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ChemTECH Special WORLD EXPO 2015

Focus: Make in India

ChemTECH WORLD EXPO

South 2015

Gujarat 2016

10-12, December 2015 Chennai, India

21-23, January 2016 Ahmedabad, India

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Chemical Engineering World

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CEW Contents

VOL. 50 | ISSUE 1 | JANUARY 2015 | MUMBAI | ` 150

NEWS ►

CHEMTECH SPECIAL ►

Industry News/ 10 Technology News / 18

EDITOR’S NOTE/ 50

NEWS FEATURES ► Prime Time to Invest in Talent & Technology: Kallada / 24

Urbanisation, Young Force, & Digital Capability Will Drive ‘Make in India’ Campaign: Rabindranath Burman / 52 Fluid Controls Targets Growth through People and

FEATURES ►

Process/ 56

‘Make in India’ Promises a Brighter India, But… / 28 – Jason Cooper, Managing Director, Linde Engineering India Pvt Ltd

With Make-In-India’s Launch, Old is the New NEW!:

Can ‘Make in India’ Pave Way for Solar Industry? / 36 – Hitesh Doshi, Chairman & Managing Director, WAAREE Group

Raj Process Equipments: Confident of Sustainable

Kevin M Shah / 60 Chem Process: ‘The Right Solution to Each Client’ / 64

Growth / 68 Gopani Product: Offering “World’s Top Filtration Products” / 70

Indian Pumps & Valves Industry: Time to Go Global /40 – Shripad Ranade, Sr Principal, & Yogesh Shivani, Associate Consultant, TSMG.

Advance Valves: A Distinct and Significant Manufacturer / 72 RCF: Committed to Indian Farmers / 76

Complementing ‘Make in India’ / 44 – Haresh K Sippy, Managing Director, TEMA India Limited

PRODUCTS ► / 99

Transflow Asia / 78 Super Industrial Lining Pvt Ltd / 80 Everest Blowers Pvt Ltd / 82

EVENTS ► / 106

DIP-FLON Engineering & CO / 84

PROJECT UPDATE ► /107

Safety, Productivity & Visual Turnkey Solutions: BRADY

BACK OF BOOK ► Ad Index / 109 Book Shelf / 111 Interview/ 112 “From Corrective Actions to Proactive Approach –Dr Samir Degan, MD, Osnar Chemical Pvt Ltd and Chairman, NACE International Gateway India Section (NIGIS)

8 • January 2015

Company India Pvt Ltd / 86 G R Engineering Pvt Ltd / 88 Long Live Water Heaters (Outokumpu) / 90 The New Ferritic on the Block (Outokumpu) / 92 Technological Advancements are Backbone of SS Techno: Shripad Khatav / 94 Dipesh Engineering Works Targets 30% Growth / 96

Chemical Engineering World

CEW Industry News Vipul Shah Joins RIL as COO, Petrochemical Division; Shenoy New CEO for Dow India

Vipul Shah, COO, Petrochemical Division, RIL

Mumbai, India: Reliance Industries Limited (RIL), which indicated its intention to expand its petrochemicals business with an investment of about USD16 billion last year, has appointed Vipul Shah as the Chief Operating Officer (COO) to head its petroleum business.

Shah is also the Chair man of Central A d v i s o r y B o a r d ( C A B ) fo r S p e c i a l t y C h e m i c a l Wo r l d Expo 2015.

Sudhir Shenoy will be the new CEO of Dow Chemical International Pvt Ltd (Dow India).

Shenoy star ted his jour ney with Dow in 1997. In mid 2012, Sudhir was Sudhir Shenoy, CEO, named General Manager for the Home, Dow India Pe r s o n a l & I n d u s t r i a l C a r e bu s i n e s s i n A s i a Pa c i f i c a n d i n 2 0 1 3 , h e m o ve d t o S h a n g h a i , China as the Commercial Director for Dow Polyurethane, responsible for regional profit and loss, business strategy and organisational effectiveness.

Pluss Polymers Organises E-waste Management Programme Gurgaon, India: Pluss Polymers and Advit Foundation, in order to spread awareness about the importance of waste management, organised an E-waste Management Programme last month in Mount Abu School in New Delhi. According to Samit Jain, Managing Director, Pluss Polymers, the company is working with several schools and corporates across National Capital Region (NCR) to educate people on e-waste management.

TCL Plans Expansion of Nutrition Business Mumbai, India: Tata Chemicals is planning to expand its nutrition and wellness business by using latest innovations and technologies.

Company’s President, Arup Basu, who is also on the Central Advisory Board for Speciality Chemical World Expo 2015, said that the company is keen to grow the pulses business as the consumer products business is an area of interest for it. According to Basu, the business of nutrition and wellness is not like a chemical plant as there are different set of partners and company needs to involve farmers and consumers. He also stressed on the relationship with the government and said that it is also important as they are the regulators who matter the most to get a nod for any new product.

10 • January 2015

SPIC, MFL to Re-start Urea Production Chennai, India: According to the Union Ministry of Chemicals and Fertilizers, Southern Petrochemical Industries Corporation Ltd (SPIC) and Madras Fertilizers Ltd (MFL) are now allowed to produce urea using feedstock naphtha for a limited period. A regulatory filing reads, “The Ministry had informed they would be allowed to produce urea using naphtha for 100 days from the date of the notification, which is January 7, 2015… The company has, therefore, commenced starting up activities.” Earlier, Tamil Nadu Chief Minister O Panneerselvam had written a letter to Prime Minister Narendra Modi and sought subsidy for two fertiliser units.

`175-crore order for VA Tech’s Filipino Arm Chennai, India: The Philippine subsidiary of VA Tech Wabag has bagged a `175-crore order to set up a sewage treatment plant at Valenzuela, the Philippines. The company informed the BSE that it would design and build 60 million litres a day sewage treatment plant for Maynilad Water Services. Wabag will maintain the facility for one year as part of performance assurance. The project is funded by the World Bank. The Philippines has emerged a major market for the Chennai-based multinational water and wastewater treatment company, which has executed three projects in Bagbag, Tatalon and Dona Imelda and is implementing two large projects at Illugin, where it is setting up a 100 mld plant, and Putatan.

Gujarat to Form Joint Working Group Ahmedabad, India: The state of Gujarat, where already more than 50 per cent of total chemical production takes place, is now willing to further fast track projects related to chemical industry within the state. The Chief Minister of the state, Anandiben Patel has met Union Minister for Chemical and Fertilizer to discuss various projects related to the state in the fields of chemicals, fertilisers and pharmaceuticals. The state has now decided to form a joint working group, which will actively monitor the projects in the pipeline.

The government has also decided to develop a full-fledged campus for the National Institute of Pharmaceutical Education & Research (NIPER) at Ahmedabad, to fur ther develop the Petroleum, Chemicals and Petrochemicals Investments Region (PCPIR)/SEZ at Dahej.

Currently, Gujarat is the only state, where the PCPIR is functioning.

According to Kumar, further steps are to be taken to expand the industry in this sector. It can also be explored for setting up of an exclusive tech park for medical devices. The issue of setting up of fertiliser plants in Gujarat under New Investment Policy of the ministry was also discussed during the meeting.

Chemical Engineering World

CEW Industry News RIL, Mitsui to Ship Liquefied Ethane to India Mumbai, India: Reliance Industries Limited (RIL) and Mitsui OSK Lines Ltd have agreed to transport ethane from North America to India. Both the companies have been reported to sign the agreement for the same. According to the MOU signed by RIL and Mitsui, the latter will supervise the construction of six very large ethane carriers (VLECs), ordered recently by RIL from South Korea’s Samsung Heavy Industries. The VLECs are being specifically built by Samsung Heavy Industries Co Ltd and are expected to be delivered in the last quarter of 2016 and will enter into service thereafter. RIL had earlier reported that it is implementing a project to source 1.5 million tonnes per annum of ethane from the US to feed its crackers in India. The company intends to save about USD 450 million per annum by importing 1.5 million tonnes of ethane from the US for its petrochemical plant, said a research report.

