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Chemical Engineering World
CEW Industry News Global Energy Demand to Increase by 35% by 2040 New Delhi, India: ExxonMobil Lubricants Private Limited shared a perspective on effective lubrication practices and the need for guidelines on industrial lubrication in India’. Every year ExxonMobil produces an ‘Outlook for Energy’ report - ‘The Outlook for Energy: A View to 2040’, which provides a window to the future of the world’s energy needs. The Outlook for Energy is used to guide strategies and investments at ExxonMobil. One of the key findings of this report is the essential role that energy efficiency will play in the future to help solve energy challenges. Companies in the industrial sector are increasingly looking at new technologies to reduce their energy usage. One opportunity for energy conservation that is often overlooked in industrial facilities is the technology behind the lubricant used. Lubricants are often considered as a negligible contributor towards the annual profitability of the plant. This is because of lack of appropriate awareness and quantification methods that capture benefits associated with the proper usage of a lubricant. ExxonMobil defines Total Cost of Ownership (TCO) as an effective way to consolidate key benefits. The concept attempts to cover the complete set of cost components from ‘Purchase to Disposal’. TCO comprises capital expenses incurred in acquiring and installing the equipment as well as operating expenses including operating cost, maintenance and repair, downtime cost, energy cost, environment cost, routine and overtime labour, training and disposal cost etc. High performance lubricants with significant energy efficiency benefits have the ability to achieve potential savings in energy, operation and maintenance costs in Indian industry. Find the complete press release on cewindia.com
LyondellBasell to Buy SJS Aurangabad-based Firm Mumbai, India: LyondellBasell has signed an agreement to acquire Aurangabad based SJS Plastiblends Pvt Ltd (SJS). SJS is a polypropylene compounds (PPC) manufacturer while LyondellBasell is a leading global plastic, chemical and refining company. According to the company, this agreement will help the organisation strengthen its existing footprint in India and further enhance the company’s position in India’s growing automotive market. “This acquisition will expand our global PPC manufacturing footprint and allow us to better compete in the long-term growth of India’s automotive market,” said Bhavesh V (Bob) Patel, CEO and Chairman of the Management Board of LyondellBasell. “We are very proud of the strong, global reputation we have built by manufacturing high-quality products and providing excellent service to our customers. We look forward to continuing this tradition in India through this expansion.” The acquisition agreement was signed on August 7, 2015, and the transaction is expected to close in late 2015. This acquisition will follow the company’s strategic growth model by enhancing its competitive position in attractive markets. Until the transaction is complete, SJS will conduct business as usual and continue to provide the same level of support, service and high quality products to its customers. 6 • August 2015
KSBSol - KSB Introduces New Range of Solar Powered Pumps Pune, India: Pune-based KSB Pumps Ltd has launched a new product called KSBSol which is a submersible pumpset with high energy efficiency and reliability suitable to run using solar power. KSBSol pumpsets are centrifugal pumps in radial and mixed flow type construction coupled with AC motors and are specially designed and matched to the requirements of solar pumping applications like drip irrigation, sprinkler irrigation, water supply etc. Pumpsets are capable to work under low sun intensity. Motors are suitable to work with VFD/MPPT controller. These pumpsets are suitable for borewells of sizes 100 mm and above. These pumpsets are designed using the proven German technology and are manufactured in its ultramodern plant located at Sinnar, near Nashik in Maharashtra state. These KSBSol pumpsets in the first phase are available up to 5 HP motors which can deliver heads up to 65 metres and flow up to 1,26,000 litres per day. Other customized models are also offered from KSB’s wide range up to 150 HP.
LANXESS’ Employees Contribute to PM’s Relief Fund Mumbai, India: Lanxess in an initiative to bring succour to those affected in the recent earthquake in Nepal, contributed a sum of over ` 12 lakh to the Prime Minister’s Relief Fund. The employees of Lanxess India have come together for the cause and contributed a day’s salary each, in their endeavour to support the victims. The contribution from Lanxess India is therefore, a sum of all its employees’ contributions. Talking about the contribution, Surabhi Mittal, Head – Human Resources and Administration, Lanxess India, said, “We are happy and proud to be able to make a difference to the lives of those in need. Our employees too, have always come forward with a helping hand even in the past, whenever the community at large has been in distress. We hope our contribution makes a positive difference.”
Pradhan Launches the “Bio Fuel Blended HSD” New Delhi, India: The Ministry of Petroleum & Natural Gas (MoP&NG), India celebrated “World Bio Fuel Day”. On this occasion, Ministry announced Marketing of High Speed Diesel blended with Bio-diesel in selected retail outlets of OMC’s in New Delhi and Vishakhapatnam (by HPCL), Haldia (by BPCL) and Vijayawada (by IOCL). It is a path breaking step in India’s retail sector for launching Bio-diesel B 5 blend to diesel consumers. As a green initiative by MoP&NG, Bio-diesel blended HSD was launched by the Minister of State (I/C) for Petroleum and Natural Gas, Dharmendra Pradhan at HPCL’s retail outlet in New Delhi. He also launched the sale of Bio-Diesel blended HSD in other cities through live streaming from Conference Hall of MoP&NG, Shastri Bhavan, New Delhi. Chemical Engineering World
CEW Industry News Draft Notification for Emission Standards for Biodiesel Fuelled Vehicles
FICCI Proposes Exclusive Industrial Estates for MSMEs
New Delhi, India: The Ministry of Road Transport and Highways formulated a Draft Notification for Mass Emission Standards for Bio-diesel (B100) fuelled vehicles. These standards have been long awaited by the industry especially those manufacturing bio-diesel and will provide alternate source of income to the farmers and the forest dwellers. The Ministry has also included the standards for test requirements for type approval and extension for four-wheeled and three-wheeled vehicles using both B100 and diesel as fuel, or either of the two. The standards also include the conformity of the production tests and the deterioration factor. Further, the technical specification of the reference fuel B100 has also been formulated. This Draft is for wider consultation with all the stakeholders so that vehicles fuelled on bio-diesel (B100) or in all similar blends of bio-diesel with diesel can be manufactured and used in the country. Large areas of degraded land in the country have a vast potential of producing bio-diesel which can be utilised as a source of fuel for transportation in the country. In addition, the Ministry of Shipping is also working on a scheme to promote bio-diesel powered engines in the ports and inland waterways.
New Delhi, India: FICCI-Confederation of Micro, Small and Medium Enterprises (FICCI-CMSME) has stated that The Government should consider developing industrial estates exclusively for MSMEs with transport, power, water, road, etc. and adequate support from budgetary allocation. The chamber, which presented an action agenda paper titled ‘Ease of Doing Business: Recommendation for the MSME Sector’ to Prime Minister’s Office, has also suggested that the state governments should look at developing ‘flatted factories’ with a ‘plug and play’ concept. “The Centre should incentivise states for building flatted factories at existing industrial estates at least in urban areas for MSMEs,” it added. “The process of land acquisition remains cumbersome and long drawn…. There is an urgent need for a stable land policy that balances interest of all stakeholders. Industry needs confirmed availability of land at an affordable rate over the long term,” stated the paper.
Arkema Expands Bostik Adhesives Production Capacities Bangalore, India: Bostik, a leading global adhesive specialist for industrial manufacturing, construction and consumer markets, today announced that it has extended its hot melt pressure sensitive adhesives (HMPSA) production capacities with the opening of a new plant, at its manufacturing facility in Bangalore, India. The development will particularly enhance Bostik’s ability to serve customers in the disposable hygiene sector. Working with global manufacturers of baby diapers, feminine hygiene and adult incontinence products, Bostik supplies solutions for demanding applications including elastic attachment, wetness indication and stretch.
V-Guard’s Kashipur Factory Felicitated as Bronze Winner in NAMC Bangalore, India: V-Guard Industries Ltd’s Kashipur factory was felicitated as the Bronze Winner in National Awards for Manufacturing Competitiveness (NAMC) instituted by International Research Institute for Manufacturing (IRIM) for the year 2014-15. This award was received by R P Singh, General Manager, Kashipur, V-Guard Industries Ltd. Anand Louie, Director-IRIM welcomed the gathering and spoke about the optimistic trend prevailing in the Indian manufacturing scenario despite the challenging times at the global arena. The Chief Guest of the function was Dr S K Nanda, IAS, CMD, Gujarat State Fertilizer Corporation Ltd. Dr S K Nanda distributed the awards, addressed the gathering and encouraged the participants to adopt the global best practices. He also discussed about the development of new technology and innovative products and hinted that improving environmental health and safety standards will be a key to growth in sustaining manufacturing standards in India. 8 • August 2015
Aker Solutions appoints Asma Lata as new HR head for India Mumbai, India: Asma Lata has been appointed as Country Head – Human Resources for Aker Solutions’ operations in India. Asma, who has over 15 years of experience in Human Resources, will spearhead various strategic initiatives for the Aker Solutions operations in Mumbai and Pune. She will oversee the HR function, and will be based out of the Mumbai head office. Asma has a Bachelor’s degree in Law and Legislation and a Master’s degree in Human Resources Management. She has held a variety of roles in Human Resources, across diverse industries including manufacturing, chemicals, financial and IT services. Aker Solutions has over 2000 employees across India, serving the entire value chain of the global oil and gas industry, from the design of subsea products, to processing facilities, refining, petrochemicals, and the allied industries. “Our people are our core asset, and as Head of Human Resources, Asma will play an integral part in the growth of the company. I am very pleased that she has joined us, and wish her every success in her endeavours”, said Sanjay Joshi, India Country Manager, Aker Solutions.
Movitec B Pumps – Now Available in complete Stainless Steel construction Pune, India: KSB in India, has further enhanced range of materials for its existing range of pump series – Movitec B. Multistage, vertical in-line high pressure pumps, Movitec B; are now available in complete Stainless Steel materials in addition to the existing version of Cast Iron (VCF). These versions will be known as VF and VSF having Stainless Steel 304 and Stainless Steel 316 grades respectively. Movitec pumps are capable of handling variety of applications like RO plants, irrigation systems, pressure boosting, washing plants, chemical applications, HVAC systems etc. These pumps can generate a flow up to 22 cubic metres per hour with the head up to 250 metres. The pumps are also backed by KSB Pumps’ wide industrial dealer’s sales and authorised service centre’s network available across India. Chemical Engineering World
CEW Industry News African Potash Signs Landmark Trade Deal with COMESA London, UK: African Potash, the AIM listed exploration company focused on sub-Saharan potash assets, is pleased to announce that it has entered into a trading agreement (the Trading MOU) with the Common Market for Eastern and Southern Africa (COMESA) and the Mask Africa Crowd Farm Fund Limited (MACFF), with a view to creating a vertical platform for the mining, production and distribution of fertiliser, focussed on the Eastern and Southern Africa (COMESA States) region and beyond. This represents a significant step in the development of the company’s cor porate strategy to transform into a ver tically integrated African fertiliser business. This is the first agreement of this nature entered into by COMESA, the signing of which represents a significant milestone in the African fertiliser industry and provides the Company with first-mover advantage. African Potash enters into three year fertiliser trading agreement with COMESA to supply and deliver at least 500,000 metric tonnes (MT) of fertilisers on an annual basis during an initial three year period to off-takers identified and introduced by COMESA. Trading agreement complements the company’s Lac Dinga Potash Project in the Republic of Congo, which continues to advance.
Zeljko Pockaj is Romaco Innojet’s New MD Steinen, Germany: Zeljko Pockaj has taken over as Managing Director of Romaco Innojet on August 1, 2015. Dr h c Herbert Hüttlin, founder and long-time head of the company, will continue to support Romaco Innojet in an advisory capacity. Zeljko Pockaj (47) will take over as new Managing Director of Romaco Innojet with effect from August 1, 2015. He was appointed by the Romaco Group’s Board of Management and Advisory Board. The Romaco Group is a portfolio company of Deutsche Beteiligungs AG. “Zeljko Pockaj is a proven industry expert with international management experience that will stand him in good stead as Romaco Innojet’s new Managing Director”, explained Paulo Alexandre, CEO Romaco Group. “We are confident that Mr. Pockaj will push ahead systematically and in a targeted fashion with Romaco Innojet’s ongoing strategic development and make a lasting contribution to the company’s success.” Pockaj gained a degree in Business Administration and Business Engineering and spent many years working for Roche Vitamine and Roche Pharma, where he held various executive positions in national and international sales as well as in commercial functions. At DSM Nutritional Products, he was in charge of Mergers & Acquisitions amongst other things. Prior to joining Romaco Innojet, he was Vice President Food and Beverage Ingredients at DKSH Holding Ltd. in Switzerland, where he also oversaw Asian business. 10 • August 2015
Lonza Has Acquired Zelam Basel, Switzerland: Lonza has acquired Zelam, a research-focused chemical company based in New Zealand (NZ), which develops and manufactures products for crop protection, specialising in fungicides, insecticides, herbicides, foliar nutrients and additives. Zelam also develops and manufactures products for wood protection. Zelam has facilities based in New Plymouth (NZ) with field research and timber facilities nearby in New Zealand, as well as in Australia and the United States. “We see this acquisition as an excellent opportunity to further our growth strategy for Agro Ingredients by providing entry into new strategic markets and products that are complementary to our existing Meta business. It also allows Lonza to leverage Zelam’s existing agrochemical business for registration and sales into other global regions, particularly the United States, EU and South America. Zelam’s unique formulated products and patented delivery systems will benefit both the Agro Ingredients and Wood Protection markets,” said Sven Abend, Chief Strategic Officer, Lonza. For more than 25 years, Zelam has researched and developed smart products that meet specific needs of the agrochemical and timber treatment markets. Zelam has a reputation for responding quickly with first-rate research, testing, product development and enhancements. Zelam’s manufacturing facilities are world class and include New Zealand’s first micro-encapsulation plant, pollen tube growth testing, and glueline treatment of engineered wood products. Additionally, product brand names like TAG G2, Vixen, Taratek and Permatek are widely known in New Zealand.
Sun Chemical Acquires Kingfisher Colours New Jersy, USA: Sun Chemical and its parent company, DIC, have acquired Kingfisher Colours Limited, a privately-owned decorative cosmetics colour manufacturer based in Reading, United Kingdom. With the acquisition, Sun Chemical will expand its leading global position in the decorative colour cosmetics marketplace. Together with Kingfisher’s complementary colour portfolio, Sun Chemical can provide cosmetics formulators new, innovative styling looks while further expanding colour space capabilities. Additionally, Kingfisher’s European-based production sites will enhance Sun Chemical’s global cosmetics colours manufacturing capabilities and will allow for further penetration into developing markets. “The addition of Kingfisher’s diverse, high quality product lines and specialised tailor-made products will further expand Sun Chemical’s cosmetics and personal care product offerings globally. Sun Chemical has experienced tremendous growth in the global cosmetics market and this acquisition will help us grow quickly into this strategic market and enable us to better serve our customers,” said Myron Petruch, President, Sun Chemical Performance Pigments. James Ward, Supply Chain Director, Sun Chemical Performance Pigments, will manage Kingfisher Colours and its integration into Sun Chemical’s existing global cosmetics business led by Bart Vanderbiest, Global Director Cosmetics. Chemical Engineering World
CEW Industry News S u r ya E s a Pe r k a s a S t a r t s C o n s t r u c t i o n o f Ammonia Factory Jakarta, Indonesia: PT Panca Amara Utama (PT Surya Esa Perkasa Tbk’s subsidiary) ammonia factory in Banggai Regency, Central Sulawesi, is local business initiative to lead the development of one of Indonesia’s largest industrial projects in the last decade. On 2 August 2015, the President of Indonesia, Joko Widodo (Jokowi), inaugurated the groundbreaking PT Panca Amara Utama’s (PAU) ammonia facility in Banggai Regency, Central Sulawesi. PAU was established by PT Surya Esa Perkasa Tbk (SEP). The factory is to be constructed on a landbank of 192 hectares and an investment of USD 830 million, underlines PAU’s commitment in supporting the government’s directive of significant value addition to Indonesia’s natural resources, particularly the usage of natural gas as a raw material in the production of ammonia. In addition to the groundbreaking, the President inaugurated the Mega Integrated Pertamina Projects, that include the JOB Pertamina Medco E&P Tomori Sulawesi (JOBPMTS) Central Processing Plant, PT Donggi – Senoro LNG’s first cargo shipment and the operation of GG Pertamina Hulu Energi Offshore North West Java (PHE-ONWJ). PAU President Director Garibaldi Thohir said that the President’s groundbreaking of its ammonia factory proves that the facility stands to play an important role in boosting the growth and development of the national manufacturing industry. Garibaldi explained that the factory will produce ammonia, a chemical compound used to manufacture fertilisers, explosives, acids and other petrochemical products. The facility features an annual production capacity of 700,000 tons, with 55 million standard cubic feet per day (MMSCFD) of natural gas to be supplied from the Senoro – Toili Block, operated by JOBPMTS.
