine from 100-TPM to 1,100-TPM, ortho nitro aniline/para nitro aniline from 300-TPM to 2,300-TPM, isomers of DCA from 80-TPM to 1,080-TPM, isomers and DCNB such as 2:3 DCNB, 2:5 DCNB. isomers of DCNB such as 2:3 DCNB, 2:5 DCNB, 3:4 DCNB from 200-TPM to 2,200-TPM, H-acid from 50-TPM to 500-TPM and addition of a new product namely, 1,500-TPM derivatives of nitro phenol and a new 10-MW coal-based CPP. 10-MW power requirement is to be met from MGVCL and 10-MW from the CPP. The effluent will be treated in proposed effluent treatment plant. Saras Plywood Products is planning a 60-TPM urea formaldehyde resin manufacturing plant in New GIDC Gundlav, district: Valsad, Gujarat. The existing land area is 1.5 acres. The estimated cost of the project is ` 7.5-million. Kalyan Industries is the equipment supplier. The project is waiting for environmental clearance. Civil work will commence in 3 months. The project is planned for completion in this year. According to SEIAA sources, the company has proposed primary treatment plant followed by evaporator for treatment of industrial effluent and has also proposed a multi-cyclone separator. FMC India is planning an expansion of its chemical manufacturing unit at IDA Patancheru, district: Medak, Telangana. The estimated cost of the project is ` 17.5-million. As of September the project was waiting for the environmental clearance. According to MoEF sources, the plot area is 4.027 acres. The company proposes to manufacture 50-TPM of products as part of the expansion. Green belt on 33 per cent of the land area will be developed and maintained. Power requirement will be made available through SPCPDCL. The project will be completed within 2 years. Globex Laboratories (R&D) proposes a pigments manufacturing unit at village: Dabhasa, district: Vadodara, Gujarat. According to MoEF sources, the project will come up in the existing land on 9,312-sq m. Kadam Environmental Consultants, Vadodara is the environmental consultant. The project will entail manufacture of 40-TPM red pigments, 40-TPM yellow pigments and 450-TPM dilute phosphoric acid. Environment clearance has been obtained for the products – red pigments and yellow pigments. Construction work has begun, as EC and NOC have been received. Effluents generated will be treated in effluent treatment plant having MEE. The company has applied for Amendment in Environmental Clearance dated 26th September 2012 Chemical Engineering World

for change in fuel from LDO to agro waste briquettes and addition of one raw material, ie, phosphoric acid and generation of dilute phosphoric acid (25 per cent basis) as by-product. Bohra Industries is implementing an expansion of its chemical and fertilizer manufacturing unit at Umarda, district: Udaipur, Rajasthan on 14,500-sq m of existing land. The project will entail expansion of single super phosphate capacity from 400-TPD to 600-TPD, granulated super phosphate from 200-TPD to 300-TPD and addition of new products namely 150-TPD triple super phosphate, 550-TPD synthetic gypsum, 30-TPD di-calcium phosphate, 160-TPD phosphoric acid, 0.3-TPD potassium fluoride, 150-TPD H2SO4 and 0.3-TPD sodium tri poly phosphate (STPP). Machinery has been ordered from China. Civil work is in progress. The project is scheduled for completion in 2018. Ami Lifesciences proposes expansion of its synthetic organic chemicals manufacturing unit (viz, pharmaceutical bulk drugs and drug intermediates) from 65.70-TPM to 131.60-TPM in Padra, district: Vadodara, Gujarat. The estimated cost of the project is ` 87.046-million. Environmental Consultant to this project is Envisafe Environment Consultants. According to MoEF sources, total plot area is 23,760-sq m (existing 10,270-sq m and 13,490-sq m for expansion). The unit currently manufactures 2-TPM 1-Acetyl Naphthalene, 1-TPM 2-Acetyl Naphthalene, 6-TPM Itopide HCl, 1.20-TPM Loxapine Succinate, 0.30-TPM Amoxapine, 6-TPM Venlafaxine, 6-TPM Progunil HCl, 6-TPM CB-2-L-Valine, 0.60-TPM Nateglinide, 0.60-TPM Quetiapine, 24-TPM Carbomazepin and 12-TPM Oxacarbomazepin. The expansion will involve addition of new products. Water requirement from ground water source will be increased from 34.53-cu m/day to 181-cu m/day after expansion. Effluent generation will be increased from 9.35-cu m/day to 79.5cu m/day after expansion. Highly concentrated effluent will be sent to captive incinerator for incineration. Remaining effluent (70-m3/day) will be treated in the ETP comprising primary, secondary and tertiary treatment. Treated effluent will be sent to CETP for further treatment. ETP sludge, inorganic residue and incineration ash will be sent to TSDF. Spent carbon, organic residue will be sent to incinerator. Adi Finechem is planning a 40-TPA specialty products manufacturing project on a 2-acre land at an estimated cost of ` 400-million in village: Chekhala, district: Ahmedabad, Gujarat. The project is waiting for environmental clearance. RSPL is planning a 1,500-TPD soda ash plant and 40-MW captive power project in village: Kuranga, district: Jamnagar, Gujarat. Land acquisition is in progress. 85 per cent of land has been acquired. The project is waiting for environmental clearance. The entire project is planned for completion in 5 years from zero date. April 2016 • 69