` 9,000-crore Fertiliser Complex to be Set-up in Odisha New Delhi, India: A joint venture agreements to set up an integrated coal gasification-cum-fertiliser and ammonium nitrate complex in Talcher, Odisha, at an estimated investment of ` 9,000 crore has been signed by GAIL (India), Coal India, Rashtriya Chemicals and Fertilisers (RCF) and Fertiliser Corporation of India. According to Piyush Goyal, Minister of State (Independent Charge) Power, Coal and New and Renewable Energy, the units will start by March 31, 2019. Two different joint ventures - GAIL, Coal Gas (India) Ltd and Talcher Chemicals and Fertiliser Ltd have been established, which will be led by GAIL and RCF, respectively. GAIL will set up the upstream coal gasification and gas purification section for producing ammonia syngas for the unit, which will require an investment of ` 3,000 crore. And the second joint venture is responsible for setting up the ammonia-urea and nitric acid-ammonium nitrate plants.

Govt Receives 12 Proposals to Increase Domestic Output New Delhi, India: The Fertiliser Ministry has received 12 proposals from the fertiliser companies to increase domestic output by setting up new plants and scaling up capacity of existing facilities.

However, it is likely to approve maximum 5 of them. The Centre in April 2010 had decontrolled the Phosphatic and Potassic (P&K) fertilisers, like DAP and MOP, by giving freedom to manufacturers to fix prices. At present, the annual domestic demand of urea is around 30 million tonnes, while the production is around 22 million tonnes. The gap is met through imports. Eight private companies including Zuari Agro Chemicals, Indo-Gulf Fertilisers, Chambal Fertilisers, Bharat Coal Chemicals and Nagarjuna Fertilizers and Chemicals Ltd have submitted proposals. Also, four PSUs - Rashtriya Chemicals and Fertilizers (RCF), GNFC, GSFC and FACT - have applied Under the New Investment Policy.

12 • January 2015

Fertiliser Ministry Asks for Coal Block Allotment to Urea Plants New Delhi, India: The Coal ministry has been asked to allot some mines to fertiliser production plants when the blocks are up for allocation. The Fertiliser Ministry has written to the Coal Ministry about the same. In all about 101 mines including 65 through auction would be freshly allocated in the first phase. The state owned companies would be allocated almost 36 blocks. There has been an increase in the number of coal mines to be allocated or auctioned in the first phase from 92 to 101. The possibility of making use of coal gasification as alternative mode of feedstock for urea production is also being explored by the Fertiliser ministry.

Euro 4 Billion Rhenus Launches Second Warehouse Mumbai, India: Rhenus Logistics India Pvt Ltd, the Indian arm of the globally valued Euro 4 Billion Rhenus Group, opened of second warehouse near Chennai, spread in an area of 55,000 sq ft. With opening of this warehouse, Rhenus now has two multi-user facilities, with about 1 lac sq ft of warehousing space near Chennai. This new warehouse will exclusively cater to the chemical sector and boost the industry in Tamil Nadu. Due to the risk involved in handling and storing of Chemical products, the industry requires THE highest level of safety. Now more companies can take benefit of the facility, as Rhenus is among the few logistics players in India which adhere to stringent environment and safety standards. This warehouse is a state of the art facility and fully enabled with latest technologies, facilitating the company to handle chemical products with the highest level of efficiency and safety. The warehouse is endowed with modern equipment’s and in-house warehouse management software ‘Rhenus WMS’ that takes care of inventory traceability and transactions. It has a capacity of 6000 Pallet Positions (PP) with further scalability options, efficient Reach Trucks with the lifting capacity of G+7 racking systems for 1100 kgs and Forklifts for Floor management. It has prospects of fulfilling both JIT and Milk run concepts.

Dürr Right on Track in the Asian Market Bietigheim-Bissingen, Germany: The mechanical and plant e n g i n e e r i n g f i r m , D ü r r h a s r e c e n t l y d e p l oye d i t s h i - t e c h EcoDryScrubber solution in the highly competitive Japanese market. The EcoDryScrubber from Dürr is an environmentallyfriendly and reliable solution that leverages dry separation to capture and filter out overspray that occurs during painting. A leader in paint systems, Dürr has equipped 80 per cent of its paint shops with the innovative dry separation technology since the EcoDryScrubber was introduced. One of Japan’s leading train operators with its fleet of hi-speed locomotives has deployed the EcoDryScrubber technology in its new paint shop for aluminium panels on the Shinkansen high-speed train. The system is scheduled to enter service in Hamamatsu in summer 2015.

Chemical Engineering World

CEW Industry News Cathay Investments to Buy Euroresins from DSM

Sasol’s Ethane Cracker Complex in US is Complete

Heerlen, Netherlands: Royal DSM has announced that it has reached agreement with Cathay Investments for the sale of Euroresins. Subject to customary approvals and notifications, the transaction is expected to close in Q1 2015. Euroresins is a distributor of products to the composite resins industry with activities in nine countries in Europe, including the United Kingdom, Italy and France. Euroresins realises sales of approximately Euro 90 million with around 70 employees. All employees - on the closing date - will be transfered to the new owner. The sale of Euroresins is in line with the strategic actions DSM is pursuing for Composite Resins, as announced in November 2014. Cathay Investments is the UK holding company for a group of companies engaged in chemical distribution and trading.

Johannesburg, South Africa: Sasol Limited (Sasol) announced the completion of a USD 4 billion credit facility for its ethane cracker and derivatives at its existing site in Lake Charles, Louisiana.

Mitsui & SKC Form JV for Polyurethane Biz Tokyo, Japan: Mitsui Chemicals, Inc, and SKC Co, Ltd, announced the signing of a joint venture agreement to consolidate the polyurethane material businesses of both companies. MCI and SKC target to form the new joint venture company (JVC)

by April 1, 2015 subject to completion of necessary procedures, such as the obtaining of relevant approvals and licenses. The JVC is headed to be a global comprehensive manufacturer of polyurethane materials which provides value for customers and targets sales of USD 2.0 billion per year around 2020.

Basic strategies of the JVC are satisfy customer needs in growing markets, explore new businesses globally and improve profitability. The JVC will fully utilise the global networks of MCI and SKC covering Far East Asia, China, ASEAN, Europe, and the Americas based on close relationships with customers and the provision of quick and efficient technical services.

Mosaic Awards KBR with FEED Contract for Ammonia Plant Houston, USA: KBR Inc has been awarded the license and engineering contracts to perform front end engineering and design for a potential expansion of Mosaic’s Ammonia Plant in St. James, Louisiana. KBR’s ‘lean FEED’ approach will debottleneck the plant and increase Mosaic’s ammonia production capacity by 20 per cent at their plant located on the banks of the Mississippi.

KBR’s proprietary ammonia technology will be utilised to revamp and expand the original KBR designed plant. Additionally, KBR will provide the basic engineering design and the FEED requirements necessary to produce a final estimate prior to project approval.“This is a significant win for KBR and we are pleased to be able to support Mosaic with both our leading technology and our technical and project delivery expertise,” said Stuart Bradie, President and CEO, KBR. 14 • January 2015

“Securing this financing facility is another key m i l e s t o n e i n a d va n c i n g a d e f i n i n g project for the company. The support from a large number of international financial institutions is a testament to Sasol’s strong standing within the global financial markets,” said Paul Victor, Acting Chief Financial Officer, Sasol Limited. A syndicate of 18 international banks and other financial institutions are lenders for the credit facility.

Paul Victor, Acting Chief Financial Officer, Sasol Limited.