Dow Completes Divestment of AgroFresh Michigan, USA: The Dow Chemical Company announced today the completed sale of AgroFresh, its post‐harvest specialty chemical business, to Boulevard Acquisition Corp., a public investment vehicle, formed by Avenue Capital Group, for more than USD 900 million. In addition to cash and stock at closing, Dow expects to receive significant ongoing cash payments related to service and other agreements with AgroFresh and a USD 50 million cash earn out if AgroFresh achieves certain targets – putting the total value of the transaction over USD 1 billion. With this transaction and the upcoming completion of the Dow Chlorine Products merger with Olin, Dow has significantly exceeded its prior stated goal of realizing USD 7 billion to USD 8.5 billion of divestments, with the total now approaching more than USD 12 billion in pre-tax proceeds. Following the close of the transaction, AgroFresh has become a whollyowned subsidiary of Boulevard and Boulevard has been renamed AgroFresh Solutions, Inc. Dow continues to retain a non‐consolidated minority ownership position in the new entity. AgroFresh is positioned to grow through its existing innovative processes and future investments and acquisitions. Since 2013, Dow has completed transactions for the sale of its Polypropylene Licensing & Catalysts business, ANGUS Chemical Company, Sodium Borohydride business, and other portfolio management actions. 12 • August 2015
ICIG Completes the Acquisition of VYNOVA Group Frankfurt, Germany: International Chemical Investors Group (ICIG) announced the completion of its acquisition of assets being divested Certain ChlorVinyls by INOVYN, the PVC joint venture between INEOS and Solvay. The newly acquired businesses form a new ‘ChlorVinyls’ platform within ICIG named VYNOVA Group with total sales in excess of Euro 850 million, complementing ICIG’s Fine Chemicals and Custom Manufacturing Platform WeylChem Group (EUR 670 million in sales), the Pharmaceuticals Platform CordenPharma Group (Euro 330 million in sales) and ICIG Enterprises Work (CarboTech, ENKA and Rutgers Organics; Euro 110 million in sales). With the addition of VYNOVA, ICIG Becomes a leading European player in the Both suspension polyvinyl chloride (S-PVC) and the potassium hydroxide (KOH) business, resulting in sales in excess of ICIG aggregated Euro 2 billion and 6,000 employees in Europe and Approximately the US.
CF Industries and OCI to Create Global Nitrogen Leader Illinois, USA: CF Industries Holdings, Inc, and OCI NV have entered into a definitive agreement under which CF will combine with OCI’s European, North American and Global Distribution businesses in a transaction valued at approximately USD 8 billion, based on CF’s current share price, including the assumption of approximately USD 2 billion in net debt. The transaction, which has been unanimously approved by the boards of directors of both companies, will create the world’s largest publicly traded nitrogen company. The combined entity will also purchase a 45 per cent interest plus an option to acquire the remaining interest in OCI’s Natgasoline project in Texas, which upon completion in 2017 will be one of the world’s largest methanol facilities. On a combined basis the company will have production capacity of approximately 12 million nitrogen-equivalent nutrient tons by mid-year 2016.
Quaker Acquires Verkol, SA Conshohocken, USA: Quaker Chemical Corporation has acquired Verkol, SA, a leading specialty grease and lubricants manufacturer and marketer based in Northern Spain, for approximately USD 40.1 million, including net cash of USD 10.5 million. Verkol sells products into industrial end markets with a particular strength serving the steel industry. In 2014, Verkol recorded revenues of approximately USD 33.0 million and estimated EBITDA of USD 4.3 million. This transaction is consistent with Quaker’s strategy to increase shareholder value through acquisitions and to expand its entry into specialty grease. Michael F. Barry, Chairman, Chief Executive Officer and President, commented, “Verkol is a market leader in specialty grease and lubricants for the Spanish market with world-class grease manufacturing capabilities and state-of-the-art R&D facilities. This acquisition helps us expand our specialty grease platform by providing Quaker local grease manufacturing in Europe as well as giving us additional grease product technology and talent. Verkol also brings unique technology in continuous casting products that will provide us with opportunities to cross sell to our global Steel customer base.” Chemical Engineering World
Chemical Products Finder | November 2013 | 57
CEW Industry News Mitsubishi to Construct Large-Scale Fertiliser Plant in Uzbekistan Cleveland, USA: Ferro Corporation has completed the acquisition of Nubiola Pigmentos on a cash-free and debt-free basis for Euro 149 million (approximately USD 165 million), subject to customary working capital and other purchase price adjustments. The acquisition was previously announced on April 29, 2015. Nubiola is a worldwide producer of specialty inorganic pigments and the world’s largest producer of Ultramarine Blue, a pigment for the plastics and construction industries, highly valued for its durability, unique colour attributes and whitening capability. “We are excited about the Nubiola acquisition and the opportunities it provides to drive shareholder value, enhance our current position in inorganic pigments, and accelerate our strategy to become a leading global functional coatings and colour solutions company,” said Peter Thomas, Chairman, President and CEO, Ferro.
BASF & Gazprom Sign MoU to Expand Nord Stream Pipeline Berlin, Germany: BASF subsidiary Wintershall intends to participate in expanding the capacities of the Nord Stream pipeline, which delivers Russian natural gas to European customers via the Baltic Sea. A Memorandum of Understanding to this effect was signed today. This expansion of the Nord Stream pipeline will consist of two additional pipelines that could transport up to 55 billion additional cubic metres of Russian natural gas directly to Germany. “BASF and Gazprom have been cooperating for more than 20 years on the construction of pipelines to ensure secure supplies of Russian gas to Europe. We want to bring our expertise in this field to the expansion of Nord Stream and look forward to working with Gazprom and further European partners on this important infrastructure project,” said Hans-Ulrich Engel, member of the Board of Executive Directors, BASF SE. The existing pipelines already make a vital contribution to strengthening supply security and meeting long-term demand for natural gas import in Germany and Europe. The EU’s import requirements are expected to rise further, since the gap between the production and consumption of natural gas continues to grow. The IEA forecasts that European gas production will fall by about 2 per cent a year, while consumption will rise by 0.6 per cent per year.
Neste Jacobs Selected For PE Plant Modification Abu Dhabi, UAE: Borouge has selected Neste Jacobs, a technology, engineering and project management company as a Front End Engineering and Design (FEED) service contractor for its polyethylene plant modification project, located in Ruwais industrial area, United Arab Emirates. This project is the third FEED project in a row, which Neste Jacobs is delivering to Borouge in the UAE under the long term service contract that was previously signed between the two companies (Tier 1 contract). The project scope includes FEED services such as process and plant engineering and project management. The project will be executed by Neste Jacobs’ Abu Dhabi office and it will be delivered within the course of year 2015. 14 • August 2015
HB Fuller Breaks Ground on New Facility Minnesota, USA: HB Fuller Company broke ground on its future manufacturing facility in Surabaya, Indonesia. This future facility will strengthen HB Fuller’s network in the Asia Pacific region and will complement the products and technical service offered by the company’s manufacturing facilities in China, the Philippines, Malaysia and Australia. The company anticipates production of hot melt and water-based adhesives products to begin in the second quar ter of 2016. This increased capacity in the region will enable the company to consistently meet local customers’ requirements and grow significantly in Southeast Asia, particularly Indonesia. From this new site, HB Fuller will provide adhesive solutions to customers in the hygiene, packaging, woodworking, filter, product assembly, container labelling and other durable assembly industries.
Yara Expands Value Added Production Capacity Oslo, Norway: Yara is investing USD 263 million in Sluiskil, Netherlands to increase granulation capacity enabling increased production of granular urea with sulphur, and nitrates. In 2011, Yara completed the construction of a new world scale urea solution plant in Sluiskil which partly feeds an old prilling unit producing 400,000 tons of urea annually. With this investment, the prilling unit will be replaced by a new urea granulator also designed for production of urea with sulphur, a product that is sold with a premium to regular urea. The new granulator will have an annual capacity of 660,000 tons of urea with sulphur. In parallel with increasing urea production, Sluiskil will reduce UAN production by around 230,000 tons per annum, freeing up nitric acid capacity enabling 130,000 tons per annum of additional CAN production. The new plant will be based on technology developed by Yara. Construction will start in 2015, with completion expected in second half 2017.
INVISTA And Plaxica Collaborate On Bio-Derived Lactic Acid Technology Wilton, UK: INVISTA’s technology and licensing business – INVISTA Performance Technologies (IPT) – and Plaxica, a chemical technologies company focused on the development of technology for the production of low cost lactic acid from biomass, have entered into a collaboration that is expected to accelerate the commercialisation of Plaxica’s technology. Under the agreement, in which INVISTA will have an option for an equity stake in Plaxica, INVISTA will provide Plaxica engineering, technical and commercial support from its global technology licensing organisation. The two companies will work together to develop and commercialise Plaxica’s lactic acid technology, which the companies believe will offer substantial cost and performance benefits to licensees in the polylactic acid and bio-propylene glycol value chains. Chemical Engineering World
CEW Industry News INEOS Increases the Storage Capacity of Ethane Tank Grangemouth, UK: INEOS Grangemouth today saw the massive roof that covers Europe’s biggest ethane storage tank rise into place using just four low pressure fans, following six months of building work. The huge tank is 56 metres in diameter and 44 metres high – that gives it a displacement volume of 108,372 cubic metres – large enough for 560 double decker buses to fit inside. The investment in the Grangemouth tank and infrastructure is part of the company’s £450 million rescue package to equip the site to import ethane gas from the US. The project will transform Grangemouth overnight and will allow its manufacturing assets to once more compete globally, providing raw materials for thousands of manufacturing businesses across the UK and Europe. John McNally, CEO, INEOS O&P UK, says, “We know that US ethane has transformed US manufacturing and now Scottish industry will benefit as well. This will secure a cost-effective supply of ethane for the next 15 years, and give a sustainable base for Grangemouth for that time.” The building of Europe’s largest ethane storage tank is just part of INEOS’ USD 1 billion global project to get US shale gas to Europe. INEOS has contracts to access a 100 mile pipeline from the Marcellus Shale in western Pennsylvania to the Marcus Hook gas terminal close to Philadelphia. INEOS has commissioned eight huge Dragon class ships to carry the liquefied shale gas ethane from the US to Europe.
Sadara Joint Venture Now 94% Complete Michigan, USA: Sadara Chemical Company (Sadara) is progressing on-budget and on-schedule in alignment with Dow’s strategy to enable cost-advantaged growth in fast-growing regions such as Asia Pacific, the Middle East, Africa, and Eastern and Central Europe. Sadara is a joint venture developed by The Dow Chemical Company and Saudi Arabian Oil Company (Saudi Aramco). Significant progress has been made in starting up key infrastructure and utility systems. Overall construction of the manufacturing facility is now approximately 94 per cent complete with 47,000 personnel on site in Jubail Industrial City II, Saudi Arabia. The commissioning and start-up of key utilities infrastructure is underway and the process for first production units will begin in the second half of the year with initial polyethylene production beginning near the end of 2015. Full site operations remains on track for the end of 2016. Sadara’s 26 manufacturing assets are scheduled for a sequenced start-up process, beginning with the polyolefins envelope to maximise timing in the ethylene cycle, followed by ethylene oxide/propylene oxide and their derivatives, with the polyurethanes portfolio in the final phase. Customer excitement is increasing as Dow businesses actively prepare to market and sell the majority of products produced by Sadara Chemical Company via agreements with the joint venture, to support growth in key markets such as packaging, construction, electronics, furniture and bedding, automotive and transportation. 16 • August 2015
LFM Software Introduces Ground-Breaking New Technology Manchester, UK: LFM Software is launching major enhancements to its laser scan technology portfolio with new releases of LFM NetView and LFM Server. The introduction of new 3D mark-up functionality to both products allows users to add, access and share asset intelligence in the form of tag identifiers, attributes and comments as well as links to associated documents and information. Alongside these new capabilities also comes vastly improved access to massive laser scan projects, supported by cloud and tablet enablement. These deliver the as-operated asset conditions to the desktops and mobile devices of all asset stakeholders allowing for secure global collaboration across multiple project teams and partner companies. LFM NetView 4.0 provides secure, on-demand access to laser scan data via company networks or the internet. The simple, intuitive BubbleView interface has been designed using the latest web technology allowing in browser, ‘plug-in free’ global access to visualise on-site conditions and quickly add or extract reliable intelligence. Tablet enablement and the facility to take data ‘offline’ and synchronise later enables remote use for inspection tasks and on-site reviews. LFM Server 4.3 provides the data backbone for LFM NetView 4.0 by providing a live link to a master dataset ensuring all data is up-to-date and accurate.
Mobile App Brings Industry 4.0 to All Pumps Frankfurt, Germany: To help plant operators increase productivity and transparency as well as improve competitiveness across the entire life cycle, Frankenthal-based pump manufacturer KSB has developed an app for smartphones and tablets that can determine the efficiency of fixed-speed pumps in just 20 seconds. The KSB Sonolyzer app is based on an algorithm that has been integrated in PumpMeter units for five years now, of which well over 30,000 have already been sold. The smartphone-based application does not require knowledge of the individual characteristic curve or any additional technical data of the pump set to be measured, however, and can also be used with pumps from other manufacturers. Users can utilise the app to determine the load at which each centrifugal pump driven by a fixedspeed asynchronous motor is being operated. The following data must be entered for this purpose: the motor rating, the rated motor speed, the head and the flow rate of the pump. This information can be read from the name plate affixed to every pump. The KSB Sonolyzer app is available for the iOS and Android operating systems and can even be used in potentially explosive atmospheres if the smartphone or tablet PC has appropriate protection. The average life cycle of plants used in the chemical industry exceeds 30 years, which is why the pumps installed have only seldomly been connected directly with the Internet of Things. In many cases, users are not even aware of a pump’s current load condition. Chemical Engineering World
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CEW Technology News
IICT Scientists Get CRSI Award
Engineered E.coli Makes Industrial Chemical
Dr B Mahipal Reddy, Chief Scientist and Head, Inorganic and Physical Chemistry Division, at CSIR-Indian Institute of Chemical Technology, has been selected for the CRSI Bronze medal for his significant contributions in chemical sciences. CRSI has been founded by Bharat Ratna Prof. C. N. R. Rao and is the largest chemical society in our country. Prof Dr Benjaram Mahipal Reddy has obtained Ph D degree from CSIR-Indian Institute of Chemical Technology/Osmania University, Hyderabad, India in 1986. He finished his Bachelors (1979) and Masters Degrees (1981) from Osmania University and Kakatiya University, respectively, with distinction. He joined in CSIR-IICT, Hyderabad as Scientist B in 1984.
Seoul, South Korea: RESEARCHERS in South Korea have engineered a strain of the Escherichia coli bacterium to produce 1,3-diaminopropane, an important industrial chemical, through the fermentation of biomass. 1,3-diaminopropane is used in the production of epoxy resin and polyamides for medical materials, adhesives, and engineering plastics, and as a precursor in various pharmaceuticals, agrochemicals and organic chemicals. It is usually obtained from petrochemical sources but there is increasing interest in making such chemicals from renewable sources. The team at the Korea Advanced Institute of Science and Technology (KAIST), was led by chemical and biomolecular engineering professor Sang Yup Lee. While E.coli cannot naturally make 1,3-diaminopropane, there are metabolic pathways within nature that can. The researchers used computer modelling to insert the genes for various metabolic pathways for the chemical into virtual bacterial cells, allowing them to select the most effective pathway for that organism. The selected genes were then inserted into the genetic code of a real strain of E. coli and fermented with sugars. The bacteria produced 13 g/l of 1,3-diaminopropane. “Our study suggested a possibility to produce 1,3-diaminopropane based on biorefinery. Further study will be done to increase the titre and productivity of 1,3-diaminopropane,” says Lee. The researchers believe their work could be used as a starting point to develop bacteria which can produce other important chemicals usually produced from petroleum.
Natural Fertiliser to Replace Chemical Fertiliser Bangalore, India: Camson BioTechnologies Limited, India’s first integrated IPR driven agricultural biotechnology company has filed patent s for its discovery of natural fertiliser, a product which is derived from microbial extracts. This is a breakthrough step wherein Natural Fertilizer has the capacity to replace synthetic fertiliser throughout the world. Being a clean technology it also addresses the concerns about the toxicity, safety and the environment issues facing the world. This Natural Fertilizer is water soluble and can easily be supplied through drip irrigation. Furthermore, it does not harm the soil topography and is completely safe for perpetual use by the farmers. This product will encourage healthy farming practise on a global level. Eventually, on a macro level, this product/technology can help the Indian government save a significant amount spent on subsidy for import and sale of chemical fertilisers. “This revolutionary fertiliser will be extremely helpful to the agri-input industry which is overly dependent on imported synthetic water soluble fertiliser (NPK). We have the capacity to make any combination of NPK depending upon soil type. This is also very cost competitive in the market and hence, would have potential to get rapid farmers’ acceptance,” said Santosh Nair, Chief Executive Officer of Camson.