CEW Project Update • MINING Metabluu Power, a sister concern of Minera Udyog India, is planning a 75,000-TPA iron ore mining project in village: Devikonda, district: Karimnagar, Telangana. The project is awaiting Government approval. Aryan Ispat & Power is planning an expansion of its coal washery in village: Bamoloi, district: Sambalpur, Odisha. The project will come up in the existing 204.65-acre integrated steel plant premises. The capacity of the project is to be augmented from 0.70-MTPA to 5.70-MTPA. The cost of the project is ` 600.7 million. The project is awaiting environmental clearance and planned for completion in 1-year from zero date. According to MoEF sources, the expansion is based on heavy media cyclone (wet process) technology. The washery will produce washed coal of an average ash around 34% (GCV 4,350-Kcal/kg), middling (ash content about 58%) of GCV around 2,350-Kcal per kg useable as fuel in FBC boilers. The proposed expansion will be the state-of-the-art with close circuit water system, classifying cyclone, high frequency screens, thickener and multi-roll belt press filters. Power requirement of 5-MVA will be sourced from its own power plant connected with the Grid Corporation of Odisha. NTPC is planning the Kudanali-Luburi coal mining project in district: Angul, Odisha. The company has signed an agreement on June 15, 2015 with Jammu and Kashmir State Power Development Corporation (JKSPDCL) for promoting a joint venture company with 67:33 equity participation for undertaking exploration, development and operation of jointly allocated Kudanali-Luburi Coal Block at Odisha by the Ministry of Coal. DSP Associates is planning a 15,17,600-TPA sand (minor mineral) mining project in the mines of Tikola-1 Sand Unit at village: Tikola, district: Gurgaon, Haryana. Mining lease area is 42.50-hectare. The estimated cost of the project is ` 55-million. The project is waiting for environmental clearance. Mining work is expected to commence soon. According to MoEF sources, out of the total area, 31.50-hectare area falls in the river bed and 11-hectare area falls in agricultural land (outside river bed). Method of mining will be opencast semi-mechanized without drilling and blasting. The mine will be excavated out in layers up to a depth of 3-m in riverbed and 9-m in agricultural field. Letter of Intent (LoI) for mining contract has been granted for a period of 9 years. • NON-CONVENTIONAL ENERGY Viaton Energy, promoted by the 3F Group and Creative Group, is planning a 10-MW power project in Punjab. Discussion is in progress with the Government for allocation of site. The company is already operating a 10-MW biomass-based IPP at village: Khokhar Khurd, district: Mansa, Punjab from July 2013. The generated power is being sold to the Government of Punjab. Hubli Electricity Supply Company is planning solar RTPV grid connected power plants in district: Belagavi, Karnataka. E-tenders 70 • April 2016

have been floated to design, manufacture, supply, installation, testing and commissioning of solar RTPV grid connected power plants on roof-tops of 31 HESCOM office buildings in Belagavi Zone Jurisdiction for total load of 136-KWp including operation and maintenance for a period of five years. The approximate amount put to tender is ` 18.62-million.

• NON-CONVENTIONAL POWER BMS Starch, a part of the BMS Group, is implementing a 6-MW biomass-based co-gen power plant in village: Kurandi, district: Bastar, Chhattisgarh. The project is coming up along with a starch manufacturing unit on 26-acre of acquired land at a total estimated cost of ` 1,350-million. Equipment supplier is yet to be appointed. Civil work is in progress. The project is expected to be completed in this year.