In October, Sasol announced its final investment decision relating to a USD 8.9 billion petrochemical complex, which consists of an ethane cracker that will produce 1.5 million tons of ethylene annually. The complex will also comprise six chemical manufacturing plants, enabling infrastructure and utility improvements.

The remainder of the funds required for construction will be raised in a phased manner from a variety of potential sources, including surplus cash available in the group.

ALTANA Acquires Premiata and Overlake São Paulo, Brazil: The specialty chemicals group, ALTANA has acquired two companies in Brazil. As a result, the ACTEGA division now has its own sites in South America’s largest country. Both of the acquired companies are owner-operated and headquartered in the federal Martin Babilas, state of São Paulo. Premiata, which operates two Member of the facilities under the name of Premiata Tintas and Management Board, ALTANA AG Premiata Especialidades Químicas, specialises, respectively, in printing inks and coatings for the packaging industry with 140 employees. Overlake is an overprint varnishes specialist with 70 employees at one site. “Through these acquisitions we are systematically expanding our business in the growing Brazilian market,” explains Martin Babilas, Member of the Management Board, ALTANA AG. The ACTEGA division’s entire Brazilian operations will be concentrated in the new ACTEGA do Brasil company with immediate effect. “Taking over Premiata and Overlake means we can significantly expand our portfolio of solutions particularly for the Brazilian packaging industry.

I am convinced that our many years of expertise in printing inks and overprint varnishes combined with our new production facilities will swiftly make ACTEGA the preferred supplier in Brazil,” summarises Dr Roland Peter, ACTEGA Division President.

Chemical Engineering World

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CEW Industry News Orica to Set-up 3 Ammonia Flaring Plants Melbourne, Australia: Orica’s multimillion-dollar investment programme to improve the environmental performance of its Kooragang Island site has passed a new milestone with the NSW Government approving the construction of three ammonia flaring systems. General Manager of Orica Kooragang Island Scott Reid said flaring systems are considered best practice and are used extensively in modern plants around the world that produce and use ammonia. “This project will further improve our plant’s environmental performance by capturing and flaring ammonia emissions at safety release points,” Reid said.

Construction will commence shortly to install three flare stacks at heights of six, 10 and 20 metres respectively, and is expected to take three years to complete. It is anticipated that the flares will operate infrequently and should only be visible if activated at night. The programme also includes upgrades to ammonia storage vessels as well as improved detection and isolation systems.

Orica KI has also been granted approval to construct a new nitric acid tank, which will be used to store imported nitric acid as well as provide additional storage for nitric acid produced on site.

Te ch n i p t o A c q u i r e A i r L i q u i d e ’s Polymer Technologies Paris, France: Technip has entered into an agreement with Air Liquide Global E&C Solutions Germany to purchase all of its Zimmer polymer technology business. Based in Frankfurt, Germany, the business includes technologies for the processing of polyesters and polyamides, research and development facilities, and a team of around 40 skilled engineers, researchers and project teams.

The new polymers business will diversify and strengthen Technip’s portfolio of downstream technologies in its Onshore segment by enhancing the group’s position as a technology provider to the petrochemicals industries; reinforcing relationships with clients and partners worldwide, backed by the Zimmer recognised expertise; diversifying the Onshore segment, adding revenue based on technology supply; and adding skilled resources, notably in technology development in Europe.

Technip plans to integrate the new polymers technology business through Technip Stone & Webster Process Technology, the onshore global business unit formed in 2012 to manage the company’s expanding portfolio of downstream process technologies. Technip has a strong track record in major project execution and is uniquely positioned to provide services for clients ranging from conceptual studies, PDPs, FEEDs, and detailed engineering through procurement and construction.

16 • January 2015

P E T RO N A S C h o o s e s Lyo n d e l l B a s e l l ’s Polypropylene Technologies Rotterdam, Netherlands: PETRONAS Refinery and Petrochemical Corporation (PRPC) has selected the LyondellBasell Spherizone a n d S p h e r i p o l p o l y p r o py l e n e p r o c e s s t e c h n o l o g i e s. T h e technologies will be used for a 900 KTA polypropylene (PP) unit to be constructed in their Refinery and Petrochemical Integrated Development (RAPID) complex in Pengerang, Johor, Malaysia.

Dutuk Nur Iskandar A Samad, Deputy Project Director (Petrochemical) for project RAPID at PRPC stated, “Our selection of both the Spherizone and Spheripol process technologies will provide PETRONAS with a wide range of premium quality and differentiated PP products highly suited to the needs of international markets.” Key features of the Spherizone technology include a large range of high-perfor mance PP and novel polyolefinic resins with expanded properties, while Spheripol is the leading polypropylene technology for the production of high quality homopolymer, random and heterophasic copolymers.

LyondellBasell is a leading licensor of polypropylene and polyethylene technologies with more than 250 polyolefin process licenses.

Honeywell Starts Production of Low-GWP Morris Township, USA: Honeywell has star ted full-scale commercial production of a low-Global-War ming-Potential (GWP) material used as an aerosol propellant, insulating agent and refrigerant.

The material, known by the industry designation HFO-1234ze and marketed by Honeywell under its Solstice line of low-globalwarming materials, is being produced at the Honeywell Fluorine Products facility in Baton Rouge, La. “Honeywell’s Baton Rouge production facility is ready to serve customers around the world with this innovative material, which has an ultra-low GWP of less than 1,” said Ken Gayer, Vice President and General Manager of Honeywell’s Fluorine Products business. “We are seeing an increasing demand for our entire Solstice line of low GWP materials, and this new product has already been adopted by a range of customers globally,” he added. Honeywell’s Baton Rouge facility was built in 1945 and continues to serve as one of Honeywell’s main manufacturing sites for its Performance Materials and Technologies business. The site employs more than 200 people. Louisiana Governor Bobby Jindal said, “Honeywell helps support hundreds of jobs in our state, and we are proud the company is expanding in Baton Rouge with a brand new product line. This project is a good example of how Louisiana’s outstanding business climate is convincing companies like Honeywell to reinvest in our state, retain existing jobs and create additional new career opportunities for our people.”

Chemical Engineering World

CEW Technology News New Catalyst Process Uses Light for Rapid Polymerisation Santa Barbara, USA: A team of chemistry and materials science experts from University of California, Santa Barbara and The Dow Chemical Company has created a novel way to overcome one of the major hurdles preventing the widespread use of controlled radical polymerisation. Atom Transfer Radical Polymerisation (ATRP) is emerging as a key process for creating well-defined polymers for a vast range of materials, from adhesives to electronics. However, current ATRP methods by design use metal catalysts, a major roadblock to applications for which metal contamination is an issue, such as materials used for biomedical purposes. This new method of radical polymerisation doesn’t involve heavy metal catalysts like copper. Their innovative, m e t a l - f r e e AT R P p r o c e s s u s e s a n o r g a n i c - b a s e d photocatalyst - and light as the stimulus for the highly controlled chemical reaction. “The grand challenge in ATRP has been: how can we do this without any metals? “We looked toward developing an organic catalyst that is highly reducing in the excited state, and we found it in an easily prepared catalyst, phenothiazine,” said Craig Hawker, Director, Dow Materials Institute, UC Santa Barbara. (Read more on http://engineering.ucsb.edu/news/814)

Solar Cell Polymers with Multiplied Electrical Output Upton, USA: One challenge in improving the efficiency of solar cells is that some of the absorbed light energy is lost as heat. So, scientists have been looking to design materials that can conver t more of that energy into Postdoctoral fellow Erik Busby and Matt Sfeir with optical equipment they used to study useful electricity. Now a team charge carrier production in organic photovoltaic from the US Department of polymers at Brookhaven Lab’s Centre for Energy’s Brookhaven National Functional Nanomaterials.