Photoredox Catalyst Unlocks New Pathways For Nickel Chemistry New Jersey, USA: Using a light-activated catalyst, researchers have unlocked a new pathway in nickel chemistry to construct carbonoxygen (C-O) bonds that would be highly valuable to pharmaceutical and agrochemical industries. “It was extraordinary to see the reaction go from zero to 91 per cent yield just by adding a photocatalyst and switching on a light,” said David MacMillan, the James S. McDonnell Distinguished University Professor of Chemistry and principal investigator of the work. The first general C-O cross-coupling reaction, which connects ring-shaped molecules, called aromatics, to alcoholcontaining molecules, using a dual nickel-photoredox catalyst system. Extending nickel’s reach to C-O coupling reactions has great potential given the tremendous impact nickel chemistry has had on analogous C-C coupling reactions. Read more on www.princeton.edu 18 • August 2015
Challenging Classic Theory of ‘Organic’ Solar Cells Could Improve Efficiency Indiana, USA: New research findings contradict a fundamental assumption about the functioning of ‘organic’ solar cells made of low-cost plastics, suggesting a new strategy for creating inexpensive solar technology. Commercialisation of organic solar cells has been hindered by inefficiencies, but the findings point toward a potential path to create a new class of solar technology able to compete with standard silicon cells. “These solar cells could provide a huge cost advantage over silicon,” said Muhammad Ashraful Alam, Purdue University’s Jai N. Gupta Professor of Electrical and Computer Engineering. Plastic solar cells might be manufactured using a roll-to-roll process similar to newspaper printing. “This has been the hope for the last 20-25 years,” said Bryan Boudouris, an assistant professor of chemical engineering. Because organic solar cells are flexible they could find new applications that are unsuitable for rigid silicon cells such as photovoltaics integrated into buildings, and they have the potential to be lower-cost and less energy-intensive to manufacture than silicon devices. However, a critical bottleneck has prevented development of organic solar cells efficient enough to compete with silicon solar technology. “Now it appears there is no fundamental reason why organic cells have to be less efficient than silicon,” Alam said. Read more about the research on www.purdue.edu/newsroom/ Chemical Engineering World
CEW Technology News Catalyst Removes Cancer-Causing Benzene In Gasoline
Scientists Study Integrating Biofuels and Food Crops on Farms
Evanston, USA: Nor thwester n University scientists are experimenting with ways to eliminate a cancer-causing agent from gasoline by neutralising the benzene compound found in gasoline. They developed a catalyst that effectively removed benzene from the other aromatic compounds in gasoline, making it cleaner and more efficient.
Illinois, USA: We ask a lot of the land – feed the world with crops, power the world with bioenergy, retain nutrients so they do not pollute our water and air. To help landscapes answer these high demands, scientists from the US Department of Energy’s Argonne National Laboratory are designing ways to improve—and hopefully optimise— land use. In collaboration with the farming community of the Indian Creek Watershed in central Illinois, these researchers are finding ways to simultaneously meet three objectives: maximise a farmer’s production, grow feedstock for bioenergy and protect the environment. These goals, as it turns out, are not necessarily mutually exclusive. All it takes is a multifunctional landscape, where resources are allocated efficiently and crops are situated in their ideal soil and landscape position. Planting bioenergy crops like willows or switchgrass in rows where commodity crops are having difficulty growing could both provide biomass feedstock and also limit the runoff of nitrogen fertiliser into waterways — all without hurting a farmer’s profits. This is what a group of Argonne scientists has discovered through careful data collection and modelling at a cornfield in Fairbury. Negri and her team created a pilot farm site that balances the priorities of economic feasibility, bioenergy and environmental health. Read more about the research on http://www.anl.gov/articles/
An estimated 137 billion gallons of gasoline were consumed in the United States last year, according to the US Energy Information Administration, a daily average of about 375 million gallons. Within each gallon of gas is a chemical compound known as benzene, which has been recognised by the Environmental Protection Agency as a known contributor to cancer. A research team led by Northwestern’s Tobin J Marks has found a way to remove it. “The gasoline we buy is one-third a mixture of aromatics, and benzene is one of them. Only benzene is known to be cancer causing, and it is very difficult to remove. Our catalyst opened a whole new way to do that – and probably a very inexpensive way,” said Marks, explaining that aromatics are necessary to improve gas octane numbers and fuel efficiency. Marks is the Vladimir N Ipatieff Research Professor of Chemistry in the Weinberg College of Arts and Sciences and professor of materials science and engineering in the McCormick School of Engineering and Applied Science. Read more about the research on http://www. northwestern.edu/newscenter/stories
Polymer Mould Makes Perfect Silicon Nanostructures Ithaca, USA: Using moulds to shape things is as old as humanity. In the Bronze Age, the copper-tin alloy was melted and cast into weapons in ceramic moulds. Today, injection and extrusion moulding shape hot liquids into everything from car parts to toys. For this to work, the mould needs to be stable while the hot liquid material hardens into shape. In a breakthrough for nanoscience, Cornell polymer engineers have made such a mould for nanostructures that can shape liquid silicon out of an organic polymer material. This paves the way for perfect, 3-D, single crystal nanostructures. The advance is from the lab of Uli Wiesner, the Spencer T Olin Professor of Engineering in the Department of Materials Science and Engineering, whose lab previously has led the creation of novel materials made of organic polymers. With the right chemistry, organic polymers self-assemble, and the researchers used this special ability of polymers to make a mould dotted with precisely shaped and sized nano-pores. Normally, melting amorphous silicon, which has a melting temperature of about 2,350 degrees, would destroy the delicate polymer mould, which degrades at about 600 degrees. But the scientists, in collaboration with Michael Thompson, associate professor of materials science and engineering, got around this issue by using extremely short melt periods induced by a laser. Read more on http://news.cornell.edu/stories/ 22 • August 2015
Unlocking Lignin for Sustainable Biofuel Tennesse, USA: Turning trees, grass, and other biomass into fuel for automobiles and airplanes is a costly and complex process. Biofuel researchers are working to change that, envisioning a future where cellulosic ethanol, an alcohol derived from plant sugars, is as common and affordable at the gas station as gasoline. The key to making this vision a reality? Unravelling the tightly wound network of molecules—cellulose, hemicellulose, and lignin—that make up the cell wall of plants for easier biofuel processing. Using high-performance computing, a group of researchers at the US Department of Energy’s (DOE’s) Oak Ridge National Laboratory (ORNL) provided insight into how this might be accomplished, simulating a well-established genetic modification to the lignin of an aspen tree in atomiclevel detail. The team’s conclusion—that hydrophobic, or water repelling, lignin binds less with hydrophilic, or water attracting, hemicellulose—points researchers toward a promising way to engineer better plants for biofuel. Jeremy Smith, the director of ORNL’s Centre for Molecular Biophysics and a Governor’s Chair at the University of Tennessee, led the project. His team’s simulation of a genetically modified lignin molecule linked to a hemicellulose molecule adds context to work conducted by researchers at DOE’s BioEnergy Science Centre (BESC), who demonstrated that genetic modification of lignin can boost the amount of biofuel derived from plant material without compromising the structural integrity of the plant. Read more about the research on http://www.newswise.com/articles/ Chemical Engineering World
CEW News Features
Building Invincible Trust with Customers: Kaushik S Gandhi Starting with mere two people and an investment of ` 100 thousands in January 2011, Apogee has grown significantly over last four years and is currently doing an annual turnover of ` 1.25 crore. Its solutions and services are very niche and it caters to relatively smaller segment of Industrial Automation business pie ie, Manufacturing Operations Management (MOM) Solutions, says Kaushik S Gandhi, Founder and Director, APOGEE Process Control Consulting Private Limited. The company claims to be among the top five companies in India delivering advanced software solutions and services for MOM business segment. Harshal Y Desai further seeks views of Gandhi on the automation standards adopted by the manufactures, major market trends and its ‘cost effective MES and advanced automation solutions for MSME segment.’
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POGEE Process Control Consulting was started as a private limited company in January 2011 with the objective to deliver advanced software solutions and consulting services in the area of process control for continuous manufacturing industries such as O&G, refining and petrochemicals, fertilisers and chemicals, power generation etc. Since then, Gandhi says, Apogee has grown to firmly stand on its best practices, business values and ethics and the motto of COMMIT, DELIVER & EARN TRUST of its customers by delivering high quality software solutions and professional consulting services for Industrial Automation and Manufacturing Operations Management (MOM).
VIEWPOINT
Gandhi further updates that after more than four and half years of journey from January 2011 till date Apogee has added several advanced software solutions to expand its basket of solutions and services to cover all aspects of Industrial Automation and Manufacturing Operations Management (MOM). “In 2013, Metso ExperTune Inc, USA (formerly ExperTune Inc,) entrusted
Apogee to represent their business interests in India in and Apogee added ExperTune’s Process Control Performance Management (PCPM) solutions viz, PlantTriage, ProcessApex and Advanced PID Loop Optimiser to its basket of solutions and services,” he reveals. Apogee also extended its solutions and services portfolio by adding integrated Refinery Supply Chain Management (SCM) solution Prometheus Decision Support System (DSS) through its technology partnership with Prometheus S R L, Genoa, Italy for exclusive representation of Prometheus in India. Automation Standards Gandhi believes that Indian manufacturing industry is far ahead of their peers in other developing economies it terms of the automation standards adopted. “Especially in primary industries like O&G, Refining and Petrochemicals, Fertilisers, Power Generation etc, the penetration automation solutions is good,” he states. Gandhi shares his experience of working with similar industries in the Middle East
Kaushik S. Gandhi and affirms that Indian manufacturers have adopted some of the most modern automation technologies. He mentions two programmes that set the benchmark for Indian industries to look towards integrated automation using Internet of Things (IOT) and Internet of Services (IOS), which are the pillars of Industrie 4.0. “Indian Oil Corporation Ltd (IOCL) adopted Refinery Operations and Production Management Systems way back in 2001 through their MANTHAN programme where they integrated their refinery operations with business and supply chain planning. This was the first step that any Indian company
“I would recommend very judicious approach (with the word of caution) in talking about Industrie 4.0 to downstream industries in India. One must always keep Indian perspective and India specific challenges in mind while talking about it. Note that too much automation (or anything for that matter) is not called for and is not good as well. One has to strike a balance between the costs of automation vs the benefits it brings. This was also unanimously voiced by most speakers in the recently concluded 13 th ARC India Forum on Internet of the Things (IOT) in Bangalore where I was invited as a guest. I certainly believe in talking to downstream industries about advanced automation technologies such as Manufacturing Execution Systems at level 3 (as per ISA classification) which is above their basic control systems at Level 1 and 2. Manufacturing Execution Systems (MES) at Level 3 are mostly based on advanced software solutions that help and enable manufacturing industries to more efficiently manage their operations.” - Kaushik S Gandhi
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CEW News Features took towards the Internet of Things (IOT). HPCL-Mittal Energy Ltd. (HMEL), Bathinda refinery, when they successfully implemented the first Integrated Refinery Information System programme named PRISM, were the first refinery in India and only the second globally to Saudi Aramco-Total Refinery & Petrochemicals (SATORP) in Saudi Arabia to adopt such integrated refinery automation programmes.” While primary industries have successfully embraced latest technologies in industrial automation and manufacturing operations management, Gandhi admits that downstream industries like metals and minerals, specialty chemicals, sugar, pharmaceuticals, food and beverages and other Micro, Small and Medium Enterprises (MSME) are still trailing behind their big brothers in adoption of latest automation technologies, though most of them have adopted level 1 and 2 (as per ISA classification) automation ie, process measurements and basic control systems like DCS, PLC, SCADA etc. Gandhi is of the opinion that poor penetration or slower adoption or longer time in adoption of new automation technologies in such market segments is more attributed to the mind set or mental stigma of decision makers in such industries. He also comments on breaking this mental stigma about adoption of automation technologies and adds talking about cutting edge automation technologies and business integration concepts with their tangible and non-tangible benefits to the business to industry leaders and decision makers in downstream industries is of utmost importance. Challenges However, chemical and petrochemical industry in India is facing some challenges while implementing automation software and tools, agrees Gandhi. “Though the penetration of automation and advanced automation technologies is very good in primary industries like O&G, refining and petrochemicals the biggest challenge that these industries face in quick adoption of latest technologies is the buying pattern, the mind set and the bureaucracy in buying and implementation process and the human nature to object to any ‘change’,” Gandhi adds. With another example of one of the prequalifying criterion in a tender for automation technologies from a public sector undertaking (PSU) companies, Gandhi throws light on the mind-set of the buyer who is not ready to take risk but is ready to embrace an old technology. In this case, the criteria mentions that “the proposed technology should have been proven for X number of years”. This clearly means that the company is asking for a technology which is already X years old and is not the latest, he explains further. Gandhi elucidates other cases about the bureaucracy in buying and implementation, “In many PSUs the projects for technology adoption, right from tendering till completion of implementation are so much longer due to bureaucratic process that the technology being adopted becomes obsolete by the time the implementation is completed.” 26 • August 2015
INTERNET OF THINGS The term ‘Internet of Things’, or IOT as it is called now is not new though it is emerging now, was coined by British entrepreneur Kevin Ashton in 1999. It broadly means an integrated network of devices, business systems, and services that connects people and processes and enables them to carryout business in a collaborative manner, thereby bringing more agility in business by making quick decisions, based on accurate and consistent information, that the people do not need to ask for or wait for to receive from someone else, thus breaking that annoying interdependability. Advanced automation and level 3 MES solutions, that are designed and built on an integrated platform based on guidelines and principles of IOT, if effectively adopted by users then they certainly result in following benefits to individuals and the enterprise. • • • • • • • • • • •
Improved operational performance Improved asset availability and life Safer and smoother operation Tighter environment compliance Quick decision making Agility in business Improved profitability (reduced cost) Improved people effectiveness Consistent information – everywhere Highest data integrity (no manual entry) And many more…
IOT and its adoption is not new for many Indian industries. A classic example is of IOCL corporate supply chain team, taking critical decisions on crude supply planning and crude contract management, sitting in their corporate headquarter in Delhi, through an integrated refinery supply chain planning and operation scheduling model that integrates all refineries of IOCL, is the best example of effective exploitation of IOT.
- Kaushik S Gandhi He further talks about the basic human nature to remain within their comfort zone and resist any ‘change’ and describes, “This human nature has catastrophic effect (significant impact) on effectiveness of adopted technology. Even if the organisation invests heavily in adopting the best and the latest technologies to replace the old and cumbersome ones, if the users (humans) who are supposed to make effective use of this new technology, does not do so (or resist this change) then the failure of the adopted technology, however the best implemented, is inevitable.” “All these must CHANGE if one aspires to adopt the latest and the best and reap the benefit of adopting the best,” Gandhi emphasises. Chemical Engineering World
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CEW News Features Solutions for MSME Small or mid-size plant operations are sometimes hesitant to invest in new technologies due to the cost involved. According to Gandhi, Apogee very well understands automation needs of MSME segment and provides dedicated and special focus on these industries. In our basket of solutions and services, we have included very cost effective MES and advanced automation solutions for MSME segment. “One of the best examples we can provide is our Process Control Performance Management (PCPM) service delivery model for optimisation of base layer control loops on DCS or PLC,” he divulges further. Commenting further on PCPM, Gandhi reveals that PCPM service is like a ‘Software as a Service (SaaS)’ delivery model in which we request our MSME customers to subscribe to this service wherein we use shared infrastructure (software and server hardware) among multiple customers and still deliver value added services for optimising process control performance. “Through SaaS model for PCPM services we ensure that our MSME customers are not forced to buy expensive software licenses and associated annual maintenance support contract.”
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Gandhi claims that Apogee has many such innovative ways of offering the best-in-class advanced automation and MES solutions to its MSME customers in a very cost effective way. Training and Application Development Support Apogee also offers advisory services and helps its customers in achieving manufacturing excellence through optimal adoption and exploitation of advanced automation technologies. Its business advisory services include a mix of business consulting and programme management services. (Know more on www.apcconsulting.net) Plans for Future “In keeping with our commitment to deliver the best-in-class advanced automation, MES and MOM solutions to our customers, we intend to continuously innovate and keep adopting the latest technologies to bring more and more values to our customers through our offerings,” Gandhi states. Based on its experience in working with several integrated information system projects that are designed on IOT principles, Apogee intends to develop its own software solutions that are based on open source technologies such that it is cost effective to Indian industry. This will be our small contribution to ‘Make in India’ campaign and thereby reducing our (India’s) dependencies on foreign innovations and technologies.
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CEW News Features
Wireless Technology for Automation Industry With the advancement of time and technology, wireless technology has replaced by the pneumatic transmission, wired transmission, wired communication method, etc in transmitting signals from control room to remote areas for data processing. While wireless technology has many advantages as well as own limitations, the article urges that it is the responsibility of design centers to choose whether to implement wireless technology towards real time and accurate data processing, and how to overcome its limitations.