• THERMAL POWER Surguja Power, a 100 per cent subsidiary of Adani Mining, proposes a 540/600-MW coal washery rejects based thermal power project spread over 47.5-hectare of land in villages: Parsa, Kete, district: Surguja, Chhattisgarh. The estimated cost of the project is ` 35-billion. According to MoEF sources, Greencindia Consulting is the environmental consultant. The project will comprise of a 4 x 135/150-MW power plant based on the coal washery rejects within the Parsa East and Kete Basan coal block at Udaypur Tehsil, district: Surguja. The Group has been assigned work by Rajasthan Rajya Vidyut Utpadan Nigam (RRVUNL) for mining, development and operation of Parsa East coal block and supply of beneficiated coal. Sizeable amount of rejected coal will be generated, which shall be utilized for power generation by setting up the power project within the coal block. The plant is proposed to have circulating fluidized bed combustion-based (CFBC) coal fired boilers.

Rain Cements is planning a 7-MW waste heat recovery-based power plant in village: Boincheruvupalli, Peapully Mandal, district: Kurnool, Andhra Pradesh. The estimated cost of the project is ` 700-million. The project will come up in the existing cement plant premises. The project will generate up to 7-MW of gross electrical energy from the waste heat and the flue gases evolved during the cement manufacturing process. The project that will be financed by a combination of internal accruals and bank loans is expected to be completed in about 14 months. The Board of Directors of the company had approved of the project at its meeting held on 27 th February, 2015.

Seven Star Steels is planning an expansion of its thermal (coalbased) captive power project from initial 8-MW to 12-MW at a cost of ` 600-million in village: Kalendamal, district: Jharsuguda, Odisha. The project will come up along with an expansion of its sponge iron plant from 60,000-TPA to 180,000-TPA and ingot plant from 39,200-TPA to 80,000-TPA. Machinery will be partially procured locally and partially imported; orders are yet to be placed. The project is waiting for industrial clearance. Work on the project will commence soon. Chemical Engineering World

Book Shelf CEW Understanding and Negotiating Turnkey and Epc Contracts Author Price Pages Publisher

: Joseph A Huse : USD 464.12 : 1101 (Hardcover) : Sweet & Maxwell

About the Book: This work is a practical commentary on the FIDIC and EPC turnkey contracts widely used in the international construction industry. It provides clause-by-clause analysis of these contracts, accompanied by practical guidance on their application in specific projects. It also reproduces the contracts in full as an appendix. Detailed, clause-byclause approach makes it a highly practical working tool. Invaluable for international projects where the use of FIDIC standard contracts is increasing all the time

Industrial Megaprojects: Concepts, Strategies, and Practices for Success Author Price Pages Publisher

: Edward W Merrow : USD 41.38 : 384 (Hardcover) : Wiley

About the Book: More than half of large-scale building projects, such as drilling platforms, chemical plants, or dams, have miserably poor results: billions of dollars in overruns, long delays in design and construction, and poor operability once they are finally completed. Occasionally, these fiascos make the news, but for obvious reasons, companies usually bury the disasters with as little publicity as possible. Yet, management at the companies know full well the complexity and the difficulty faced when mounting megaprojects. Industrial Megaprojects explains the underlying causes of over-budgeted, delayed, and unsafe megaprojects: poor project management, destructive team behaviours, weak accountability systems, an almost pathological focus on the short-term, and the unwillingness to invest in deep technical expertise.

Process Plant Construction: A Handbook for Quality Management Authors Price Pages Publisher

: Patrick Noble : USD 157.54 : 228 (Hardcover) : Wiley-Blackwell

About the Book: This handbook introduces engineers, project and construction managers, and senior technicians to a methodology for the management of quality on a process plant construction site. The eleven chapters of the handbook define the roles and appellations of the parties involved in a project as well as outlining the fundamental strategic and contractual orientations to be decided. The ISO 9000 series of standards are examined within the context of the process plant construction site. A study is then made of the roles of the organizations involved and of the interfaces between them. Special attention is given to document and materiel control, followed by a review of the various monitoring and feedback systems to keep the project on track moving towards the ultimate goal of satisfactory construction completion leading to turnover. Model procedures are proposed, complete with forms attached, and a number of case studies are included to illustrate the practical application of the principles presented. Chemical Engineering World

Mastering Risk and Procurement in Project Management: A Guide to Planning, Controlling, and Resolving Unexpected Problems Author Price Pages Publisher

: : : :

Randal Wilson USD 59.99 288 (Hardcover) Pearson FT Press

About the Book: Master the crucial risk management and procurement tasks that are indispensable to project success! In Mastering Risk and Procurement in Project Management, expert project manager and seasoned professor Wilson addresses every stage of the project where risk management and procurement are relevant, especially planning, monitoring, and control. Teaching through relevant examples and case studies, Wilson explains: • Why risk management and procurement are so crucial to achieving your project’s goals • The deep and surprising linkages that exist across risk management and procurement • How to avoid common pitfalls • How to integrate best-practice risk management and procurement throughout your PMBOK processes. Drawing on his own extensive experience, he offers in-depth coverage of topics ranging from contracting and risk monitoring to project close-out, and gives readers practical knowledge of critical processes and tasks in project management. April 2016 • 71

CEW Interview

Building Economies of Scope for Business Value Creation Ajay Durrani, Managing Director, Covestro India Pvt Ltd, shares that despite being a huge consumer market, per capita consumption of specialty chemicals is one of the lowest as compared to other emerging economies. In an exclusive interaction with Chemical Engineering World via e-mail, Durrani states, “As chemical industries are not labour intensive industries, India should focus on creating economies of scope rather than emulating other countries and focusing only on capacity building.”