Laborator y and Columbia University has paired up polymers that recover some of that lost energy by producing two electrical charge carriers per unit of light instead of the usual one. “Critically, we show how this multiplication process can be made efficient on a single molecular polymer chain,” said Physicist Matthew Sfeir, who led the research at Brookhaven Lab’s Centre for Functional Nanomaterials (CFN), a DOE Office of Science User Facility. Having the two charges on the same molecule means the light-absorbing, energy-producing materials do not have to be arrayed as perfect crystals to produce extra electrical charges. Instead, the self-contained materials work efficiently when dissolved in liquids, which opens the way for a wide range of industrial scale manufacturing processes, including ‘printing’ solar-energy-producing mater ial like ink. (Read more on science.energy.gov) 18 • January 2015

Graphene Plasmons Go Ballistic Barcelona, Spain: Squeezing light into tiny circuits and controlling its flow electrically is a holy grail that has become a realistic scenario thanks to the discovery of graphene. This tantalising goal is realised by exploiting so-called plasmons, in which electrons and light move together as one coherent wave. Plasmons guided by graphene - a two-dimensional sheet of carbon atoms - are remarkable as they can be confined to length scales of nanometers, one to two hundred times below the wavelength of light. However, until now these plasmons were found to rapidly lose energy, limiting the range over which they could travel. This problem has now been solved, as shown by researchers from the Nano-optoelectronics group at ICFO led by Prof Frank Koppens, in collaboration with CIC nanoGUNE (San Sebastian, Spain), CNR/Scuola Normale Superiore (Pisa, Italy) – members of the EU Graphene Flagship - and Columbia University (New York, USA).

The research, carried out by ICFO PhD students Achim Woessner and Yuando Gao and postdoctoral fellow Mark Lundeberg, is just the beginning of a series of discoveries on nano-optoelectronic properties of new heterostructures based on combining different kinds of two-dimensional materials. The material heterostructure was first discovered by the researchers at Columbia University.

(Read more on http://www.icfo.eu/)

Chitosan: Sustainable Alternative for Food Packaging B a s q u e C o u n t r y, S p a i n : A r e s e a r c h g r o u p o f t h e UPV/EHU-University of the Basque Country has used a material known as chitosan, made from crustacean shells, to substitute petroleum by-products. Riverbanks and oceans are full of plastic; there are bits of this material in the organism of a large number of fish, etc. Packaging and wrappers made from petroleum by-products are seriously damaging the environment.

The search for less harmful materials has driven many pieces of research; among them that of Itsaso Leceta. This researcher has shown in her work entitled Quality attributes of map packaged ready-to-eat baby carrots by using chitosan-based coatings, that chitosan films are effective in preserving some of the properties of carrots as well as in preserving them longer. What is more, chitosan films are less harmful for the environment than those made of plastic in various impact categories.

Food items are covered with plastic films to make them last longer and protect them from microbes. The environment, however, is seriously affected by the use of this material. The plastic bottles and films present everywhere in our civilisation take between 100 and 400 years to degrade.

So, the quest for alternative materials to plastics produced from petroleum is an environmental priority. (Read the complete news on university’s website - www.ehu.eus) Chemical Engineering World

CEW Technology News Cheap Asphalt Provides ‘Green’ Carbon Capture New York, USA: The best material to keep carbon dioxide from natural gas wells from fouling the atmosphere may be a derivative of asphalt, according to Rice University scientists. The Rice laboratory of chemist James Tour followed up on last year’s discovery of a ‘green’ carbon capture material for wellhead sequestration with the news that an even better compound could be made cheaply in a few steps from asphalt, the black, petroleum-based substance primarily used to build roads.

The research appears in the American Chemical Society journal Applied Materials and Interfaces.

The best version of several made by the Tour lab is a powder that holds 114 per cent of its weight in carbon dioxide. Like last year’s material, these new porous carbon materials capture carbon dioxide molecules at room temperature while letting the desired methane natural gas flow through. The basic compound known as asphalt-porous carbon (A-PC) captures carbon dioxide as it leaves a wellhead under pressure supplied by the rising gas itself (about 30 atmospheres, or 30 times atmospheric pressure at sea level). When the pressure is relieved, A-PC spontaneously releases the carbon dioxide, which can be piped off to storage, pumped back downhole or repurposed for such uses as enhanced oil recovery. “This provides an ultra-inexpensive route to a high-value material for the capture of carbon dioxide from natural gas streams,” Tour said. “Not only did we increase its capacity, we lowered the price substantially.” He said they tried many grades of asphalt, some costing as little as 30 cents per pound. (Read the complete news on http://www.rice.edu/)

Fossil Fuel Reserves that Must Stay in the Ground to Avoid Dangerous Climate Change London, UK: A third of oil reserves, half of gas reserves and over 80 per cent of current coal reserves globally should remain in the ground and not be used before 2050 if global warming is to stay below the 2 degree C target agreed by policy makers, according to new research by the UCL Institute for Sustainable Resources. The study funded by the UK Energy Research Centre also identifies the geographic location of existing reserves that should remain unused and so sets out the regions that stand to lose most from achieving the 2 degree C goal. The authors show that the overwhelming majority of the huge coal reserves in China, Russia and the United States should remain unused along with over 260 thousand million barrels oil reserves in the Middle East. The Middle East should also leave over 60 per cent of its gas reserves in the ground.

The development of resources in the Arctic and any increase in unconventional oil – oil of a poor quality which is hard to extract – are also found to be inconsistent with efforts to limit climate change.

For the study, the scientists first developed an innovative method for estimating the quantities, locations and nature of the world’s oil, gas and coal reserves and resources. They then used an integrated assessment model to explore which of these, along with low-carbon energy sources, should be used up to 2050 to meet the world’s energy needs. (Read more on http://www.alphagalileo.org/) 20 • January 2015

Entrepreneurs Cutting Equipment

Design

Automated

Colonia Roma, Mexico: The ‘OpeCNC’ system, consists of software and hardware for machine control. It can be applied from ornamental ironwork, cutting spare par ts, pipes to a d ve r t i s e m e n t s . W h e n t h e The “OpeCNC” system, consists of software and hardware for machine engineer Isaac Navarro Alcazar control. It can be applied from needed to make two meters high ornamental ironwork, cutting spare 3D dinosaur figures, you did parts, pipes to advertisements. not find the right tool to make the cuts, so he decided to make his own machine: an innovative, automated and efficient equipment capable of making plasma cuts through plating and metal foils such as carbon steel, stainless steel and aluminum, among others. A graduate of the National Polytechnic Institute (IPN), with a Bachelor in Communications and Electronics specialising in control and automation, Navarro Alcazar and his brother designed a machine that can cut ‘any type pf figures, however complex.’ The entrepreneurs called the project ‘OpeCnc,’ which is a set of software and hardware to control these machines and ‘CNC’ because of the computerised numerical control. “With this technology, if a circular plate cut is required it can be made from an AutoCAD drawing with the actual measurements, we generate the code, translate it to the computer and the machine does the cutting,” explained the Mexican entrepreneur.

The machine measures 1.22 x 3.05 meters, has mounted a plasma torch and cuts plates up to an inch wide. It can be applied in conventional and artistic ironwork, for example, to design and cut a door or window, plus the system also serves on advertising by executing metal channel letters.

(Read more on http://www.invdes.com.mx/)

Controlling the Properties of Nanomaterials New York, USA: Scientists at the US Department of Energy’s Oak Ridge National Laboratory are learning how the properties of water molecules on the surface of metal oxides can be used to better control these minerals and use them to make products such as more efficient semiconductors for organic light emitting diodes and solar cells, safer vehicle glass in fog and frost, and more environmentally friendly chemical sensors for industrial applications.