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he process industry is predominantly dependent on reliable and accurate measurement, controls and shutdown functionalities for safe and optimum plant operations. Transmission of signals for process control or for safety system applications are critical for centralised processing. The industr y has seen considerable evolution in the types of signal being utilised for transmitting the field data to the control room for further processing. With every technology evolution, a transition of signals has happened, from tubes, to wires and now the new wave, wireless. In the early days, pneumatic mediums were utilised to transmit field signals to remote locations. Tubes were utilised for transmission of these pneumatic signals to the control room, or to a centralised panel in the field. The signal levels were in the range of 3 to 15 psi. With time and technological advancement, the pneumatic transmission was overshadowed with wired transmission by means of low powered electrical signals (mA, mV). As for any new system, acceptance of this step change met with resistance, and the industry took some time to accept this wired communication method. With further development, digital technology started taking the place of low powered electrical signals. The next huge step in signal transmission took place with the establishment of wireless technology. Wireless technology has many advantages, but at the same time has its own limitations. It is the responsibility of design centers to choose whether to implement wireless technology towards real time and accurate data processing, and how to overcome its limitations. Basics of Wireless Technology The ISA100 committee of the Instrument Society of Automation is responsible for the
30 • August 2015
standardisation and generation of guidelines for the implementation of wireless devices and systems for industrial applications. This committee was formed in 2005, and comprises of experts from various verticals of the industry, like manufacturers, technology providers, experts from networking, and end users. The committee developed a set of standards known as the ISA 100 family of standards. The most relevant for our industry is the ISA 100.11a, Wireless Systems for Industrial Automation: Process Control and Related Applications. As the title describes, this standard has been developed considering the requirements for the automation of process control applications. The ISA100.11a standard deals with technologies which ensure high reliability and openness, and enable network expansions. These are critical steps towards achieving the following: • Flexibility for multivendor interoperability • Integration between the wired instrument systems and wireless instrumentation • Interfacing between field devices and state of the art IT systems Wireless technology has been in existence for quite a long time now. There are various wireless systems today, with applications utilising RF signals, RF ID systems and cell phones. Considering this scenario, the co-existence of an additional set of devices for automation, apart from those already available, did not pose a major challenge in terms of signal. However, wireless devices can only utilise battery power, which therefore requires a shift from direct power usage to operability on portable batteries. Wireless operates in the Industrial, Scientific, and Medical (ISM) radio band that typically
operates from 2.400-2.480 GHz. The exact frequency limitations and RF output power levels may differ from country to country. The ISM radio bands are license-free, but do require approval from governmental regulating agencies. These approvals are typically obtained by the wireless vendor. Since multiple vendors can use the same spectrum for various applications, wireless technologies must be able to successfully coexist. Multiple techniques are utilised to enable the coexistence of various wireless applications: • Network segmentation – Provision of a unique ID • Spectrum isolation – Operations in different portions within the spectrum • Hopping – Self-organising mesh networks can hop on different paths, as required by different RF conditions, thus avoiding the obstacles offered by other RF devices • Utilisation of different channels – Use of 15 channels within the 2.4 GHz spectrum • Data encoding - Transmitting unique encoded data • Scheduled transmission of data – Prescheduled transmission of data to reduce interference Applications of Wireless Field Devices Today wireless devices are available for every practical application in process automation environments. The brief spectrum of applications where there are options for utilising wireless instruments is as follows: • Measurement instruments - Available for measurement of pressure flow, level and temperature process parameters • Analytical instruments - PH measurement • Discrete and position monitoring - Valve position indicators • Machinery health monitoring system Chemical Engineering World
CEW News Features Vibration monitoring devices, corrosion monitoring, winding temperature
• Distance between the location of the devices and the wireless gateway
Wireless Network Design Considerations The decision to utilise wireless technology for field instrumentation needs to be taken at the early stage of the project, preferably at the FEED stage. The drivers for utilisation of wireless devices and networks shall be evaluated and analysed from the points of view of reliability, availability, the risk associated, economics, delivery and nature of the project. Once the decision of utilisation of wireless technology is confirmed, then proper planning needs to be embedded in the project execution for implementation of this wireless technology.
Battery life becomes important from the maintenance perspective, especially when the sites of the installations are remote from the main control rooms, and the cost of each visit has to be considered. The industry is now working towards a controlled maintenance regime, and frequent visits for battery changes would significantly increase the operation cost.Frequent data transmission from field devices to the gateway requires more power and negatively impacts the battery life. Hence, the key is assessing how often updated process data is required from each application.
The types of process monitoring and control signals that need to be performed via wireless should be considered. This assessment should be based on the criticality of the loops, the acceptance of the delayed dynamic updates at the control system, and the availability and reliability of devices in the market for the selected applications. The current industry practices are more focused on monitoring loops and the extension of certain control loops. An area where a focus shift is visible, however, is with regard to the machinery health monitoring systems, such as motor winding temperatures and vibration devices, as well as applications required for maintenance and accessibility for the lifecycle of the equipment. Once the philosophy for allocation of wireless devices is confirmed, a technical specification for the wireless system needs to be outlined.
From the data gathering and processing aspect, the technical requirements should identify: • The wireless gateway interfaces with the main control system • The redundancy requirements of communications between the wireless gateway and main control systems • Future expansion needs for the wireless gateway sizing • The type of communication • Software needs • Any special requirements for the conditions to be achieved during loss of power supply to the field devices
The wireless system shall comprise of field devices, the wireless gateway and the interfacing between the gateway and the main plant control system. For field devices, the specification should include the technical performance requirements (accuracy, repeatability etc.) based on the following: • Applications • Device battery life, corresponding to the process parameter update time • Type of antenna, material of construction for the device • Certification requirements • Maintenance spares identification • Type of network for communication from the field devices to the wireless gateway 34 • August 2015
All the above requirements along with the plant equipment layouts shall be utilised as guidelines for the lifecycle procurement of the field devices and the wireless gateway. The supplier’s site visit is always recommended to identify: • Mapping of the field devices • The physical obstacles in the path of the field devices and the wireless gateway, to enable early identification of repeaters in the project • Location of the wireless gateway and the gateway antenna • Determining the type of antenna • Identify the cable length between the gateway and the antenna • Any other check points as required by the manufacturer for proper functioning of the entire system Integrated testing of the entire system, comprising of the plant main control system,
gateway and random field devices, is highly recommended. The test should be performed as per the functional design specification of the system. This will avoid any delays due to interfacing issues between the two systems. Commercial Advantages Cost benefits are the key driver for adopting wireless technologies. The advantages include the following: • Adoption of wireless networks can create high economic savings as compared to the wired alternative. The installation time is considerably reduced and this facilitates faster mechanical completion and start-up. Engineering costs are reduced as there is no need for generation of deliverables such as junction box schedule, drum schedules, and cable route diagrams. • Availability of remote information Replacing manual readings with automated measurement results in information that is more accurate, reliable and dynamic. This also reduces visits by the operator to hazardous areas. • Scaling - Engineering the system for future expansion facilitates quick augmentation of the existing system. • Operational savings - Remote data availability will contribute to a quick diagnosis of any issues, as well as swift troubleshooting. This will also facilitate in the prediction maintenance programme. • Migration of existing plant - Upgrading an existing plant to automation wireless system has a considerable economic benefit and minimises the plant downtime. Conclusion Wireless technology has multiple benefits if the system is selected appropriately. Although the current applications are more concentrated on monitoring and controls, the coming years could see further technological developments, such as the extension of wireless technology to safety shutdown systems.
(Article authored by Parag Mantri,
Department Manager – Instruments, Aker Powergas Pvt Ltd; E: Parag.Mantri@akersolutions.com) Chemical Engineering World
CEW Features Guest Column
Enhanced Biosolids Treatment With a number of projects being implemented such as the Namami Gange, plans of Smart Cities and pressures of increasing urbanisation makes wastewater infrastructure of utmost importance. In this article, John Tattersall, Global Director – Water Technology, Black & Veatch and Rajesh Patwardhan, Director Business Development, Black & Veatch Water, India share insights on incorporating enhanced biosolids treatment in these projects and the benefits.
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ndia is set to make significant investments in wastewater treatment infrastructure. For example, in the first phase of plans to restore Ganga, 118 towns have been tentatively identified for the provision of new wastewater treatment works. Efficient management of wastewater is also among the attributes the Smart Cities Mission requires for the proposed smart cities project. In addition to the many new-build projects envisaged in Namami Gange and the smart cities programme, many towns and cities are seeking to improve the performance of existing wastewater treatment assets to cope with the pressures of increasing urbanisation. Incorporating enhanced digestion processes into both new and retrofit wastewater treatment infrastructure projects offers
John Tattersall Global Director – Water Technology, Black & Veatch
Rajesh Patwardhan Director – Business Development Black & Veatch Water, India 36 • August 2015
potential benefits: increased capacity of existing works, a byproduct safe for use as fertiliser, and the possibility for energy recovery. The latter attribute can support the element of the Ministry of Urban Development’s Draft Concept Note on the 100 Smart Cities which calls to, ‘adopt new methods for loss and energy consumption in water networks.’ One advanced digestion technology that is fast gaining global acceptance is thermal hydrolysis. Thermal hydrolysis is a high-pressure process that typically heats Waste Active Sludge (WAS) or a combination of WAS plus primary sludge for a short period of time to high temperature and pressure. The
Consideration
Typical Improvement Achieved
Digester loading rate
More than double the digester loading rate for conventional digestion.
Biogas production
25 to 30% additional biogas.
Overall energy production
Site specific, but generally the additional energy required for steam is offset by energy recovered from increased biogas production
Volatile Solids Destruction (VSR)
60% VSR compared to around 45 to 50% VSR with conventional digestion.
Dewaterability
Dependent on application a 30% dry solids in cake dewatered using centrifuges or belt filter presses (compared to around 23 to 25% dry solids for conventionally digested sludge)
Reduction in wet cake load out
Up to 25 or 30% reduction in wet sludge volume for disposal (resulting from a combination of the additional VSR and the improved dewaterability).
Biosolids product
Meets requirements for Class A biosolids under the time-temperature criterion.
Table:1
Chemical Engineering World
CEW Features high temperature and the rapid decrease in pressure during depressurisation ruptures cells in the WAS and break down extracellular polymer, making more material bio-available for anaerobic digestion. This makes the sludge more digestible for microbes which results in significant improvements in digester loading and performance, opening up possibilities for improved energy and resource recovery from biosolids. The benefits are summarised in Table 1. Thermal Hydrolysis Process (THP) technology was commercially developed by Cambi approximately 20 years ago, but Veolia, TurboTec and others also offer THP systems. In the Cambi process sludge is fed to a pre-heating vessel, the pulper, at a concentration of 16.5 per cent dry solids and is heated using steam recovered from the flash tank. Preheated sludge is fed to one of the reactors, heated via steam injection to 165 Degree C, and held for 20 to 30 minutes. In addition to providing the required retention time for hydrolysis, the process meets the time-temperature criterion for US Class A Biosolids, having very low levels of pathogens. Following the reaction period, sludge from the reactor is discharged to the flash tank. During discharge to the flash tank, the sludge is rapidly depressurised. This causes cell rupture and release of flash steam, which is recovered to the pulper. From the flash tank, hydrolysed sludge is fed continuously to anaerobic digestion via a cooling system which is required to reduce the sludge temperature from approximately 100 Degree C or higher to the 40 Degree C required for digestion. The most common current configuration for THP is to use it upstream of anaerobic digestion although it can be used in other configurations. A thermal hydrolysis and digestion facility at United Utilities’ wastewater treatment works in Davyhulme, Manchester, England has increased the site’s biosolids processing capability from 39,000 tonnes dry solids (tDS) per year to a maximum capacity of 38 • August 2015
Figure:1 The HPH facility at Colchester WRC with – from left to right - heating, pasteurisation and hydrolysis tanks
121,000 tDS per year (with an average of 91,000 tDS per year). The new plant provides United Utilities with a central biosolids processing facility and allows for import of dewatered biosolids cake from seven satellite sites which previously used lime treatment. The increase in capacity means that Davyhulme is now capable of processing biosolids equivalent to a population of approximately 4.4 million people. The Engineering, Procurement, Construction (EPC) contract was undertaken by Black & Veatch. The THP at Davyhulme processes biosolids via two routes: • Liquid biosolids from Davyhulme treatment works is dewatered on site to approximately 25 per cent dry solids using 4 decanter centrifuges and fed to a storage silo which feeds the THP • Imported cake is brought into site from the seven satellite sites via two cake reception facilities. The sludge is fed to the THP from two sludge storage silos There are 4 thermal hydrolysis streams feeding 8 digesters (2 digesters per stream). Each THP stream can be fed with dewatered biosolids from Davyhulme,
imported biosolids or a combination of the two. Prior to being fed to the digesters, sludge is cooled to approximately 40 Degree C. Biosolids displaced from the digesters flow by gravity into a degassing tank where air is injected to inhibit methanogenesis. From the degassing tank, sludge is transferred to digested sludge storage tanks. Biogas from the digesters is balanced using two 9,000 cubic metre (m3) double membrane gas holders. The gas is pumped via a gas clean up system to feed 5 combined heat and power (CHP) engines and 3 combination boilers. The combination boilers are capable of raising steam for the THP using a combination of exhaust waste heat (from the CHP engines) and biogas burned in the fired section of each boiler. Heat is recovered from the CHP engine jacket cooling systems and is used to preheat final effluent dilution water used to dilute sludge cake being fed to the THP and boiler feed water. Electricity is generated from the CHP engines making the site energy self-sufficient. Another advanced digestion option is the HPH process which has recently been Chemical Engineering World
CEW Features also utilise heat recovery from the CHP engines’ flue gases to create steam used by the process. The pre-heating process raises the sludge temperature to 42 Degree C at which time it is ready to feed the pasteurisation stage. This stage utilises direct steam injection to raise its temperature to 57 Degree C. The hot water and steam systems are designed to harvest all heating needs from the CHP power generation process. If the CHP is out of service the boilers may be fuelled by burning surplus biogas, or if necessary, by diesel oil from the new storage tank.
Figure:2 Constructing the THP at Davyhulme, Manchester, England
added to the Colchester Wastewater Recycling Centre (WRC). Owned and maintained by Anglian Water, Colchester WRC treats flows from 135,000 homes and businesses in and around Colchester, Essex, England. The existing WRC comprised a conventional digestion process and served as a sludge reception facility for liquid and cake imports from other Anglian Water satellite sites. The facility was recently upgraded as an enhanced digestion treatment centre with capacity for 14,526 tDS per annum. The facility’s increased capacity provides for all indigenous sludges from the works, expanded liquid sludge imports and a new cake import processing capability. The various sludges are blended, pasteurised, digested and finally dewatered to cake, ready for transportation off-site for use as an enhanced quality agricultural product. As principal EPC partner, Black & Veatch was selected to design and manage construction of the new treatment process. The work comprised modifications to the existing primary and imported sludge plant; enhanced tanker imports facility; new Surface Activated Sludge (SAS) treatment; new cake reception facility; Heating, Pasteurisation And Hydrolysis (HpH) process; new digesters and associated biogas holder; post digestion dewatering and return liquors 40 • August 2015
treatment facility. HpH is a unique advanced digestion process, developed, trialled, and up-scaled to full operational capacity by Anglian Water. The three-stage system performs the following functions: • pre-heats the blended feed sludges prior to pasteurisation • pasteurises the sludge and achieve an ‘enhanced’ sludge product and rapid pathogen kill • pre-conditions (hydrolyses) the digester feedstock for optimum biogas production Colchester’s HpH is in full operation and on target to treat 14,526 tDS per annum. The system comprises four reactors: 1 for pre-heating, followed by 2 for pasteurisation and 1 for hydrolysis. The system operates an automated batching arrangement centring on the two (280m 3 each) pasteurisation tanks. Whilst one pasteurisation tank is filling and heating, the other is holding at temperature and pasteurising its batch for at least five hours. After its holding period the batch is fed forward to the (1,115m 3) hydrolysis tank and the cycle is repeated.
Following the pasteurisation stage the batch is discharged to the hydrolysis tank. The sludge is then transferred via a heat exchanger where final effluent is used to cool the flow to less than 38 Degree C ahead of being slowly pumped forward to the digesters. Two new mesophilic anaerobic digesters, with a working volume of 3,802m 3 each, receive the HpH treated sludge and hold it for a minimum period of 14 days. Biogas evolved from the digestion process is passed from the digesters to an existing (1,500m 3) gas holder which feeds the site’s CHP engines. The aim of the CHP installation is to provide power generated by biogas from the enhanced digestion process. Two CHP engines rated at 1.2 MW each, provide sufficient power and heat to run the treatment process, but also allow the site to export surplus power to the grid. All power generated by this process is subject to ROC accreditation which generates an additional source of revenue. Total output from both engines is 2.4 MW/h; of this approximately 1.3 MW/h is consumed on site with the remainder taken up by the grid.
The initial pre-heating stage utilises a circulating hot water loop (80 Degree C) fed from the heat recovery systems of 2 CHP engines. Additional heat is added as required from 2 steam boilers which Chemical Engineering World
CEW Features Technical Article
Challenges in Setting Up ETP For Refineries Petroleum refining is a complex operation and unit operations within refineries vary depending on the type of crude and the type of end products. Refining is a water intensive operation which generates large quantity of waste water that needs to be treated so as to avoid environmental degradation. A proper understanding of the unit operations as well as pollutant loads is necessary in order to set up a suitable Effluent Treatment Plant (ETP). This article discusses about various challenges that we have faced in the designing and operating of several Refinery ETPs in India.
C
haracterisation Of Waste Water In order to design an ETP for an upcoming refinery, design parameters like the flow rate, Biological Oxygen Demand (BOD), Chemical Oxygen Demand (COD), Suspended Solids (SS), Oil & Grease (O&G), Sulfides, Phenols, Ammonia etc., have to be assumed. The selection of the scheme and the estimation of unit sizes depend on the inlet characteristics and hence it is imperative that the assumed design parameters be as close to the actual parameters that will be encountered once the plant is commissioned. It is quite normal to assume higher values while designing the plants. However, one should keep in mind that some processes do not perform efficiently when they are over designed.
separator followed by a Dissolved Air Flotation (DAF) or Induced Air Flotation (IAF) unit. • Flow Equalisation: Flow of wastewater generated from refinery from various manufacturing process units is not uniform. The flow variation is equalised by providing an equalisation tank of sufficient capacity and constant flow is maintained in all downstream treatment units. This makes the process control much easier. • Removal of Suspended Solids: This is achieved using a clarifier or it can be combined with O&G removal in a DAF unit
Typical Treatment Scheme The treatment philosophy adopted to treat refinery waste waters consists of a series of steps to sequentially remove the pollutants so that the treated wastewater meets the required regulatory norms. The typical treatment steps are:
• Removal of Sulphides: Lower sulphide concentration can be handled in biological treatment system. However, high concentrations of sulphides need to be taken care before wastewater enters into biological treatment system. Oxidation of sulphides using Hydrogen Peroxide is most popular method of oxidising them.