72 • April 2016

Chemical Engineering World

Interview CEW What is your outlook towards the global and Indian specialty chemicals industry? After suffering an adverse impact during the recession, specialty chemicals industry has grown steadily. In terms of value, the specialty chemicals market size is projected to reach USD 470 Billion by 2020, growing at CAGR of more than 5 per cent between 2015 and 2020. Globally, specialty chemicals industry is in a phase of transition. The rapid growth of the newly industrialised Asian and Middle Eastern economies and rising standards of living in these emerging economies, has led to the increased demand from these regions. This development has shifted the centre of gravity of the global chemical industry towards the emerging economies. In India, the specialty chemical segment is one of the fastest growing sectors in the chemical industry and is growing at rate of about 15 per cent per annum. India’s share in global specialty chemical industry is estimated to grow from about 2.8 per cent in 2013 to 6-7 per cent in 2023 with market size in the range of USD 80-100 billion. The sector is expected to grow at double digit CAGR in next five years as exports have emerged as key growth driver with encouraging opportunities in domestic market. But, despite the improving standards of consumption, the per capita consumption of specialty chemicals in India is one of the lowest in comparison to developed and other emerging markets. However, with focus on improving products and usage intensity of specialty chemicals coupled with high growth in end user industry I feel that the industry is poised for strong growth in India. How do you see the evolution of Middle East market in this domain in the years to come? With the availability of cheap petrochemical feed stock, trade liberalisation, spread of process technology and breakdown of various economic barriers, Middle East is poised to play a pivotal role in the development of speciality chemical Chemical Engineering World

industry. Additionally, the strategic location of the Middle East countries in bridging the emerging eastern markets and developed western markets, are attracting key global participants to establish their manufacturing assets and in turn fuel the speciality chemical market in the region. If you look closely at India’s specialty polymers portfolio of - commodity polymers, mid-range polymers, high performance polymers and ultrapolymers; it is heavily inclined towards mid-range polymers and forms approximately 95 per cent of market share and the share of high performance and ultra-polymers stands at around 5 per cent. What are your thoughts on such wide gap between the end user segments for the specialty polymers in India? High performance polymers are a class of polymers which differ from commodity and mid-range polymers due to their better mechanical properties and high chemical and heat stability. Due to their better thermal stability the high performance polymers are difficult to process and require special machinery. Also high performance polymers are more expensive than the mid range polymers. With no certainty of significant price declines in near future as investment costs for production equipment, R&D and high distribution costs remain constant the industry would remain inclined towards the mid-range polymers. What is the scope of opportunities at present for the specialty polymer manufacturers in the space of high performance and ultra-polymers currently in the Indian market? The scope of opportunities for high performance and ultra polymers is high as these polymers are used in every aspect of our lives such as automotives, defence, energy, medical, sports and electronics. Due to the high thermal and chemical stability these polymers are excellent materials for the harsh conditions. The high performance and ultra polymers offer huge scope in electronics manufacturing and are set to grow rapidly

as the full effects of National Policy on Electronics come into picture. What are your thoughts on impact of the Make in India campaign in the near foreseeable future on specialty chemicals industry in the advanced polymers in India? The ‘Make in India’ campaign by Indian government will help in boosting the speciality chemicals industry in India which is driven by three main factors. First, growth in key consumer industries such as electronics and automotives, second, rising consumer needs in key consumer industries such as durable electronics, light weight and sturdy automotive parts and third, new manufacturing processes leading to upgraded equipment. We would also urge Indian government to focus on creating business value for attracting chemical industries. As chemical industries are not labour intensive industries, India should focus on creating economies of scope rather than emulating other countries and focusing only on capacity building. As of now India lacks a well-established manufacturing base for advanced electronics, semiconductors, smart devices and medical devices. What steps do you think should be taken by the industry and government in concurrence as way forward? The government has taken cognizance of the lack of indigenous manufacturing capabilities for electronics system design and manufacturing. In this regards, the government launched National Policy on Electronics 2012 which aims to transform the domestic electronic hardware manufacturing segment into a USD 400 Billion industry by 2020. The proposed national policy has the potential to be a game-changer for the country with farreaching consequences. The policy aims to address the huge gap between locally produced electronics and the domestic demand for electronics in India. Also the industry and government needs to work hand-in-hand to enhance the April 2016 • 73