The behaviour of water at the surface of a mineral is determined largely by the ordered array of atoms in that area, called the interfacial region. However, when the particles of the mineral or of any crystalline solid are nanometer-sized, interfacial water can alter the crystalline structure of the particles, control interactions between particles that cause them to aggregate, or strongly encapsulate the particles, which allow them to persist for long periods in the environment. As water is an abundant component of our atmosphere, it is usually present on nanoparticle surfaces exposed to air. (Read more on the website of Oak Ridge National Laboratory) Chemical Engineering World

CEW News Features

Prime Time to Invest in Talent & Technology: Kallada The logistics industry in India already lags behind other countries when it comes to technology adoption and investments. And as the country – with a new initiative of ‘Make in India’ – is likely to increase its chemical production capacities to the next level, logistic mechanism will play a vital role in the overall development of the industry. Harshal Y Desai brings forward the perspective of Pavithran M Kallada, Managing Director, BDP International, India. Based in the US, BDP International operates freight logistics centres in more than 17 cities throughout North America and a network of subsidiaries, joint ventures and strategic partnerships in nearly 140 countries.

I

n developing economies such as India, the demand for well-tuned logistics and compliance processes, which match the same high practice standards of multinational companies conducting business to and from our in-country markets, have become a matter of competitive necessity, agrees Kallada.

While highlighting the impact of changing role of Indian chemical industry in global supply chains on the logistics industry over the last couple of years, Kallada further comments that beyond ethical practice and behaviours, which are inevitable, there is a new generation of supply chain and logistics leaders and decision-makers who have earned a place at their company’s Strategy Table. Accordingly, the old practices of divvying small batches of import and export business among scores of third party providers is evolving - and swiftly to a more efficient and effective paradigm of single-sourcing to achieve real-time visibility and measurable command and control of international purchase - and sales-order execution. He states that the excellence and unwavering reliability in conventional services such as freight forwarding, customs clearance and transportation management are a must.

The chemical industry in India is giving high priority to building more compliance-focused infrastructures. For example, service providers participate with chemical sector clients in safety and quality process improvement initiatives.

Moving risk avoidance from concept to action is a key area of focus including clearly defined processes and measurable Key Performance Indicators (KPIs) for safe, compliant service, Kallada elucidates.

24 • January 2015

Talent and Consistency – the Two Major Issues When asked about the major challenges for the logistics services providers for chemicals and petrochemicals industry in India, Kallada mentions two major issues - talent and consistency. “Finding, hiring and retaining drivers, cleaners and handling labourers are perpetual challenges. In terms of consistency (or the lack thereof), the industry as a whole must give higher priority to common operating standards, safety parameters and vendor qualification processes. Fly by night operators in business to make a quick rupee, sans the long-term vision to invest in their customers through safety, training and responsible handling processes, represent a clear and present danger for the chemical Industry and for our nation,” he worries. Kallada mentions ‘competition and entrepreneurialism’ as the benefits to our economy, but added that there is simply no room in the business of chemical supply chain and logistics management for cutting corners to make a few rupees.

According to him, greater access and transparency in the raising of common standards are a must. “Another core issue which government and industry must address is port and road congestion. Until infrastructure commitment turns to action, safety, productivity and economic transformation from third world to first world remain status quo.’

Pavithran M Kallada The Impact of Outdated Infrastructure and Labour Laws Are the issues of infrastructure and outdated and inflexible labour laws affecting the industry? “Yes, they are,” Kallada replies.

“And the impacts on the growth of India’s chemical industry are significant.” Kallada states that the most obvious weaknesses are in the speed and velocity of shipping and asset utilisation. The cost of logistics in India is comparatively higher than in most of the other major international markets.

At this point Indian chemical products are at a competitive disadvantage with other international markets such as China. The new national government has pledged to fast track greenfield and infrastructure projects, but it is going to take a sea change from old fashioned thinking and self-serving behaviours on many fronts to

Logistics can be the next professional frontier in tandem with the proliferation and envisaged growth of the manufacturing sector. In that regard, I strongly advocate the establishment of a Nodal Ministry at the national level dedicated to the advancement of the Logistics Industry to support and even accelerate our nation’s growth.

Chemical Engineering World

CEW News Features make the Indian economy more competitive, he adds. Kallada also suggests that there is dire need to build massive transportation and distribution infrastructure between remote locations and ports, and to revamp antiquated, bureaucratic labour rules.

Logistics service is being redefined in India as the best practices that meet international standards for quality, training and measurable performance become the rule rather than the exception. However, there is no quick fix; an abundance of challenges must be addressed if the chemical sector in India is to achieve its potential. Trained work forces for transport, storage and distribution and safe and reliable transportation or distribution infrastructure and establishment of designated chemical zones with common, shared infrastructure including emergency response centre, fire and safety corners, waste management processing, packing and handling facilities, warehouses, and a pool of well-trained labour all under one area would enable the chemical and logistics industries to leverage common standards of compliance, safety, performance and avoidance of calamity.

Kallada claims that this framework of shared cost - shared investment - would go beyond yielding ROI - it is simply the right thing to do.

Need for Chemical Port Though India is the 6 th largest chemical producer globally and 3 rd largest in Asia, the country has just one chemical port and that too on the west coast.

Kallada believes that berth and terminal facilities at existing ports on India’s west coast and east coast dedicated to bulk and liquid chemical shipping would be an asset. He further explains, there is also a need to address the growing demand for containerised cargo handling at existing ports.

With the growth of speciality chemicals shipped in ocean containers and ISO tanks, designated chemical zones adjacent to ports with common, shared infrastructure for emergency response, fire and safety corners, waste management processing, packing and handling facilities, warehouses, and a pool of well-trained labour all under one area would enable the 26 • January 2015

The Critical Components • Excellence and unwavering reliability in conventional services such as freight forwarding, customs clearance and transportation management are a must.

• On time delivery is critical, but understanding and measuring lead times is just as important. For example, a surface transportation carrier moves the shipment from a seaport or airport, (or domestically) from a factory to a forward warehouse for eventual distribution. However that same inventory may sit in a delay mode for days even weeks due to incorrect or unavailable documentation for final delivery, damages during the handling, or unresolved tax and compliance issues. All of these factors and more impact supply chain effectiveness and deliverability.

• Visibility and automation of many of these far flung components of supply chain management are catching up with global standards as all stakeholders involved recognise the financial value of an orchestrated approach. Manufactures, customers, transport companies, warehousing companies logistics/ handling agents and government agencies must see and act in unison toward the common goal to boost adoption and implementation.

• Sustainability is another contemporary driver including green (carbon neutral) transportation; warehouses that operate on solar/alternative energy; and paperless customs, documentation, and border/cross border forms. The Indian Chemical Council’s Nicer Globe Responsible Care programme also offers a framework for safety and sustainability practices which all logistics service providers should meet and exceed.

- Pavithran M Kallada, MD, BDP International, India chemical and logistics industries to leverage common standards of compliance, safety, and productivity.

selecting vendors and logistics service provider is a trend that must move from talk to action,” he adds.

The Positive Elements Kallada makes mention of two initiatives while commenting on the best practices that should be mandated for practicing in Indian chemical logistics sector.

Conclusion Kallada believes that the growth of manufacturing can have significantly positive impacts on the logistics sector.

He strongly emphasises on the need to invest in talent and technology in order to reach global standards and expectations.

“The risk to our customers’ - chemical manufacturers - reputations and financial well-being demand that we raise the competency bar.

It is a competitive necessity; beyond the need for work force training and retention, the Indian logistics industry must become a destination - a home - for some of our nation’s best and brightest minds,” he comments.

According to Kallada, “The Indian Chemical Council’s Responsible Care initiative is a vital mechanism for raising safety, environmental and performance standards which will raise India’s profile as a viable market for chemical industry development.”

He also talks about Nicer Globe initiative that offers a framework for safety and sustainability practice which all logistics service providers should endeavour to meet and exceed. Kallada is of the opinion that the mandatory participation in Nicer Globe by logistics service providers will also appeal to chemical manufacturers siting locations in South East Asia.