• Removal of O&G: This is necessary as downstream operations are sensitive to the presence of high levels of O&G. In a refinery wastewater treatment system, two steps of oil removal are typically required to achieve the necessary removal of free oil from the collected wastewater prior to feeding it to a biological system. This oil removal is achieved by using an American Petroleum Institute (API) or Tilted Plate Interceptor (TPI) or equivalent oil water
• Biological Treatment: Various biological systems have been adopted including Activated Sludge Process, Bio-tower, Sequential Batch Reactor, Anaerobic reactors, Membrane Bioreactors etc. Every process has its own inherent advantages and disadvantages and a suitable system has to be selected by the designer based on factors such as organic load, treatment efficiency required, land area available etc.
42 • August 2015
• Polishing of Treated Waste Water This step includes units like Pressure Sand Filters (PSF), Dual Media Filters (DMF), Activated Carbon Filter (ACF) to remove the residual suspended solids as well organic pollutants that have passed through the earlier treatment steps. • Reuse and Recycle : As the refinery consumes a large quantities of water, it is imperative one must try and reuse the treated waste waters back in the process. Additional treatment units like Microfiltration, Ultrafiltration or Reverse Osmosis may be adopted in order to meet the reuse water quality that is required Challenges and Solutions in Biological Treatment of Refinery Wastewater The key treatment step in the refinery ETP is the biological treatment as the bulk of the pollutants are removed in a cost effective manner in this step. Hence it is important to design this system in a robust manner so that it can operate efficiently. It is important to note that in the biological treatment step, the pollutants are degraded by microorganisms and it is imperative that a conducive environment is maintained such that the microorganisms can operate up to their maximum potential. A list of various factors that influence the design and operation of the biological system are given below: • Fluctuation of Wastewater Characteristics: One of the main challenges in refinery wastewater treatment is its variation in characteristics. As mentioned earlier, when assuming the Chemical Engineering World
CEW Features in a biological system of a refinery is shown here (Figure 1).
Figure1: Foam in refinery
Figure2: Typical Refinery ETP
pollutant load for design of the ETP, it is normal to assume higher values so that the designs are ‘safe’. This causes problems during the operation of the ETP when the actual pollutant load is much lower. Also, based on variations in quality of crude and refining process, wastewater quality also varies. The biological system should be selected to take care of these variations. The biological system should be able to vary process parameters such as air supply, Mixed Liquor Suspended Solids (MLSS), Food to Microorganism (F/M) ratio, etc., to suit variations in feed. Modular design of biological process also helps in handling variations of wastewater quality. If provided with multiple process tanks, plant can be operated based on the actual pollution load by using all process tanks or part of them. • Oil & Grease: The performance of the O&G removal equipment is sometimes upset due to a surge in the inlet O&G quantity due to dumping of oil within the refinery. This causes O&G to slip into the biological system affecting the microorganisms. This also causes foaming in the aeration tanks that affects the quality of the treated water. A figure showing the foaming 46 • August 2015
• Sulphides: Refinery wastewaters contain high levels of Sulphides that are toxic to microbes and hence have to be removed prior to the biological treatment. In case sulphides slip into the biological system, it exerts demand on the aeration system since it consumes the oxygen that is meant for the respiration of the microorganisms. Hence it is normal to consider a safety margin in the design of the air blowers so that it can meet any contingency due to sudden air demand because of sulphides. Care should be taken that sulphide concentration in biological system are below toxic limits. • Complex Organic Compounds and Heavy Metals: Complex organic compounds such as phenols, benzene products, etc. are also part of refinery wastewater. Their concentrations depend on the source and quality of crude oil. These compounds are not easily biodegradable and may be toxic to biological system at higher concentrations. Hence, the ETP should be designed to handle these complex organics in case they are present in wastewater. Heavy metals also pose problem to biological treatment. Both complex organics and heavy metals should be taken care in pretreatment if present in higher concentrations. • Nutrients: The growth and performance of the microorganisms depend on the availability of critical nutrients like nitrogen and phosphorous in the waste water. Ideally, a BOD:N:P ratio of 100:5:1 is required for best performance. Normally abundant nitrogen is present in the refinery wastewater. However, it is important to constantly analyse the wastewater and add nitrogen (typically as Urea) and phosphorous (as Phosphoric acid or Di Ammonium Phosphate) to make up for any deficit. Many a times, total nitrogen levels in the wastewater are much more than required which necessitates treatment to reduce them. Hence, the biological system selected should be able to remove excess nitrogen along with organic pollutants.
• Energy efficiency: The oxygen required for the microorganisms are delivered through fine bubble diffusers that release small bubbles of air from the bottom of the aeration basins. Air blowers are installed to supply air into biological process. Air blowers constitute major portion of power consumption in the ETP. Any steps taken to optimise energy consumption shall result in energy efficiency of the plant. Biological process should be provided with oxygen control system to supply air as per the organic pollution load coming into it. Dissolved Oxygen (DO) or Oxygen Uptake Rate (OUR) based blower control optimizes both energy consumption and process performance. Energy efficient blowers further improve the energy efficiency of the ETP. • Process Automation: Due to variations in wastewater characteristics, it is advisable to install process automation to control vital process parameters such as DO, OUR, MLSS, Sludge recirculation, Sludge wasting, etc. This helps in automatically keeping the process parameters at their optimum levels and generates consistent quality of treated wastewater. Conclusion Refinery wastewater characterisation is very complex exercise that requires an understanding about the refining processes involved. The designing of the ETP is a challenging job as treatment units have to be robust enough to handle continuous variations in the concentration of pollutants. The operation of the biological system governs the performance of the ETP, as it removes the bulk of the pollutants. Ideal operating conditions have to be provided for the microorganisms in order to ensure effective treatment. The biological system should be selected to handle any variations in flow and characteristics of refinery wastewater.
Author’s Details Satya Narayana Y V V SFC Environmental Technologies Pvt Ltd satya@ctechsbr.com Chemical Engineering World
CEW Features Technical Article
Innovative Membrane Technologies For Boiler Feed Water Acceptance of Liqui-Cel membrane contactors and Electropure EDI modules has been driven by lower costs, higher water quality demands and improvements in the manufacturing techniques of the process. The unique properties of Liqui-Cel membrane contactors and Electropure EDI modules allow them to be installed in almost any location in high purity water system. The author gives an insight into the advantages of incorporating Liqui-Cel membrane contactors and Electropure EDI modules for boiler feed water.
M
embrane technology has always played a significant part in the production of high and ultra-high purity water for pharmaceutical, electronics and power industries. It is now over a decade, the conventional technologies such as forced draft degasifiers and deaerators (for removal of dissolved gases) and further ion exchange mix-bed systems (for removal of the dissolved solids have been replaced by a more efficient and reliable membrane technology such as Liqui-Cel membrane contactors and Electropure Deionisation (EDI) modules respectively. Background Proper treatment of boiler feed water is an important component of a boiler system. As steam is produced, dissolved solids become concentrated and deposit inside the boiler. This leads to poor heat transfer and efficiency reduction of the boiler. Dissolved gasses such as oxygen and carbon dioxide will react with the metal surfaces inside the boiler promoting corrosion. It is for this reason to incorporate improved and better technologies for removal of dissolved solids and dissolved gasses before entering the boiler.
typically tall towers in mild steel rubber lined construction with packed column and mounted on mild steel rubber lined storage tank. The degasser tower limits the outlet carbon dioxide to 5 – 6 ppm. This becomes an additional load on to the downstream anion exchange/mix-bed units. For every 1 ppm carbon dioxide, the feed conductivity equivalent is 2.79 times. The carbon dioxide from the reverse osmosis permeate increases the feed conductivity equivalent and this is detrimental for EDI systems in ultrapure water applications. Hence, Liqui-Cel membrane contactors are more economical than the conventional degasifier for removal of carbon dioxide. Chemical Treatment Chemical treatment is widely used to control dissolved oxygen in a boiler. The cost of operating a chemical treatment programme consists of chemical costs and blowdown costs. Periodically the water in the boiler must be flushed out to remove non-volatile compounds. They are flushed out of the
boiler in a process called blowdown. Chemical addition to the water can increase the frequency of blowdown, which increases the operating cost of the boiler. There are two components of blowdown costs. Water and steam that is purged from the boiler during blowdown is sent to drain. This water must be replenished by fresh makeup water and there is a cost associated with it. The second cost is heat or energy cost. The water blow down from the boiler is hot. It is replaced with cold water that must be reheated in order to produce steam. Liqui-Cel membrane contactors are widely used to remove dissolved oxygen in feed water. By incorporating membrane contactor there is substantial savings in boiler blowdown rate and cost, chemical dosages and cost are also drastically reduced. This results in substantial savings in operating cost.
Conventional Methods for Boiler Feed Water Typical conventional water treatment schemes incorporate the following technologies: • Reverse Osmosis + degasser tower + ion exchange (two bed/mix-bed) systems + deaerator/chemical treatment. Degasser Tower Commonly used for removal of dissolved carbon dioxide. Degasser towers are 48 • August 2015
Figure:1 Extra-Flow Liqui-Cel Membrane Contactor
Chemical Engineering World
Features CEW Improved Technologies for Boiler Feed Water Due to several advantages, Liqui-Cel membrane contactors have replaced the conventional forced draft degasifier/deaerator for removal of dissolved gasses such as carbon dioxide and oxygen while the mix-bed ion exchange systems have been replaced by a more efficient Electropure EDI modules. The most economical scheme for boiler feed water would be: Reverse Osmosis + Membrane Contactor (CO2 removal) + EDI + Membrane Contactor (O2 removal)to Boiler What Are Membrane Contactors? Membrane Contactors are typically shell-and-tube device containing micro porous hydrophobic hollow-fibres. The material of construction of hollow-fibres is polypropylene having internal diameter: 200-220 mm, outer diameter: 300 mm and having an average pore size of 0.03 mm. Water is passed on one side of the membrane and a gas is passed on the other. Since the membrane is manufactured using a hydrophobic material and the pores are small, water does not easily pass through the pores. The membrane essentially acts as a support between the gas and liquid phases, and allows them to interface at the pores. Gases, however, freely pass through the pores on a molecular level. (See Figure 1 on previous page)
Figure2: Gas Transfer Mechanism
Chemical Engineering World
Gas Transfer Mechanism (See Figure 2) • Gasses in the atmosphere dissolve into water until equilibrium is reached. • Equilibrium between the liquid and gas Phase is offset when a vacuum and/or source of strip gas is applied. • This creates a driving force to move gasses. • By changing the partial pressure of the gas we can either remove or dissolve gas into water. Features And Benefits Of Membrane Contactor: (See Table 1) Electropure EDI What is Electrodeionisation? Purified water is widely used in pharmaceutical, semiconductor and power industries. • EDI is a process to obtain ultrapure water • Produces water of consistent quality from 1-18.2 m‘Ω-cm resistivity or • 1-0.057 µS/cm conductivity • Conforms to USP grade water as ‘Purified Water’ (PW) and ‘Water For Injection’ (WFI) • Replace conventional DI mixed resin bed system • Continuous process, no shutdown required • No regeneration required • Compact size • Low energy Process Of EDI • Product stream (90% water recovery) • Concentrate stream (typically 10%)
• Electrolyte stream catholyte to drain)
(10 lph, anolyte +
The electrodeionisation process uses a combination of ion-selective membranes and ion-exchange resins sandwiched between two electrodes anode (+) and cathode (-) under a DC voltage potential to remove ions from RO pretreated water. Ion-selective membranes operate using the same principle and materials as ion-exchange resins, and they are used to transport specific ions away from their counter ions. Anion-selective membrane are permeable to anions but not to cations; cation-selective membranes are permeable to cations but not to anions. The membranes are not water-permeable. By spacing alternating layers of anion-and cation-selective membranes within a plate-and-frame module, a ‘stack’ of parallel purifying and concentrating compartments are created. The ion-selective membranes are fixed to an inert polymer frame, which is filled with mixed ion-exchange resins to form the purifying chambers. The screens between the purifying chambers form the concentrating chambers. This basic repeating element of the EDI is called a ‘cell-pair’. The ‘stack’ of cell-pair is positioned between the two electrodes, which supply the DC potential to the module. The influence of the applied DC voltage
Figure3: Process Of EDI
August 2015 • 49
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CEW Features Improved Technologies for Boiler Feed Water Due to several advantages, Liqui-Cel membrane contactors have replaced the conventional forced draft degasifier/deaerator for removal of dissolved gasses such as carbon dioxide and oxygen while the mix-bed ion exchange systems have been replaced by a more efficient Electropure EDI modules. The most economical scheme for boiler feed water would be: Reverse Osmosis + Membrane Contactor (CO2 removal) + EDI + Membrane Contactor (O2 removal)to Boiler What Are Membrane Contactors? Membrane Contactors are typically shell-and-tube device containing micro porous hydrophobic hollow-fibres. The material of construction of hollow-fibres is polypropylene having internal diameter: 200-220 mm, outer diameter: 300 mm and having an average pore size of 0.03 mm. Water is passed on one side of the membrane and a gas is passed on the other. Since the membrane is manufactured using a hydrophobic material and the pores are small, water does not easily pass through the pores. The membrane essentially acts as a support between the gas and liquid phases, and allows them to interface at the pores. Gases, however, freely pass through the pores on a molecular level. (See Figure 1 on previous page)
Figure2: Gas Transfer Mechanism
50 • August 2015
Gas Transfer Mechanism (See Figure 2) • Gasses in the atmosphere dissolve into water until equilibrium is reached. • Equilibrium between the liquid and gas Phase is offset when a vacuum and/or source of strip gas is applied. • This creates a driving force to move gasses. • By changing the partial pressure of the gas we can either remove or dissolve gas into water. Features And Benefits Of Membrane Contactor: (See Table 1) Electropure EDI What is Electrodeionisation? Purified water is widely used in pharmaceutical, semiconductor and power industries. • EDI is a process to obtain ultrapure water • Produces water of consistent quality from 1-18.2 m‘W-cm resistivity or • 1-0.057 µS/cm conductivity • Conforms to USP grade water as ‘Purified Water’ (PW) and ‘Water For Injection’ (WFI) • Replace conventional DI mixed resin bed system • Continuous process, no shutdown required • No regeneration required • Compact size • Low energy Process Of EDI • Product stream (90% water recovery) • Concentrate stream (typically 10%)
• Electrolyte stream (10 lph, anolyte + catholyte to drain) The electrodeionisation process uses a combination of ion-selective membranes and ion-exchange resins sandwiched between two electrodes anode (+) and cathode (-) under a DC voltage potential to remove ions from RO pretreated water. Ion-selective membranes operate using the same principle and materials as ion-exchange resins, and they are used to transport specific ions away from their counter ions. Anion-selective membrane are permeable to anions but not to cations; cation-selective membranes are permeable to cations but not to anions. The membranes are not water-permeable. By spacing alternating layers of anion-and cation-selective membranes within a plate-and-frame module, a ‘stack’ of parallel purifying and concentrating compartments are created. The ion-selective membranes are fixed to an inert polymer frame, which is filled with mixed ion-exchange resins to form the purifying chambers. The screens between the purifying chambers form the concentrating chambers. This basic repeating element of the EDI is called a ‘cell-pair’. The ‘stack’ of cell-pair is positioned between the two electrodes, which supply the DC potential to the module. The influence of the applied DC voltage
Figure3: Process Of EDI
Chemical Engineering World
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EMJAY ENGINEERS, Mr. Jayant Joshi B/102, Shubh Sarita CHS, Near Shrikirshna Nagar, Appasaheb Sidhaye Marg, Borivali (East), Mumbai 400066 Tel. 02228975275 | Mobile 9820047858 E-mail:electromech.engg.entp@gmail.com
CEW Features potential, ions are transported across the membranes from the purifying chambers into the concentrating chambers, it becomes free of ions. This stream is the pure water product. In the concentrate stream, electrical neutrality is maintained. All the streams from the concentrate chamber are combined to form a concentrate header and the concentrate stream outlet is led to drain. The electrolyte stream flow pass the anode and cathode sequentially. Electrolyte waste stream expels the unwanted chlorine, oxygen and hydrogen gas from the respective electrodes. Advantages of EDI over Conventional Deionization System • Consistent quality from 1-18.2 M‘W-cm resistivity or 1-0.057 µS/cm conductivity. • Continuous process, no shutdown required • No regeneration required • Compact size • Low energy • Economic use of capital-saves operating expenses Pure Water Grades and Applications There are many grades of pure water available as defined by various standards. Each grade of pure water is used in a number of applications listed in Table 2. Pure Water Quality Classification It is important to be quite specific about the definition of ‘high purity’ water as often the term is used to describe the range of pure water specifications. Refer Table 3 for pure water quality classification. Feed Water Quality to EDI There are several manufacturers across the globe with different configuration and specifications of EDI module. Each manufacturer specifies the feed water quality entering EDI both recommended for optimum performance and maximum limit, and other operating parameters such as operating and maximum feed pressure, voltage and current drawn. EDI process is always RO fed water. Feed water quality entering EDI module is different for different grades pure water. For example the treated water quality for USP grade water is 1.3 µS/cm, for high pressure boiler, power system 52 • August 2015
Features
Benefits
Small size —10x the surface area of conventional degasifiers
–Compact skids can fit inside of existing buildings –Lower installation costs
Modular like other water treatment components
–Can be easily expanded –Allows for redundancy with multiple contactors
Total gas control
–O 2, CO 2, and N 2 control with one device
Cleanliness
–Quick to rinse
High inlet pressures
–Can eliminate or reduce the number of transfer pumps required
Performance can be accurately modelled
–Quick sizing estimates –Guarantee outlet of < 1 ppb for O 2, < 1ppm for CO 2
Does not require chemicals to operate
–Environmentally friendly and safe for employees
Table:1 Features and Benefits of Membrane Contactor
Type of water
Applications
• Deionised water
Medium pressure boiler feed, renal dialysis make-up, battery top-up
• Purified Water
Pharmaceuticals, cosmetics, chemical manufacturing
• Apyrogenic Water
Vial washing, tissue culture, water for injections
• High Purity Water
High pressure boilers, combined heat and power systems, laboratories
• Ultrapure water
Micro electronics, supercritical boilers
Table:2 Various Grades of Pure Water
it is 0.1 µS/cm and for microelectronics it is 0.057 µS/cm. The lower the ions fed to EDI, the better is the quality. Hence, feed water quality entering EDI for high pressure boiler, power system will be more stringent than for USP grade systems. Feed Conductivity Equivalent and Performance of EDI The performance of EDI is affected by the presence of carbon dioxide and silica in the feed water. The pH of RO permeate is around 5.6 with generation of gaseous carbon dioxide from bicarbonate alkalinity in raw water. Feed water conductivity does not show a complete picture of the total ionic load in RO permeate. Conductivity measurement devices do not detect the full amount of weakly ionised species like carbon dioxide and silica. Both carbon dioxide and silica have weak anionic charge under normal
operation and pH. Due to formation of carbonic (H2CO3) and silicic acid (H2 SiO3) they are weakly adsorbed by the resins and the applied voltage has little driving force. High levels of carbon dioxide will increase the working section of the module and the polishing section decrease. For better EDI performance, the polishing section has to be large which will aid the removal of different ions such as carbon dioxide and silica. EDI systems are therefore designed based on feed conductivity equivalent (FCE) value. Calculations for Feed Conductivity Equivalent (FCE): FCE = Feed conductivity (µS/cm) + 2.79 (CO2) ppm + 1.94 (SiO2) ppm For Example: Feed conductivity : 5 µS/cm Carbon dioxide : 4 ppm Reactive silica : 0.5 ppm FCE = Feed conductivity (µS/cm) + 2.79 Chemical Engineering World
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CEW Features Pure water type
Conductivity µS/cm at 25 oC
Maximum Micro Organisms CFU/ml
Maximum Total Dissolved Solid (TDS) mg/l
Pyrogens (Endotoxins) EU/ml
Reactive Silica µg/l as SiO 2
Total Organic Carbon (TOC) mg/l as C
Deionised
20.0
not specified
10
not specified
500
not specified
Purified
1.3
100
1
not specified
100
<0.5
Apyrogenic
1.3
0.1
1
0.25
100
0.05 – 0.07
High Purity
0.10
1
0.5
not specified
20
not specified
Ultrapure
0.057
1
0.005
not specified
2
0.05
Table3: Pure water quality classification
(CO2) + 1.94 (SiO2) = 5 + 2.79 (4) + 1.94 (0.5) = 5 + 11.16 + 0.97 = 17.13 µS/cm
FCE is in the working range (< 33 µmS/cm) but outside optimum range (< 9 µmS/cm 9). Hence, it is important to reduce the carbon dioxide and silica content entering into the EDI unit. Removal Of Carbon Dioxide In RO Permeate: Carbon dioxide in RO permeate is removed by the following methods • Caustic dosing in the pretreatment to RO so that RO permeate is around 7.0. At pH 7.0 the carbon dioxide level is approximately 1 – 2 ppm. • Degasification using Liqui-cel membrane contactors. They are basically hydrophobic hollow fine fiber membranes and are installed in the RO permeate outlet. The carbon dioxide is brought down to 1 – 2 ppm. Final Treated Water Quality from EDI: The final treated water quality from EDI will vary between 1 – 18.2 mega-ohms-cm resistivity. The quality from EDI Module depends upon several factors as follows • System design and engineering of ultrapure water system. • Designing the system at optimum/ maximum feed water limiting conditions to EDI. The lower the feed quality to EDI, the better is the output quality. • Proper instrumentation and controls. • Removal of all constituents such as hardness, iron, particulate matter, carbon dioxide, organics, and oxidising agents. 54 • August 2015
• Pressure drop across system. • Proper operation and maintenance of RO & EDI system. • Pure DC power supply. There is always a trade-off in designing RO/EDI systems whether to design RO with a single pass with high feed quality (greater than optimum level) in which case EDI performance gets affected or double pass RO which will increase system cost but will give consistent and satisfactory performance of EDI. Applications EDI produces treated water quality conforming to the following applications • Pharmaceutical industries • Automobile industries • Power stations • Boiler feed water • Process industries • Laboratories for process water Power Consumption A typical EDI module operating at 2 m 3/ hr will require 300 VDC and draws 2 Amps. The Power Consumption can be calculated as follows :
DC Power (Watts) = Voltage (VDC) x Current(Amps) =300 VDC x 2.0 Amps. = 600 w There is some power loss at the power supply during the conversion from AC to DC. Assuming power supply efficiency is typical 85% (15% losses)
AC Power =
DC Power 0.85
= 600w x 1kw 0.85 1000w
= 0.7 kw
Energy KWH = AC Power x Time (kw) x 24 Hrs. = 0.7 kw x 24 Hrs.