CEW Interview Plastics industry - while playing an important role for the national economy with the huge scope for growth - also faces sustainability challenges. Issues such as plastic waste management and recycling are important avenues for us to provide a sustainable growth for the industry. limited knowledge of diverse nature of manufacturing technologies for advanced electronics and smart devices. We also lack effective and appropriate regulatory framework for these industry sections and as a result fail to provide guidance & advice to meet legal obligations and safety of consumers. Please talk about Covestro’s unique specialty polymers portfolio and presence in the Indian market. Which segments will drive the growth of Covestro in India in the near foreseeable future? Covestro is the leading polymer company in India and supplies high-tech polymer materials and application solutions for Indian sub-continent including Nepal, Bangladesh and Sri Lanka. Our three key supply areas - polyurethanes, polycarbonates and coatings, adhesives, specialties are growing rapidly. In India, our biggest segments are automotive, foam and furnishings, and electronics. We have three manufacturing plants across the country at Greater Noida, Ankleshwar and Cuddalore to support the Indian market needs. We manufacture Polyols in our Greater Noida facility, and poly-isocyanate at the Ankleshwar facility for coatings. In our commitment towards ‘Make in India’ campaign we have expanded our manufacturing capacity at Cuddalore in Tamil Nadu for production of Thermoplastic Polyurethanes (TPU) to cater to footwear, IT, cables, industrial mechanical, automotive, compounding and films and coatings segments. In the near foreseeable future, growing interest towards high end automotives will drive the demand for polyurethanes, coatings and sealants in India; whereas the green and sustainable lighting solutions 74 • April 2016

such as LEDs will drive the market for Polycarbonates. With the presence of many global players already in the market and manufacturing facilities in India, how do you plan to be competent in the Indian market? As a leading polymer company in India we are very well established in the and already command a respectable market share. We are growing more than the GDP in India which is a testament of our good business performance in the country. Moreover, our recent commitment to expand the Cuddalore facility for production of Thermoplastic Polyurethanes (TPU) is aimed at increasing our service to the footwear, IT, cables, industrial mechanical, automotive, compounding and films and coatings segments. All these highlight our competitiveness. There is a generic view that bringing regulatory guidelines across the end user industries of specialty chemicals like automotive, packaging, construction, paints and coatings etc. help increase demand of specialty chemicals. What are your views and if such process has been implemented in other countries? Strong and robust regulatory frameworks across end-user industries will undoubtedly aid speciality chemicals industry to grow. For example, a regulatory focus on reducing pollution or sustainable energy could have tremendous upside for speciality chemicals. Hence, such guidelines will not only drive the demand but would also help in leveraging best solutions available globally. How have things changed for the company since the organization acquired a new identity? The things have been positive since we acquired new identity. Since September 1, 2015, Covestro is fully independent from

Bayer Group. Since October 6, 2015, we are listed on Frankfurt Stock Exchange and have also been named among the top 80 companies in Germany. Our shares were oversubscribed by three times indicating good market sentiment towards company. What are the challenges for in this domain in the foreseeable future and how do you plan to capture growth opportunities? Plastics industry while playing an important role for the national economy with the huge scope for growth also faces sustainability challenges. Issues such as plastic waste management and recycling are important avenues for us to provide a sustainable growth for the industry. Though we have challenges in terms of low capita consumption of plastics in India but increased growth in end user industries could propel the growth of plastics in India as full potential of plastics in various industries such as construction, food processing and electronics is yet to be tapped Tell us about the role the Indian arm playing in the global growth strategy , new investments and expansions in the Indian market. We are currently not looking to expand or have any new investments in India as we have sufficient production capacity to support Indian market which we will be fine tuned as per the local needs at an appropriate time. Covestro India plays very important role in global growth strategy. As markets world over plummet due to economic slowdown, Indian markets provides us with opportunities and avenue to further our R&D and expertise. To cater and support Indian needs and market, we have wellestablished manufacturing facilities across the country. Chemical Engineering World

R.N.I. No. 11403/1966 Date of Publication: 29 th of every month. Postal Registration No: MCS/095/2015-17 Posted at Patrika Channel Sorting OďŹ&#x192;ce, Mumbai 400001, on 29th & 30th of every month. Total Pages No.:76