The competitive nature of inter-regional chemical logistics cannot be over-stated as production moves closer to consumption.

“An accreditation benchmarking process with minimum qualification criteria for

“There is certainly no shortage of engineers, doctors and lawyers. Logistics can be the next professional frontier in tandem with the proliferation and envisaged growth of the manufacturing sector. In that regard I strongly advocate the establishment of a Nodal Ministry at the national level dedicated to the advancement of the logistics industry to support and even accelerate our nations’ growth,” he recommends.

Chemical Engineering World

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CEW Features Guest Column

‘Make in India’ Promises a Brighter India, But… In this insightful article that highlights a number of elements crucial for the success of ‘Make in India’ campaign, Jason Cooper, Managing Director, Linde Engineering India Pvt Ltd, suggests that the country has immense potential that needs to be tapped systematically. “The value and quality of ‘Make in India’ products will be intrinsic to the domestic consumer and preferred because of the value benefit both in price and availability,” Cooper writes.

A

s Managing Director of an EPC company in India, I am fortunate to work with over 1100 highly talented and skilled professionals, and we continue to grow. Our ability to deliver world class engineering and process plant know-how from India is a key differentiator that allows Linde Engineering to be competitive globally.

There are many benefits to working in India; however, there are challenges as well. But one thing is certain, there remains untapped potential in India to shift the balance of trade towards more home grown technologies and solutions that would reduce the demand of imported goods to India. The impact to India over time could dramatically change the economic landscape in the country. The talent is here and the motivation is high.

But, there are obstacles.

Make in India is not just a slogan but a strategic initiative to improve the Indian economy, create better job opportunities and raise the standard of living for all Indians. The ability to generate incremental value addition by increasing the domestic production content of manufactured goods is essential to developing economies. The greater value addition will reduce the amount of imports, and thus, it will create more opportunities for wealth and job creation. ‘Make in India’ is a necessity as India transitions to a global power in the world economy. India must reduce 28 • January 2015

the gap between import and export value and begin to develop home grown technology solutions that make it more competitive and sustainable. The ‘Make in India’ know-how must become a sought after commodity.

Most developing economies grow as they exhaust mineral wealth or through basic agricultural exports. But, as these economies begin to flourish and the demand for imported items increases with the developing middle class, the lack of a fully integrated economy across the value chain means that dependence on imports increases as inflation increases while debt burden also increases. The only way to fight this cycle is to create a balance between imported and exported goods such that ideally, the country is neutral or export positive. In this way, the currency is stable and the incremental wealth generated can be used for diversification of the economy with real investment in factories, development of new products for export and increasing domestic consumption and production.

Sustainability for a developing economy can only be created in a methodical and structured way. Regulatory policy and tax policy must be structured in such a

way that promotes entrepreneurship while being fair and agile for the developing middle class. The key to sustainability is the middle class. Once growth is a clear agenda item for the government and policy relative to strengthening the middle class is clear, the economy will self-prime and grow organically. (See India’s rising middle-class in Figure 1) As can be seen from Figure 2, the balance of trade as the middle class emerged aggressively in the last decade is that imports surged and generated a balance of payments challenge that the RBI had to manage. This has resulted in relatively high inflation and put pressure on the rupee. Figure 3 illustrates the effect of the trade imbalance on the rupee and clearly indicates that the pressure from the trade imbalance actually deteriorated wealth in real terms in India over the same period.

How to break the Cycle? ‘Make in India’, like ‘Make in China’ or ‘Make in America’ campaigns, take advantage of nationalist pride to promote domestic consumption and production. With a decrease in demand on imported goods, the real value creation can be reinvested in new production and help drive growth.

There remains untapped potential in India to shift the balance of trade towards more home grown technologies and solutions that would reduce the demand of imported goods to India. The impact to India over time could dramatically change the economic landscape in the country.

Chemical Engineering World

CEW Features India has developed a strong service industry in Engineering and IT. The same energy now needs to be applied to build world scale highly efficient manufacturing processes. This can be achieved through joint ventures and technology partnering arrangements or though organic home grown development. Obviously, the latter will take more time, but could yield better results in the long term in some cases. I have heard often that “you need an Indian solution to an Indian problem.” Perhaps that could be the competitive edge to take an obsolete technology available in the US, Europe or elsewhere, revamp for the Indian market and redeploy for Indian consumption to fit a niche application.

The Indian market is complex with many socio-economic dimensions. The creativity of the Indian entrepreneur is boundless. I have been amazed during my time in India to see how very simple ideas can be converted into low cost creative solutions to solve a problem.

We need to bring this to bear on a larger scale and address the strategic needs of the country.

Figure 1: India’s rising middle-class.

Figure 2: India Balance of Trade from 1990 to 2014.

The impact to the economy can be significant and more importantly helps stimulate sustainable growth and job creation. We have a unique opportunity with the excitement generated by the new government to really kick this off and make real progress in curbing the trade deficit.

One essential feature of any campaign like ‘Make in India’ is to clearly convey the value that the campaign brings to the consumer. The creativity and innovation of a young and well educated workforce will drive the introduction of new and creative product solutions.

In time, the value and quality of ‘Make in India’ products will be intrinsic to the domestic consumer and preferred because of the value benefit both in price and availability.

Some of the challenges that India will face to create a real push for the campaign 30 • January 2015

whereby a meaningful dent in the balance of trade can be realised will be availability of venture capital for modern manufacturing investment, product development know-how (IP) and logistics.

Venture capital should flow more freely as the interest rates decline and cash flows more freely for investment. Fiscal policy of the Modi government has made this a priority. Modern manufacturing capacity is an evolving story in India. Some of the most technologically advanced factories exist in India alongside some of the least advanced. Managing quality along the supply chain as well as schedule performance will be a challenge as sub vendors for complex products will have differing levels of quality management systems as well as compliance cultures.

Manufacturing to international engineering and quality standards is required and quality compromises can no longer be accepted in Indian manufacturing.

Energy, infrastructure and logistics will play a huge role in realising the benefits of the campaign.

Improvements in the reliability of power, warehousing, distribution and transportation infrastructure are required to improve the timeliness of products to market and to ensure they are not damaged getting there.

Domestic special economic zones need to be setup to promote vertical integration to simplify supply chain challenges. High speed trucking and rail corridors need to be established between major urban areas and regional distribution hubs. As the middle class expands and wealth increases, so will expectations for speed and quality. Suppliers will increasingly not only be judged by price, but by speed and availability. Also, given that India remains a largely rural country, accessibility to the rural towns and villages and logistic solutions that address the ‘last mile’ must be considered and developed.

Energy policy in particular needs to be improved to accelerate the development of coal assets for power and the Chemical Engineering World

CEW Features

Figure 3: FOREX rates of INR/USD - Source, Yahoo.

production of Synthetic Natural Gas (SNG) and to expand the exploration and production of domestic oil and gas. The dependence on imported oil and gas is going to hamper the fight against inflation as long as landed LNG and crude remain at their current levels.

policy makes manufacturing and reselling in India highly complex. The intrastate and central tax regimes that are in place impose significant burdens on the producers and resellers that can limit competitiveness and often embroil them in red tape and hampered cash flow.

Energy prices at parity with other developing countries will allow India to truly leverage manufacturing capacity and drive expansion. Alternative energy credits and investment in wind and solar, especially in isolated areas, will promote opportunities in rural areas off the grid.

India has both the burden of 1.3 billion people and also the wealth of 1.3 billion people from which manufacturing has often developed labour centric solutions in lieu of investment in technology.

Tax, importation and regulatory obstacles will remain significant challenges to growth and domestic trade development.

Liberalisation of tax policy including the introduction of GST in India needs to take centre stage of any growth policy. The combination of different taxes imposed in India and the frequent changes in tax

The labour pressure will only continue to build with the increasing mechanisation of rural agriculture and the increasing migration from rural to urban areas.