Power cost/m 3 of treated water
= 16.8 kwh
= 0.7kw 2 m3 =0.35 kw/m 3
Conclusion Meeting the water specifications of boiler feed water is a challenging task. The unique properties of Membrane Contactors and Electropure EDI modules allow them to be installed in almost any location in high purity water system. Membrane contactors can deliver 1 ppb of dissolved oxygen and 1 ppm carbon dioxide while EDI module can produce up to 18.2 Mega-ohms-cm resistivity water. Other benefits include redundancy, system stability and versatility which allow the end user to incorporate these well-established technologies. Authors’ Details Pinakin J Sampat Technical Adviser and Consultant Evergreen Technologies Pvt Ltd Mukesh C Khagram Director Evergreen Technologies Pvt Ltd info@evergreenindia.com Chemical Engineering World
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CEW Market Insights
India, Most Important Market Globally for Vacuum Pumps Italvacuum has its presence in India since 1995 and has been consistently serving the Indian industry with high quality pumping solutions be it for the pharmaceutical, specialty chemicals or any other industry. On the backdrop of ACHEMA, Paolo Santi, Marketing – Manager, Italvacuum and Jayant Joshi, EM Jay Engineers spoke to CEW about how Italvacuum remains a cut above the rest of the competition with its high quality products, latest technologies and how the Indian market makes up 40 per cent of the vacuum pumps sale for the company.
I
talvacuum has been in India for the last two decades now and had appointed Jayant Joshi as their agent in the Indian market. Despite the turmoil in the market in the past decade, the company has seen growth as high as 20-25 per cent year-on-year. The company has had a large presence in the pharmaceutical sector among others, be it fine chemicals, agrochemicals, in the country. Joshi states, “Italvacuum has a strong network of service which has been one of the crucial aspects for better market penetration.” When asked how the company supports its India operations in terms of products, technology and training Paolo Santi replied, “Firstly, we take care of the technical systems. After we have put them in place, we arrange for two customer trips every year and believe in assisting customers to resolve any kind of issues they could be facing.” He added that on the technology front, the company is especially in the vacuum pumps sector and are trying to penetrate more the Indian market with vacuum dryers. Challenges Faced in the Emerging Markets – India and China There are a few challenges that the company faces related to costcompetitiveness and technology. Italvacuum’s products offer high quality and technology and few companies find that the products are expensive. What they fail to understand is that the customer is making an investment in technology which will serve them well rather than choosing locally produced products that are not high in quality. This is a problem in China as well since the number of local manufacturers in China and India is quite high. The local industries in both these industry have to be made aware of the fact that although the local manufacturers produce good products, they are not always high quality. Another common trend in markets like India and China is reverse engineering, and this risk does exist but Santi is confident of Italvacuum’s internationally patented products and its long experience and know-how in vacuum process applications. Crucial Markets with Growth Opportunities Santi states that in Europe, Italvacuum is majorly focused on Italian, German, French and Spanish markets. Talking about Eastern 56 • August 2015
Europe, Paolo explained, “The company has begun seeing the results of the on-going promotion with several new installations in the last 5 years. In Asia, India is the most important market for Italvacuum especially for the vacuum pumps. As a matter of fact, the India market is the most important market globally as almost 40 per cent of the vacuum pumps sale is done in India and the installations for this will be increased. The company also has its presence in Singapore, Malaysia, Thailand and South Korea. Joshi adds, “South East Asia will be the market we will focus on in the near future, especially Myanmar, Vietnam and Indonesia. Make In India Campaign Santi asserts, “Italvacuum is not thinking of manufacturing locally in the near future. It has a manufacturing facility in Italy with a well-established system of suppliers/ vendors. The co-operation between Italvacuum and EM Jay Engineers is bringing great results and our sales have been increasing all through the years.” Joshi adds, “We offer cutting-edge technology with very high technology equipment and the machines that we provide last for almost 10-15 years without any maintenance requirement”. Paolo concludes, “At present, for Italvacuum the main issue is improving the technical assistance that it can offer its customers and not on investing in manufacturing facilities in emerging markets like India and China.” To this Joshi adds that the target that the company is looking at is of almost 30 per cent growth year-on-year.
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RCF’s Saves Mumbai’s Water
E
xisting Sewage Treatment In the days when most of the companies are being charged with gobbling natural resources, RCF has set an example for other companies. RCF has gone ahead and established a unique plant in which it takes sewage from Ghatkopar sewage station, a site away by 5km from the factory and treats it in a 5 million gallons per day (MGPD)Sewage Treatment Plant that has a dual purpose. Firstly, this project helps to dispose 950 cum/hr of sewage and secondly, it reduces the pressure on BMC’s water supply system by 3 MGPD. RCF’s Sewage Treatment Plant is one of the many initiatives undertaken to help the city protect to its environment and conserve its scarce natural resources. The vision of RCF can be gauged by the fact that very few projects of this capacity exist in the country. The sewage treatment plant cost RCF ` 39.30 Crores in 1999 and it uses modern reverse osmosis technology from AQAUATECH, USA. Though it was established way back in 2000, RCF as always has been modest in its achievement. So far in nine years 8100 Million gallons has been treated by RCF. The raw material i.e, sewage water from Mumbai Municipal Corporation is pumped from Ghatkopar Sewage Station which is 5 km away. RCF has laid down the pipeline for getting sewage from Ghatkopar station up to its Trombay plant at its own cost. RCF also pays MCGM for the sewage it buys from MCGM. The plant is designed in two streams and is capable of handling 475 M3/hr. of flow into the storage tank. After the storage tank, the plant is designed in two streams, each with a capacity of 325 m3/hr. The reclaimed water of desired quality is stored in a 10,000 M3 open storage tank and pumped to various plants through a dedicated piping network. The quality of water thus produced is superior than the local potable water supply. The plant treats 18.95 million litres (ML) of sewage and generates approximately 11.37 million litres of pure water each day and saves the equivalent amount of potable water for the city. This is sufficient to take care of needs of 25,000 families in the city of Mumbai. The treated water is then used for several purposes in our plants. The plant also produces approximately 1.4 Tonnes Per Day of fertiliser which is used as a manure the gardens. Buoyed by the success of this plant, RCF is planning to setup one more sewage treatment plant at Trombay. New Sewage Treatment Plant Rashtriya Chemicals and Fertilizers Limited (RCF) and Bharat Petroleum Corporation Limited (BPCL), two leading Public Sector Undertakings have entered into Memorandum of Understanding to set up a Sewage Treatment Plant (STP) at RCF, Trombay. The Sewage Treatment Plant shall be named as RCF-BPCL Sewage Treatment Plant. The RCF-BPCL Sewage Treatment Plant will be based on latest Membrane Bio-Reactor Technology with design capacity to treat 22.75 Million Litres per Day (MLD) of Municipal Sewage to produce about 15 MLD of treated water. The treated water shall be shared by RCF and BPCL. The project is being set up with an active support from Municipal Corporation of Greater Mumbai (MCGM). 58 • August 2015
RCF Mumbai 14th Nov. 2014 : Union Minister for Chemicals & Fertilizers Ananth Kumar laying foundation stone of RCF - BPCL Sewage Treatment Plant on 14-11-2014 in presence of Chief Minister of Maharashtra Devendra Fadnavis, Secretary (Fertilizers) Jugal Kishore Mohapatra, IAS, Rajiv Yadav, IAS, SS & FA, R G Rajan, Chairman & Managing Director, RCF & other dignitaries of RCF & BPCL
This project is a Sustainability Development Project as it will treat waste sewage generated in the city and convert it in to treated water. This project, which will be a first project being set up by two PSUs located nearby. The said project when operational will also reduce the load on MCGM Sewage Treatment facility to the extent of 22.75 MLD The said project when goes on- stream will generate 15 MLD of treated water for usage in plant operation. RCF and BPCL thereby saving fresh water intake to that extent which will benefit about 30,000 families in the city of Mumbai. Being sustainable development project, RCF-BPCL STP will be of great value to residents of Mumbai and Society at large, besides being beneficial to both RCF and BPCL. The estimated cost of the project is about ` 200 Crore. BPCL shall provide 40 per cent of the Project Capital Cost by way of interest free deposit. The project will be put into operation within 28 Months from the award of Contract. RCF is already operating one STP of similar capacity for last 15-years and new STP will double the generation of treated water from sewage.
• • • • • • • • •
Project being set up by RCF and BPCL Sustainability Development Project Supported by Municipal Corporation of Greater Mumbai Shall save 15-MLD of fresh water for residents of Mumbai. Project Capital Cost: ` 200 Crore Municipal Sewage intake-22.75 MLD Treated water generation- 15 MLD Process: Membrane Bio-Reactor (MBR) Improved reliability for RCF and BPCL
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Marketing Initiative
Accurate Flow Measurement for Drinking Water, Waste Water, Industrial Applications
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vaporative cooling towers are key components in the effective operation of plants in the electric power, industrial process and manufacturing industries. They also are essential in the heating, ventilation and air conditioning (HVAC) systems that provide climate control in large facility complexes, such as educational and corporate campuses; casinos, hotels and convention facilities; data centres, and government, research and medical buildings The proper control and treatment of cooling water is essential for efficient, safe and economical operations. Chemicals are fed to these systems that protect against fouling, corrosion and microbiological contamination. The proper dosage of these key chemicals is determined by having accurate information on the system make-up and blowdown water. To achieve effective cooling through the cooling tower, it is necessary to maintain proper design flow through the cooling tower and thus provide adequate cooling of the system. Insufficient cooling water can affect critical equipment or building climate control. Accurate flow meters are the most effective tool to achieve reliable flow results and control system costs. Here are three ways to optimise cooling water management with flow metres:
Tip 1: Install a flow metre at the plant water intake source, which can turn the metres submetres. Comparing the flow data on all three lines helps identify potential water leaks and determine the system water balance plus other system issues. Tip 2:Install flow metres upstream from pumps to provide flow data alerting the system to low flow situations leading to potential pump problems caused by low flow conditions. Otherwise, the result can be expensive pump repairs or even system shutdowns. Tip 3: Accurate flow information collected from both the blowdown and make-up water lines can be used to calculate rates for evaporation, cycles of concentration and cooling water chemical treatment rates. Tracking these related factors is important to the assessment and improvement of a system's water treatment program. For example, maintaining the highest cycles of concentration can offer significant savings on cooling water treatment costs. Having accurate blowdown and make-up flow rate data is essential in achieving this goal. The flow data translates into savings on chemicals, sewage fees and associated energy costs related to cooling water usage. Flow Metre Technologies Different flow meter technologies have their advantages and disadvantages, depending
on the fluid and application. Cooling tower and HVAC systems require the ability to measure flow to +0.5 per cent accuracy in high instrumentation is tight, and low maintenance and long life are essential. McCrometer's FPI Mag Electro Magnetic Flow Metre meets the accuracy requirement in water for cooling tower service with its accurate sensing across the full diameter of the pipe. The metre installs without cutting pipe, welding flanges, de-watering lines or interrupting service. This reduces installation time and costs by up to 45 per cent over traditional full pipe flow meter installations. Conclusions When choosing a new or replacement flow metre for service in cooling tower systems, be sure to consider the metre's accuracy, ease of installation, maintenance requirements and life of the instrument. Flow measurement at multiple points in cooling tower and HVAC systems is a best industry practice to minimise: water consumption, energy expenses, the cost of water treatment consumables and repairs to pumps and other equipment. Toshniwal Hyvac Pvt ltd 267,Kilpauk Garden Road Chennai - 600010 T: +91 44 26445626 / 8983 E: sales@toshniwal.net W: www.toshniwal.net
Mag Meters 60 â&#x20AC;˘ August 2015
Chemical Engineering World
Marketing Initiative
Switch to Grundfos Boosters for Optimal Water Pressure at Home
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he Grundfos Home Booster is a compact and cost-effective solution for water pressure boosting in homes. Its self-contained and neat size makes it ideal for a range of domestic installations where space is at a premium. These self-contained water booster sets, have been specifically designed for domestic services where the existing overhead storage tank is insufficient to meet the demand requirements of pressurised water supply systems. The Home Booster is suitable for most domestic applications that run simultaneously, such as standard showers, taps, washbasins and other normal household appliances in the same pressure. Another important benefit is that the installation is straight forward – it just requires a connection of the water supply, discharge pipe, overflow pipe and electrical connections. These sets are typically installed near to the overhead storage tank. For larger properties, there are a range of alternatives that could be considered including the Grundfos Twin Booster systems. In India, the Home Booster has been designed and developed by Grundfos specifically to meet the demands of the Indian market and these units are built in the country as well. Commenting on the Home Booster, Venkataramanan Vishwanathan, Head – Domestic Building Services, Grundfos India, said “With the increasing demand for water to meet a range of applications simultaneously, many households are facing an acute shortage in obtaining a constant water pressure. Being a market leader of booster pumps in the country for over 15 years, the Grundfos Home Booster has helped find a solution for this hidden problem. Their efficiency and performance is the best in range, delivering the precise pressure as per the requirements”. About Grundfos India: Grundfos Pumps India Pvt. Ltd. (Grundfos India) a wholly owned subsidiary of Grundfos Holdings was established in March 13, 1998. Grundfos India is responsible for sales of Grundfos products in India, Bangladesh, Bhutan and Maldives. Currently, Grundfos India has more than 250 employees and works with 200 distributors and dealers with 20 offices across India. Grundfos India provides energy efficient pumps and smart pumping solutions for various applications – heating and hot water service systems, cooling and air-conditioning systems, industrial applications, pressure boosting and liquid transfer, groundwater supply, domestic water supply, sewage and wastewater, dosing, chlorination systems, disinfection systems and pumps running on renewable energy. For more information, visit: http://www.grundfos.in/ Chemical Engineering World
August 2015 • 61
Marketing Initiative
ARC Advisory Group’s 13 th India Forum
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RC Advisor y Group's thir teenth India Forum for the process and discrete industries, titled Industry in Transition: The Infor mation Driven E n t e r p r i s e fo r t h e C o n n e c t e d Wo r l d from July 09-10, 2015, Bangalore, India attracted over 300 delegates. This two day forum was structured to disseminate information and technology effectively and provide end users, solution providers a n d d e c i s i o n m a ke r s a n o p p o r t u n i t y and platform to network and understand the market requirements and dynamics. The forum's focus was on maximising productivity and increasing retur n on investment (ROI) by channelising relevant information and investing in technologies. The session topics covered advancement in digital enterprise; challenges in automation, digital connect and asset infor mation management; strategies to achieve business performance enhancement; strategies to achieve operational excellence; and strategies for growth. Keynote presentations, which set the tenor for the day were given by Dr Valentijn, Vice President, ARC Advisor y Group Europe; KS Viswanathan, Vice President, NASSCOM; Ar undhati Bhattachar ya, General Manager, NTPC; Gautam Dutta, Director-Mar keting, Siemens Industr y Software India; Harish Mehra, Global Head - Manufacturing Operations Management, Engineering & Industrial Services, TCS; and Suresh S, General Manager – South, Rockwell Automation. Besides the supplier presentations and case studies ARC had invited speakers from the pharmaceutical, chemical and steel industries too. Today’s manufacturers face increasing demand for better quality and zero defects, while costs have to be maintained. The end user perspective gave a whole new dimension to the forum as it
62 • August 2015
showed how products and solutions have been successfully deployed. The end user presentations substantiated the claims of the suppliers. When a supplier talks about his product/solution it seems like marketing spiel; but when an end user endorses it, the supplier’s credibility in the market rises. And through actual user experiences and statistics the technology gets market visibility and acceptance. The well attended two-day forum made it clear that to remain competitive and achieve operational excellence, organisations must sift through the information glut and adopt appropriate technologies. The presentations made it clear that adopting new processes and technologies is not an option - it is mandatory to achieve operational excellence and sustainability. When competition and markets are global, companies must become collaboratively networked enter prises, managing dispersed centres of technology, engineering, production, and resources. Systems need to be flexible and ready for business change. In addition to a host of new and sometimes disruptive technologies entering the marketplace, companies must also face rapid changes in government regulations, energy and raw materials availability, markets, and competition. By deploying leading edge information technologies, today’s companies can thrive.
technologies, such as cloud computing, mobility, social technologies, Inter net of Things, Big Data/analytics, and 3D visualisation. Information driven digital enterprises leverage new technologies to achieve agility and sustain a competitive edge. All these were discussed at the ARC forum. ARC received support from: Fo r u m S p o n s o r s – S i e m e n s ( G l o b a l Sponsor), TCS (Gold Sponsor); and our Silver Sponsors – Bentley, FDT Group, GE, Mitsubishi Electric, Rockwell Automation, Schneider Electric, and STEAG. Industry Association Sponsors - AIA, CIO Forum, CSIA, Indian Profibus Profinet Association (IPA), and TechPro. Media Sponsors – A&C Today, A&D, Chemical Engineering, Chemical Engineering World, Chemical Industry Digest, Control Engineering Asia, Engineering Review, Industrial Products Finder, Industrial Automation, Manufacturing Today, MMI India, OnWindows, Pharma Focus Asia, Pharmaceutical-Tech.com, and Process Worldwide.
The major challenges confronting organisations are how to improve their processes and infrastructure to compete on a global turf. The buzzwords for success in today's competitive market place are greater agility, flexibility, responsiveness, and innovation. Market forces, such as globalisation, resource constraints and environmental concerns, changing demographics, and IT trends are influencing manufacturing companies and their dynamic market ecosystems and value networ ks. It is imperative for industries to adopt new information
Chemical Engineering World
Products CEW Diaphragm Vacuum Pumps & Compressors Diaphragm vacuum pumps/compressors are completely oil less with continuously rated built-in meter. These are preferred due to their minimal maintenance and compact size as compared to sliding vane type vacuum pumps and reciprocating piston type air compressors. In reciprocating motion, with a short stroke, the diaphragm at the top of the connecting rod flexes up and down in a closed chamber, creating pressure or vacuum. Even at maximum duty, output air is cool and oil-free. As ambient air enters and leaves the head, it never goes near the motor to pick up heat and foreign matter. Cooler temperatures add to overall efficiency and service life. The connecting rod is bonded to its bearing, not clamped as in light duty pumps, ensuring greater strength and durability where work loads are greatest. For details contact: Shree Siddhi Vinayak Industries Plot No: 19 Kashimira Indl Estate Post Mira, Mira Road Dist: Thane, Maharashtra 401 104 Tel: 022-28457073 | Fax: 91-022-28458372 E-mail:response@minivacpumps.com / response@cuumcleanerindia.com or Circle Readers’ Service Card 1
Pressure Transmitter The M5100 Series from Measurement Specialties sets the price/performance standard for transducers used in demanding environments. The M5100 exceeds the latest heavy industrial CE requirements including surge protection and is over-voltage protected to 16 V DC in both positive and reverse polarity. The pressure port is machined from a solid place of 17-4PH stainless steel (316L optional). There are no O-rings, organic or weld exposed to the pressure media. This allows for a leakproof, all metal sealed pressure system, which withstands more than 10 million pressure cycles without failure. It finds application in advanced HVAC controllers, refrigeration systems, automotive test stands, gas compressors, industrial process control, pumps and compressors, hydraulic/ pneumatic systems, agriculture equipment, energy and water management industries: engine and vehicle, general industry, medical, etc. For details contact: Jupiter Electronics A-401 & G-414-416 Kailash Indl Complex B/h Godrej Colony, Parksite, Vijhroli (W), Mumbai 400 079 Tel: 022-67551606, 25185474 Fax: 91-022-25170867 E-mail: sales@jupiterelectronics.co.in or Circle Readers’ Service Card 2
Chemical Engineering World
August 2015 • 63
CEW Products Four-point Suspended Centrifuge Four-point suspended centrifuge with trolley mounting are available from 12” to 36” dia giving a cake load of 170/200 kg per batch maximum. Manual dome opening available up to 24” dia. The machine can be easily taken from one place to another.
Seals The seal can accommodate up to +/- 2 mm (+/- 0.080”) axial movement. The seals spring is all located in the seals stationary housing. The fluid supply to the seal cools, cleans and lubricates all components.
Safety features includes nitrogen blanketing system; zero speed interlock; vibration tripper; and FLP lid and dome sensor.
The CS18D seal is suitable for abrasive and effluent liquids. The most typical applications are cooking, evaporation and carestizing plants in pump mills. In addition to process pumps, the seal can be used for other process equipment such as agitators, etc.
For details contact: Ace Industries (India) Pvt Ltd 113 Alpine Indl Estate Marol Military Road, Andheri (E) Mumbai 400 059 Tel: 022-42258000, 29201763 Fax: 91-022-29204939 E-mail: ace_centrifuges@yahoo.co.in
For details contact: Chem Seals Engg Pvt Ltd 10 Sidhapura Industrial Estate, Gaiwadi Lane Off S V Road, Goregaon (W), Mumbai 400 062 Tel: 022-28712765, 28772286 Fax: 91-022-28785876 E-mail: chemseals@chemseals.com mktg@chemseals.com / sales@chemseals.com
or Circle Readers’ Service Card 3
or Circle Readers’ Service Card 4
Clean Room High-speed Doors Gandhi Automations Pvt Ltd offers clean room high-speed doors - Prime Clean. A clean room is an environment typically used in manufacturing and scientific research with a low level of environmental pollutants such as dust, airborne microbes, aerosol particles and chemical vapours. Simply put a cleanroom has a less or no level of contamination. It finds use in the pharma industry, which require the environment to be free from microbial and particulate contamination and protected from moisture-controlled environment. Clean room high-speed doors are high in demand in industries such as pharma and chemical, which require quick open and close applications at the entry and exit points as controlled environment needs to be maintained. These industries make high demands with respect to hygiene, sealing, operating reliability, fitting and a trouble-free aftersales service. Clean room high-speed doors are designed for inside applications and protects your environment against draughts, humidity, dust and dirt. Operating speed and superior sealing properties improve traffic flows and provide environmental control and savings on energy costs. Concept of low air permeability in pressurized rooms with positive and negative air pressure. High leak tightness is due to curtain being tightly integrated in special SS-316 satin finish side guides. Bottom safety edges and photocells combine to ensure operator safety at all times. For details contact: Gandhi Automations Pvt Ltd 2 nd Floor, Chawda Commercial Centre Link Road, Malad (W), Mumbai 400 064 Tel: 022-66720200, 66720300 | Fax: 91-022-66720201 E-mail :sales@geapl.co.in or Circle Readers’ Service Card 6
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Chemical Engineering World
Products CEW Solar Powered Pumps KSB Pumps Ltd offers KSBSol which is a submersible pumpset with high energy efficiency and suitable to run using solar power. KSBSol pumpsets are centrifugal pumps in radial and mixed flow type construction coupled with AC motors and are specially designed and matched to the requirements of solar pumping applications like drip irrigation, sprinkler irrigation, water supply, etc. Pumpsets are capable to work under low sun intensity. Motors are suitable to work with VFD/MPPT controller. These pumpsets are suitable for borewells of sizes 100 mm and above. These pumpsets are designed using the proven German technology and manufactured at Sinnar, near Nashik. These KSBSol pumpsets in the first phase are available up to 5-HP motors which can deliver heads up to 65-m and flow up to 1,26,000 liters per day. Other customized models are also offered from KSB’s wide range up to 150 HP. For details contact: KSB Pumps Ltd Mumbai-Pune Road, Pimpri Pune, Maharashtra 411 018 Tel: 020-27101000 E-mail: Rameshwar.sonawane@ksb.com or Circle Readers’ Service Card 7
Diaphragm Valves Custom valve types may be welded tandem valve assemblies, machined from solid block types or manifolds that incorporate both technologies. Tandem valves (sterile access valves) are designed to optimise drainability and meet process design requirements for minimum dead legs. A main valve is ported and a second access valve is welded to the main valve to create a tandem cluster. The machined tandem is a variation of the serial weir family. The machined form solid tandem valve type offers several adventages over the welded tandem. Configuration of optimum process fabrication presents system designers with an ongoing challenge. Minimum space envelope, reduced hold up areas, reduced cost and facilitating ease of installation are all key considerations. For details contact: Crane Process Flow Technologies (India) Ltd Solitaire, 5th & 6th Floor S No: 131/1+2 ITI Road Aundh, Pune Maharashtra 411 007 Tel: 020-30567800 Fax: 91-020-30567812 or Circle Readers’ Service Card 8
Chemical Engineering World
August 2015 • 65
CEW Products Micro Centrifuge
Advanced Liquid Advanced Liquid Ring Technology
Ring Pumps
Micro centrifuge is microprocessor-controlled with last run memory feature. It has a large backlit LCD display that shows multiple parameters at a time; brushless DC motor delivers better power to weight ratio and fit for extended runs; imbalance detection with auto cut-off; better airflow design ensures lesser heat generation and less noise; lid lock safety – lid opens automatically on run completion; intuitive simple interface for quick and convenient setting; 1 to 999 minutes countdown timer with min sec display; one touch short - spin operation; extremely compact saves valuable bench space - suitable for use in fume hoods or cold rooms; unique airflow design ensures lesser heat generation and less noise; rotor, inner centrifuge lid and lid latch are made of metal for maximum operational safety. settable RPM/RCF; etc.
Pompetravini’s experience in manufacturing of liquid ring vacuum pumps acquired over the years has led to the creation of new improved liquid ring pumps that offer optimum performance and reliability They offer minimal water consumption and an innovative impeller design that assure extremely Pompetravini’s experience in manufacturing of liquid ring quite operation and extending its life even under vacuum pumps acquired over 70 years has led to the creation of new improved liquid ring pumps that offer harsh condition. optimum performance and reliability They offer minimal water consumption and an innovative impeller design that assure extremely quite operation and extending its life even under harsh condition. Pompetravaini has the most advanced manufacturing process with the objectiveb to reduce manufacturing times, shortening delivery times.
Pompetravaini has the most advanced manufacturing process with the objective to reduce manufacturing and delivery time. Toshniwal leader in vacuum engineering now provide further solution to your vacuum Toshniwal leader in Vacuum Engineering over 40 years, now provide further solution to your vacuum needs. needs. For Details contact:
Toshniwal Instruments (Madras) Pvt. Ltd.