However, the dependency on cheap labour as being the sole source of competitiveness needs to be changed.

Cheap labour often means unskilled and poor quality workmanship. There must be a push for skill development in key trades and tax incentives should be

Tax, importation and regulatory obstacles will remain significant challenges to growth and domestic trade development. Liberalisation of tax policy including the introduction of GST in India needs to take centre stage of any growth policy.

32 • January 2015

developed for private companies to invest and support these programmes. India must tap into the tremendous pool of talent that exists with the young engineers and scientists that it exports. Provide good jobs, based on home grown technologies that provide competitive salaries that keep this talent at home. A combination of better technology and better skills in lieu of sheer numbers will dramatically change the innovation potential, manufacturing productivity and quality landscape in India.

India has tremendous potential that can only be unlocked when the nation pulls together to support a common challenge, like ‘Make in India’. The campaign offers the promise of better jobs, a better standard of living and a more sustainable long term economy.

The public and private sector should work together to develop a joint action plan to promote a liberalised tax regime and industrial development plan, prioritised by industry, identifying the areas of development that make the most sense to increase domestic production and reduce export demand.

Chemical Engineering World

CEW Features Guest Column

Can ‘Make in India’ Pave Way for Solar Industry?

‘Make in India’ is a concept to enhance India’s position as a leading manufacturing hub in the near future. It is an initiative to prove that we can be world-class manufacturers and innovators. It is an attempt by the government to bring in much needed foreign investment in the country. This campaign aims at rejuvenating the economy, creating new jobs, to foster innovation, to launch a skill development programmes alongside building best-in-class manufacturing infrastructure. The campaign also calls for the government to be more transparent, responsive and accountable, writes Hitesh Doshi, Chairman and Managing Director, WAAREE Group.

T

he government is willing to move ahead from License Raj, our anarchic labour laws and absolutely outdated land reforms. The will of the policy makers more than anything else will contribute to the success of this initiative. Future success of this ‘Make in India’ initiative will depend a lot on government’s ideas and execution to make doing business in India easier.

Renewable energy is identified as one of the sector for this programme. The availability and scope of using renewable energy to fulfill our unfulfilled power needs has been endlessly debated in various forums. But probably this is the first time; it is a core issue of National Policy Discussion. We are undoubtedly a power starved nation with an ever growing hunger for power. This new initiative will not only increase our hunger to provide power to these manufacturing units but also increase the power needs of individuals as their per capita goes up.

For manufacturers, who have already covered substantial ground and look eagerly for the future, this is the moment to expand rapidly, developing world class R&D facilities, bringing in new partners and carefully improving our skills to match and compete with global manufacturers who seem to have jumped light years ahead. We need to believe in this concept of ‘Make in India’ and should also know that only the government would not be able to fulfill it, we the stakeholders should also contribute by means of new innovations and show the hunger to expand.

36 • January 2015

The Indian government has decided to increase the share of renewable in the energy mix from 6.5 per cent to 12 per cent in the next three years. The government has set its eye on the goal to achieve 100GW by end of 2022. Though it has not yet generated enough storms in the global market due to their previous experience.

Imagine the kind of opportunities, jobs and growth it would contribute even if half the target is achieved. The growth of this industry in India has a story to tell of its own. Despite the regulatory delays, unclear policies and challenges due to poor infra and lack of capital, the solar industry in India has done significantly well. From just few MW to raise capacity to 3GW in 4 years is no mean task when you consider the challenges faced by us.

We have the potential to fulfill most of our power deficit by way of solar generation; such is the immense potential of our country blessed by the Sun, when Germany with its difficult geographical conditions can add 40GW, what can stop a God blessed country like us which has ample sunshine.

Even a rough weather state like J&K has potential to produce 11GW of solar energy.

India will witness a solar growth on a scale, difficult to imagine and foreseen in

any country on this globe, but for this to materialise, it would require significant amount of efforts and ability to override challenges. First challenge will be to attract investment at cheaper cost than the domestic rates. At least 30 per cent of the investment will have to come from foreign investors. The challenge lies in giving confidence to the investors about their returns; the off taker has to be financially capable to servicing the agreements.

Finding the right off taker, who is buying power for the right reasons at the right price, will make the project more bankable and give assurance to the investors.

Another huge challenge comes from our ability or rather reluctance to innovate and spend on R&D and mind you this is not specific to our industry. If we want to raise our bar we have to focus on this aspect otherwise all these initiatives would fall on its face.

Furthermore, as far as our industry goes, the controlled grid prices are a huge challenge as it does not inspire confidence to foreign investors as it is not market linked but is linked to political powers in the states. The state utilities should be made autonomous and drastic changes need to be done in the Electricity Act.

The growth of this industry in India has a story to tell of its own.

Despite the regulatory delays, unclear policies and challenges due to poor infra and lack of capital, the solar industry in India has done significantly well.

Chemical Engineering World

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CEW Features This is necessary to improve the financial stability of the utilities, which plays a key role in the growth of industry. No investor would like to deal with a utility in poor health. These changes would in return boost the manufacturing ability since it would give investors the much needed confidence of the country heading somewhere.

Our anarchic land and labour laws have been a big turnoff to all investors. Though the government has slowly but steadily started revamping the labour laws and has already rolled out first phase of reforms much has been left to desire as far as land reforms are concerned. They need utmost attention. We as citizen of this country understand the need of social and environmental security of those being displaced but this at no point should become a hindrance to our growth as it would paralyse the entire nation. Rather than, this we should take steps to find a middle path. The inspector and license raj along with our at times ridiculous taxation policies need to be relaxed and reframed in case we desire to come any closer to our dream of ‘Make in India’. These policies more than anything have led to the downfall of our manufacturing industry. Now is the time to overhaul them if you really want to generate any degree of confidence in investors and manufacturers.

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India wants to achieve scale in a very short time frame so the strategy of Ultra Mega Power Projects’ (UMPP) and utility scale projects are the right way to go now. But only when solar systems become as mainstream as mobile phones we can say that we have realised its full potential. The biggest strength of solar is that it can produce power at the point of consumption. We have to allow for net metering across the country so that people can start generating electricity on their own. We also have to ensure availability of finance for such projects. We have to move from the current upfront subsidy scheme to providing soft loans which will work better. Further, we need more and more SEZ’s and manufacturing hubs which provide benefits in terms of tax rebates, lower electricity charges etc. An integrated infrastructure development with roads, ports needs to be planned and executed. The most basic challenge which we need to overcome is our logistics facilities; we are laggards to world in terms of our railways, road transport and inland transport. These basic aspects need to be improved if we are to dream of ‘Make in India’. It is core to the philosophy, a building block without it we cannot even walk a mile.

We have to encourage entrepreneurs to be part of this revolution and the recent skill development programme is in the right direction. More than capital, this industry needs skilled people, this industry alone has a potential to generate over a million plus employment opportunities. Our focus should be to develop skilled people. A mammoth effort needs to be put forward for training and development. Skill centres, autonomous institutes etc need to be promoted. This would not only generate a work force for the growing industry but would also generate employment opportunities - and more importantly - would create thousands of entrepreneurs who in their own would contribute to the ‘Make in India’ dream of the government.

38 • January 2015

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CEW Features Guest Column

Indian Pumps & Valves Industry: Time to Go Global The global economy has started to show signs of recovery. Fresh investments are being planned in the process industry worldwide. Indian pumps and valves manufacturers can thus expect opportunities to grow in the export markets, especially in the Middle East and North Africa (MENA) and NAFTA regions. But it is essential that they first get their house in order by building robust processes, say Shripad Ranade, Senior Principal, TSMG and Yogesh Shivani, Associate Consultant, TSMG.

T

he global economy has had subdued growth for the last few years with global output contracting by 0.6 per cent in 2009. However, it is expected to embark on a growth trajectory going forward largely on the back of developing economies, and the IMF expects global output to grow by 3.8 per cent in 2015.