For details contact: Toshniwal Instruments (Madras) Pvt Ltd 267 Kilpauk Garden Road Chennai 600 010 Tel: 044-26448983, 26448558 Fax: 91-044-26441820 E-mail: sales@toshniwal.net
267 Kilpauk Garden Road, Chennai - 600 010. India / Tel: +91(0)44 26448983 / 8558 Fax: +91(0)44 - 26441820 / Email: sales@toshniwal.net
For details contact: Remi Sales & Engg Ltd Remi House, 11 Cama Indl Estate Walbhat Road, Goregaon (E), Mumbai 400 063 Tel: 022-40580999, 26851998 | Fax: 91-022-40589890 E-mail: sales@remilabworld.com or Circle Readers’ Service Card 9
Web : www.toshniwal.net
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Energy Efficient & Intelligent Pumping Solutions With its energy and water efficient pumps along with remote management systems, Grundfos’ solutions can also provide the solution for monitoring these networks. Grundfos’ Demand Driven Distribution is a solution aimed at addressing the water pressure issues, directly at the consumer’s end. This solution is based on multi-pump operation at proportional pressure, where the system is designed to supply precisely the flow needed at the pressure required, with a number of pumps running at best efficiency point, instead of one big pump. Along with a good system for water supply, Grundfos’ sewage pumps are efficiently designed for applications such as transfer of unscreened raw sewage and raw water, pumping of water containing sludge and industrial effluents. Grundfos has identified and understood the role of internet technology for smart cities and has already implemented technological intelligence in its pumping solutions across the world, through Grundfos Remote Management. This Remote Management tool is a secure, internet-based system for monitoring and managing pump installations in commercial buildings, water supply networks, wastewater plants, etc. Considering Grundfos’ focus on sustainability, the company’s pumps are designed to provide optimal energy efficiency throughout its lifecycle. With the problem of increase in demand and limited resources to fulfill the demand becoming a reality, Grundfos pumps provide the right solution by ensuring minimum utilization of energy and water while delivering peak results. Grundfos also has an impressive range of solar pumps which help overcome the dependence on grid power for water supply. For details contact: Grundfos Pumps India Pvt Ltd (Grundfos India) 118 Rajiv Gandhi Salai, Thoraipakkam, Chennai 600 097 Tel: 044-45966800 Fax: 91-044-45966060 E-mail: sales@grundfos.com / mahathi@grundfos.com or Circle Readers’ Service Card 11
66 • August 2015
Chemical Engineering World
ChemTECH Chennai 2015 Dates: 10-12 December, 2015 Venue: TNTPO, Exhibition Ground, Chennai Details: World meet of chemicals, petrochemicals, pharma and process industry in India encompassing exhibition and conferences. Contact: +91 22 40373636 Email: sales@jasubhai.com Website: www.chemtech-online.com ChemTECH Gujarat 2016 Dates: 10-12 February, 2016 Venue: Ahmedabad, India Details: World meet of chemicals, petrochemicals, pharma and process industry in India encompassing exhibition and conferences. Contact: +91 22 40373636 Email: sales@jasubhai.com Website: www.chemtech-online.com
2015 SNO Conference Dates: 8 - 10 November, 2015 Venue: Portland, USA Details: This year’s SNO conference sessions will be organized around selected ‘systems’, eg, air-water systems Organiser: Sustainable Nanotechnology Organization Email: info@susnano.org Website: http://susnano.org/ POWTEX OSAKA 2015 Dates: 14-16 October, 2015 Venue: International Exhibition Centre, Osaka (INTEX) Details: The 11th Powder Technology Exhibition Osaka Organiser: The Association of Powder Process Industry & Engineering Contact: +86 10 6422 2898 Email: info2015@powtex.com Website: www.intex-osaka.com
MSME Sumit 2015 Dates: 18 September, 2015 Venue: Federation House, New Delhi Details: ‘Make in India: MSME Perspective’; Understanding the preparedness of MSMEs towards Make in India and the way forward; Bridging the skill demand and supply gap Organiser: FICCI - CMSME Contact: +91 11 23487260/ 7307 Email: cmsme@ficci.com Website: www.ficci.com Chemspec 2016 Dates: 7-8 April, 2015 Venue: Bombay Exhibition Centre, Mumbai Details: Meeting and networking with existing and potential partners and business facilitators Organiser: Quartz Businesss Media Ltd, Contact: +91 22 240 44472 Email: rohit@chemicalweekly.com Website: www.chemspecevents.com Chemical Engineering World
Biorefinery I Dates: 27 Sept - 2 Oct, 2015 Venue: Chania (Crete), Greece Details: An event on chemicals production from renewable resources Organiser: Engineering Conferences International Contact: 1 212 514 6760 Email: info@engconfintl.org Website: www.engconf.org Plastics Recycling Show 2015 Dates: 25-26 November, 2015 Venue: Belgium Details: European exhibition & conference for plastics recycling Organiser: Engineering Conferences International Contact: +32 2 742 96 82 Email: info@plasticsrecyclers.eu Website: www.plasticsrecyclers.eu August 2015 • 67
CEW Project Update
New Contracts/Expansions/Revamps The following list is a brief insight into the latest new projects by various companies in India. • CHEMICALS 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 Polyphosphate (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, 0.30TPM 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 79.5-cu 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. Astrica Laboratories is implementing a 240-TPA synthetic organic chemicals manufacturing project at a cost of ` 78.8-million in village: Ananthsagar, district: Medak, Telangana. Team Labs & Consultants are the environmental consultants. The project will come up on 6.97-acre of land. According to MoEF sources, it is proposed to treat all HTDS effluent in stripper followed by MEE and ATFD. All LTDS effluent including domestic effluent shall be treated in biological treatment followed by RO system. RO rejects sent to MEE and permeate is used for cooling towers as make up. Solid wastes are generated from the process, solvent distillation, collection/neutralization tank, waste oil from DG sets, used batteries from DG sets. The ash from boiler is sold to brick manufacturers. The solid wastes; evaporation salts, wastes from the process in inorganic form, ie, process salts and filtration aids shall be disposed to the TSDF, while the hazardous wastes of organic nature, i.e, distillation residues shall be disposed to authorized cement units and other wastes like used oil and 68 • August 2015
used batteries shall be sent to authorized recyclers. The sludge from treatment plant shall be sent to TSDF. The basic technology involved in the manufacturing of bulk drugs is the process kettles, heat exchangers, centrifuges and storage tanks. To support the process, equipment boilers, chilling plants, cooling towers, etc, are required. All the above equipment can be sourced indigenously. 80 per cent of civil work has been completed and remaining 20 per cent is in progress. The project is scheduled for completion in December 2015. 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. Lakhani Dyestuffs is implementing a 100-TPM reactive dyes manufacturing project in MIDC, Ambernath (W), district: Thane, Maharashtra. Environmental clearance has been received for the project. Land has been acquired and civil work is in progress. The project is scheduled for completion in H2 2015. 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. Superhouse is planning an expansion of its chemical mixmanufacturing project from 200-kg/day to 500-kg/day in UPSIDC Industrial Area, district: Unnao, Uttar Pradesh. The product will be used in leather tanneries. The project will involve installation of containers. The project is in planning stage. Stellar Chemical Laboratories is planning an expansion of its organic chemical manufacturing project from 7.1-TPM to 84.1-TPM in village: Derol, district: Panchmahals, Gujarat. Machinery is yet to be ordered. Work on the project is expected to commence after receipt of environmental clearances and the completion date is yet to be finalized. • MINING 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. Bharat Coking Coal is planning the Pootkee Balihari coal mining project in district: Bokaro, Jharkhand. Tenders have been floated for Chemical Engineering World
Project Update CEW development of Pootkee Balihari project and extraction of coal from Pootkee Balihari project, Pootkee Balihari area by mass production technology package for a minimum guaranteed production of 8.1 -million tonne of coal during 9 APP subject to maximum 1.04-million tonne of coal in any one year (APP) on turnkey basis. Work includes additional exploration (if desired so by the contractor); preparation of mining plan, detailed Project Report and obtaining approvals from concerned authorities. The last date for submission of bids is 21st September, 2015. 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 in December 2015. 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 semimechanized 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. Barmer Lignite Mining Company, a JV between Rajasthan State Mines & Minerals & Raj West Power, a subsidiary of JSW Energy is planning an expansion of the Kapurdi Open Cast Lignite Mining project from 3.75-MTPA to 7-MTPA in Kapurdi, district: Barmer, Rajasthan at an estimated cost of ` 18,000-million inclusive of a new lignite mining project at Jalipa mines. The project is waiting for environmental clearance. â&#x20AC;˘ NON-CONVENTIONAL ENERGY Hubli Electricity Supply Company is planning solar RTPV grid connected power plants in district: Belagavi, Karnataka. E-tenders have been floated to design, manufacture, supply, installation, testing and commissioning of solar RTPV grid connected power plants on the roof-tops of 31 of 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. Kranthi Edifice is implementing a 20-MW solar photovoltaic power project in village: Tadoor, district: Mahabubnagar, Telangana. The estimated cost of the project is ` 1.2-billion. The project is being set up on 100-acre of land. Equipment supplier is under negotiation. Civil work is done in-house. Power generated will be sold to Telangana State Transmission Corporation (TSTRANSCO). The project is scheduled for completion in September 2015. Karnataka Renewable Energy Development is planning a 10-MW solar power project at an estimated cost of ` 600-million (approximately) in village: Tingloor, taluka: Madhugiri, district: Tumkur, Karnataka. Surana Telecom And Power has received Letter of Award (LoA) for development of the project. Maharashtra State Power Generation Company is planning a 50-MWp solar photo voltaic power project in Gangakhed, district: Parbhani, Maharashtra. The company is scouting for land. Other details are yet to be finalized. Government of Odisha is planning a 20-MW solar power plant in Manmunda, district: Boudh, Odisha. Green Energy Development Corporation of Odisha is the nodal agency. According to reports, the nodal agency has identified about 120-acre of land at Manmunda for establishment of the project. Land has been allotted to the agency from the industrial park area earmarked by Odisha Industrial Infrastructure Development Corporation (IDCO).The EPC tender is for development of the power plant and maintenance for a period of 10 years. Apart from the Boudh project, the agency is in the lookout for additional land in Koraput, Kantamal and Bolangir areas for installing about 200-MW solar energy capacity. Chemical Engineering World
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CEW Ad Index Sr. No.
Client’s Name
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Nalco Water India Ltd
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Cole-Parmer India
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Desmi Pumping Technology A/S
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Rashtirya Chemicals & Fertilizers Ltd
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Gopani Product Systems
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Rotex Manufacturers & Engineers Pvt Ltd
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SPX Flow Technology (India) Pvt Ltd
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Hi-tech applicator
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Suraj ltd
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UNP Polyvalves (India) Pvt Ltd
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47 Chemical Engineering World
Book Shelf CEW Basic Environmental Technology: Water Supply, Waste Management and Pollution Control (6th Edition) Author : Jerry A. Nathanson, Richard A. Schneider Price : USD 121.13 Pages : 456 (Paperback) Publisher : Prentice Hall About the Book: Basic Environmental Technology, Sixth Edition emphasises applications while presenting fundamental concepts in clear, simple language. It covers a broad range of environmental topics clearly and thoroughly, giving students a solid foundation for further study and workplace success. This edition adds new coverage of environmental sustainability, integrated water management, low impact development, green building design, advanced water purification, dual water systems, new pipeline materials, hydraulic fracturing, constructed wetlands, single stream municipal solid waste recycling, plasma gasification of waste, updated EPA standards, and more. Hundreds of clear diagrams and photographs illuminate key concepts; practice problems and review questions offer students ample opportunity to deepen their mastery.
Wastewater Engineering: Treatment and Resource Recovery 5th Edition Author : Inc. Metcalf & Eddy, George Tchobanoglous, H. David Stensel, Ryujiro Tsuchihashi, Franklin Burton Price : USD 237.39 Pages : 2048 (Hardcover) Publisher : McGraw-Hill Education About the Book: Wastewater Engineering: Treatment and Resource Recovery, 5th edition is a thorough update of McGraw-Hill’s authoritative book on wastewater treatment. No environmental engineering professional or civil or environmental engineering major should be without a copy of this book - describing the rapidly evolving field of wastewater engineering technological and regulatory changes that have occurred over the last ten years in this discipline, including: a new view of a wastewater as a source of energy, nutrients and potable water; more stringent discharge requirements related to nitrogen and phosphorus; increased emphasis on the treatment of sludge and the management of biosolids; and an emphasis on the development of energy neutral or energy positive wastewater plants through more efficient use of chemical and heat energy in wastewater. This revision contains a strong focus on advanced wastewater treatment technologies and stresses the reuse aspects of wastewater and biosolids.
Wastewater Engineering: Treatment and Resource Recovery 5th Edition Author : Hamed Hasanlou, Hamidreza Hasanlou Price : USD 65 Pages : 80 (Paperback) Publisher : McGraw-Hill Professional About the Book: Being familiar with characteristics of industrial town effluents from various wastewater treatment units, which have high qualitative and quantitative variations and more uncertainties compared to urban wastewaters, plays very effective role in governing them. With regard to environmental issues, proper operation of wastewater treatment plants is of particular importance that in the case of inappropriate utilisation, they will cause serious problems. In order to achieve a better and efficient control over the operation of an industrial wastewater treatment plant (WWTP), powerful mathematical tool can be used that is based on recorded data from some basic parametres of wastewater during a period of treatment plant operation. Chemical Engineering World
Introduction to Water Resource Recovery Facility Design, Second Edition Author :Water Environment Federation Price : USD 165 Pages : 848 (Hardcover) Publisher :McGraw-Hill Professional About the Book: The second edition of this renowned Water Environment Federation book provides students and practicing engineers with authoritative information on state-of-the art facility design and treatment processes. The text addresses the challenges of the design engineer’s job to incorporate new technology and innovations while producing a facility that will perform as expected under variable and unpredictable loadings. Introduction to Water Resource Recovery Facility Design, Second Edition, also offers guidance on designing facilities with the flexibility to allow modifications to meet more-stringent treatment requirements as environmental regulations evolve. Comprehensive coverage includes: •The design process •Hydraulics •Preliminary treatment •Primary treatment •Suspended-growth biological treatment •Attached-growth biological treatment •Biological nutrient removal •Natural treatment systems •Physical and chemical processes •Ancillary processes •Production and transport of wastewater solids •Conditioning of solids •Stabilisation •Thickening, dewatering, and drying solids •Beneficial use and ultimate disposal August 2015 • 71
CEW Interview
Interview CEW
Leveraging 50 Years of Experience With more than 120 process units, licensed by Axens or loaded with Axens’ products, the company has been very active in the Indian petroleum refining and petrochemical Industry thus have a footprint in each and every refinery or petrochemical site in India, says Jean-Paul Margotin, Managing Director, Axens India Pvt Ltd. In an exclusive interaction with Harshal Y Desai, he further talks about the ongoing and future projects, technologies offered by the company, significance of refining and petrochemical integration and more.
72 • August 2015 Chemical Engineering World
August 2015 • 72
Interview CEW Please apprise us on the company’s presence in recent few years within the country? How has Axens India Pvt Ltd propelled in its operations within the country? Axens’ local India office was established in 2008; however, involvement in the country can be traced through IFPEN back 40 years ago. Axens has been involved in many downstream and petrochemicals projects in India. In the recent past, as a technology licensor, Axens has been awarded numerous projects including, but not limited to, all the main refining technologies for HMEL Bathinda refinery, IOCL Paradip and Haldia VGO hydrotreaters. Axens is involved, through its technology of catalytic formation of 1-butene by Ethylene dimerisation (so called AlphaButol), in Panipat petrochemical complex and GAIL, OPaL as well as Brahmaputra Cracker and Polymer Limited (BCPL) new crackers projects. As a catalyst manufacturer, Axens has been chosen by Indian refiners in multiple hydroprocessing units (Naphtha, Diesel, VGO hydrotreaters or hydrocracking units). Which are the technologies that you are typically targeted for the Indian market? Please tell us about some of the ongoing and future projects in India? In India, BS IV & BS V Specifications will be implemented in the coming years and the new projects will focus on gasoline and diesel hydrodesulfurisation but also on residue and heavy-fraction conversion in need of modernisation to maximise the production of valuable hydrocarbons and high-quality fuels. Presently, Axens is very active in the field of revamping of fuel producing units (catalytic reforming, isomerisation, diesel
hydrotreaters) as well on grass root projects for which technologies such as high-pressure hydrocracking, ebullated bed hydrocracking, residue fluidised catalyst cracking or residue hydrotreating might be contemplated. More stringent specifications of refined products and petrochemicals, capacity expansion as well as margin improvements are the driving parameters for all public and private sector refiners in India and all of them are embarked in major projects in which Axens is involved. The refining and downstream petrochemical integration is the buzz word today. Will you please comment on these changing technology trends and key drivers for the industry? Combining production of fuels and chemicals, either by shifting a portion of refineries output to chemicals using high Olefins FCC, or by integrating aromatic complexes is one of the best ways for improving margins and answering market trends in demand. This portion may become predominant for some projects – i.e. so called crude to chemicals – in any case flexible feed, multi-products assets should continue to take the lead, offering a better resilience to market changes. Our company has been participating in several of these projects in the recent past The main focus in the refining and downstream petrochemicals sector, today, is to improve the Gross Refinery Margins (GRM) by processing heavy crudes and utilising each and every molecule to a usable component while maintaining the environmental norms. How does technology licensing and engineering design services offered by Axens India Pvt Ltd contributing in achieving this goal for its clients? Technologies allowing production of both large quantities of chemical molecules
and fuels, using cheaper feedstock such as residue of distillation of crude oil, will have the major impact on the market. Example can be given such as High Severity FCC or HS-FCC, enabling to produce over 20 per cent wt. of propylene from residue, developed by JX, Saudi Aramco, KFUPM and marketed by Axens and Technip. This process operates at high temperature, high catalyst to oil ratio, but with very short contact time to avoid coking and over-cracking, thanks to the use of a down-flow reactor. Another example is in the field of the aromatic molecule production, this includes Benzene, Toluene and Paraxylene. Axens has a strong expertise on this market, and has developed advanced process schemes allowing maximising the production of aromatics through the conversion of the bottom of the barrel. This conversion suite coupled with aromatic complex will be considered by many. Energy costs represent a huge percentage of operating expenses. Please elucidates on the Axens’ energy efficiency and revamping offers. Energy is at least 50 per cent of a refinery’s OPEX. It can be even higher in older sites. Bringing imagination to work to try to better integrate processes and equipment is a must; this involves both the design of the process itself, but also the choice of equipment. The fundamental objective, when dealing with energy integration, is to use all the heat available in hot streams to warm up the cold ones; we should be seeing heat less often ‘destroyed or wasted’ by simply cooling it with water or air. This is what Axens is doing in its everyday work; in some of the processes we proposed. We
In the recent past, as a technology licensor, Axens has been awarded numerous projects including, but not limited to, all the main refining technologies for HMEL Bathinda refinery, IOCL Paradip and Haldia VGO hydrotreaters. Chemical Engineering World
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CEW Interview have created energy savings of up to 40-50 per cent compared to the previous generation. We have successfully applied this approach to FCC complexes in existing refineries and to grass roots aromatic complexes. How can your technologies help meet requirements of Indiaâ&#x20AC;&#x2122;s Auto Fuel Vision & Policy 2025 document that suggests that the fuels should meet Euro IV standards by 2017, Euro V standards by 2020? For more than 20 years now, gasoline and diesel have been gradually reformulated in order to reduce the impact of their combustion on the atmosphere; this has been done in conjunction with improvements to catalytic converters. In particular, sulfur was a concern, because it results in SO 2 when it is burned, and also is a poison for the exhaust treatment catalyst. In the mid-90s, when people were trying to find ways to desulfurise gasoline, there was no easy solution on the market. Today, Axens proposes an innovative and simple technology to do that, by concentrating the relevant fractions of gasoline in order to treat them selectively in a later step, thereby reducing the octane losses. This process, called Prime-G+, is a benchmark on the market and has been licensed more than 250 times. Regarding Diesel desulfurisation, Axens has continuously developed Prime-D a commercially proven technology that allows producing on-specification ultra-low sulfur diesel meeting Euro V standards. With 50 years of experience, Axens has a strong position in diesel hydroprocessing, having licensed more than 130 Prime-D units. Axens also offer consulting and software services to its clients. Will you please throw some light on this portfolio? Axens provides to its clients with customised solutions that take into account crude slates, integration, CAPEX, energy and product qualities and value. For example, as a leader in clean fuels technology, we know better than anyone else how to optimise gasoline and diesel pool qualities. This is the first aspect of our consulting activity which revolves around feasibility studies for the definition and optimisation of new refining and petrochemicals assets. The second part of our consulting activities consists in bringing value to process operations through technical advice and software. While many companies attempt to provide a similar service, our competitive advantage resides in our in-depth process knowledge: a lot of underlying value lies in changing feedstock, adding value to orphan ones, or changing cut-points in the units. A generalist will fail to understand what will result from these changes and will only be capable of producing generic studies. In contrast, Axens digs deep into process modelling and linear programming, enabling customers to unlock in reality the full value of their assets. 74 â&#x20AC;˘ August 2015
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 Office, Mumbai 400001, on 29th & 30th of every month. Total Pages No.:76