The Indian economy seems poised for the next phase of growth after sluggish performance over the past few years. The recent data on the composite performance of eight core industries – coal, crude, oil, natural gas, refinery products, fertilisers, steel, cement and electricity – is seen to be encouraging. Assuming such trends are sustained in the coming months, there would be much better industrial growth in H2 of FY15.

Shripad Ranade

Yogesh Shivani 40 • January 2015

The pumps and valves manufacturers are significant suppliers to the process industry and also cater to other end use sectors such as automation for discrete manufacturing and pumps for agricultural use. The pumps and valves market in India provides an opportunity of `17,500 crore

Fig 1: Indian pump market (` Cr).

and is expected to grow at an annual rate of 7 to 10 per cent over the next few years.

The new government in the centre is expected to take policy initiatives that will help the Indian industry. The signs of recovery in the global economy also bode well for pumps and valves manufacturers. It is thus time for domestic manufacturers to strive to overcome current challenges and gear up for the next phase of growth.

Indian Pumps Industry Global pump market is estimated at USD 47 billion in 2014 and is estimated to reach USD 56 billion by 2017. The Indian pump market is close to 2 per cent of the global market and was estimated at ` 8,500 crore in FY14. Agriculture and Building services are the two largest end use segments, as depicted in the figures 1 and 2.

The pump industry is classified into centrifugal and positive displacement pumps, with centrifugal pumps being 95 per cent of the market, within which single stage radial flow pumps and submersible pumps together make up 70 per cent. Rotary

Fig 2: Key end use segments

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CEW Features positive displacement pumps account for the largest share of positive displacement pumps. Key manufacturers of centrifugal pumps in India are: Kirloskar Brothers Limited (KBL), KSB, Grundfos, CRI and Aqua Group.

India exports pumps to nearly 70 countries.

In FY14, exports stood at `1,280 crores, having more than doubled over three years. As much as 16 per cent of Indian pump manufacturing capacity is geared for exports. Key export destinations are the Middle East, North Africa and other more developed economies such as USA, Germany and Russia. The emerging markets of China and Latin America also provide attractive opportunities.

Our discussions with industry players reveal that succeeding in global markets will require increased focus on quality along with low cost positioning and active marketing. India is well positioned to grow into a much larger manufacturing base for pumps driven by attractive factor conditions.

It is very likely that India will be a significant exporter of pumps in the coming years.

Indian Industrial Valves Industry Industrial valves market is divided into two segments - On-Off valves and Control valves. On-off valves accounts for 98 per cent of the valves market by volume and 80 per cent by value. About 88 per cent of the demand is from projects, while 12 per cent is replacement demand. Global market for industrial valves is expected to reach USD 75 billion by 2017 with China, Africa, Middle East and India expected to propel the demand. Figure 3 shows the Indian market which constitutes ~2.5 per cent of the global market. Oil and gas followed by power, petrochemicals, chemicals and fertilisers are the major end use sectors, as shown in figure 4.

The Indian valve industry is highly fragmented with around 600 valve manufacturers, of which more than 95 per cent are in the micro, small and medium enterprise (MSME) category. Top 10 players service 40 per cent of the market.

Demand for high end customised valves is bound to grow in the MENA region with 42 â&#x20AC;˘ January 2015

Fig 3 : Indian industrial valve market (INR Cr.)

Fig 4: Valves demand by end-use sectors (FY14).

Fig 5: Key focus areas for Indian manufacturers.

their shift from upstream oil and gas based economy to supply of refined petroleum products. Large addition of refining capacity is underway in the MENA region. Investment in desalination plants will further increase demand for valves. The NAFTA region will account for about 18 per cent of total valve demand by 2017. Discovery of shale gas and huge investment for its extraction has turned USA into a net exporter of oil and gas. These investments will drive demand for valves in the future.

Way Forward Indian pumps and valves manufacturers must capitalise on the anticipated growth opportunities that the domestic as well as the export markets present. With the global industry becoming more and more competitive, it becomes imperative for any manufacturer to strive for excellence with both inward and outward focus.

Inward Focus: Bulk of manufacturing in the Pumps & Valves industry is project based which necessitates the need for having strong but flexible business processes in organisation. Domestic

companies face growing complexity in terms of product portfolio, geographies, customer expectation etc. as they grow in revenue. Symptoms such as high and erratic lead time, underutilisation of plant and people and tapering of profit margin point to current processâ&#x20AC;&#x2122;s inability. Those companies which will embrace evolved business processes will remain competitive and grow further.

Outward Focus: With a substantial part of future opportunities expected to come from the export market, it has become inevitable for the Indian manufacturers to be at par with their global peers. While Indian products fare well on the quality front, there exists a lacuna in branding and service delivery.

While a few forward looking companies have already felt the need to address these challenges and are reorienting themselves, a large section of the industry has significant work to do in this regard. These point towards the need to gear up with robust processes to ensure relationship building with global customers and hence profiting from global growth.

Chemical Engineering World

Chemical Products Finder | November 2013 | 57

CEW Features Guest Column

Complementing ‘Make in India’ With three state-of-the-art manufacturing facilities, TEMA India Limited is serving domestic and global customers equally. The company focused a lot on innovation and research and became ‘one of the largest manufacturers of Shell and Tube Heat Exchangers in India’, writes Haresh K Sippy, Managing Director, TEMA India Limited. In this guest column, he further talks about the company’s growth story and highlights the significance of ‘Make in India’ campaign.

‘

Make in India’ concept has three facets viz import substitution, export orientation and domestic consumption.

Manufacturing in India helps the nation reduce trade deficit and increase Gross Domestic Product (GDP) and employment.

During the financial crisis of 2008, India was relatively unaffected as its growth was driven largely by domestic consumption.

While the US market gradually emerges out of the crisis, developing markets are increasingly viewed as new growth markets. These new growth markets are reflected in many industries including chemical and petroleum industries. Also, specific to oil and gas sector, US, the Middle East (ME) and Asia Pacific offer significant opportunities for equipment suppliers the world over. In India, rising income levels of the middle class and the demographic dividend have created a huge market that many multinationals are placing their bets on.

‘Make in India’ concept can be viewed in support of domestic consumption as increasing disposable incomes of citizens, through a multiplier effect, help increase demand of goods and services. Challenges associated with realising the ‘Make in India’ dream cannot be underestimated. In a way, ‘Make in India’ dream is a concerted effort to scale the concept to enormous levels by providing manufacturing access to serve lucrative market opportunities across the globe. In other words, it is making India the preferred manufacturing 44 • January 2015

location for manufacturers all over the world. This creates a fantastic opportunity for Indian and global manufacturers to ‘Make in India’ to cater to both local and global demands.

Indian companies, that supplied equipment and ancillaries to Indian oil and chemical majors, have become increasingly competitive in the global scenario. TEMA India Limited, one such company that was founded in 1987 by myself and two other like-minded individuals, mainly supplied to requirements of Indian oil and gas majors in its formative years. Aided by its experience in the Indian market and driven by focus on continuous innovation, the company gradually developed its overseas business and today derives significant portion of its revenues from export business (over 50 per cent in 2013-14).

In fact, as early as 1960s, when I was fresh out of engineering college, I ventured successfully into the manufacture of Sampling Bombs which resulted in import substitution for Esso Refinery (now known as Hindustan Petroleum Corporation Limited) and Oil and Natural Gas Corporation Limited.

In my formative years, I witnessed several inspiring developments like manufacturing

of torispherical dished-end and welded air-receiver (pressure vessel), both, for the first time in India. I further went on to learn the skills of manufacturing and designing the very first heat exchanger (after-cooler for compressors) in the country in the year 1967 and later on took an active role in the development of ‘shell-&-tube condenser’ for a cold storage plant. I then gained experience in maintenance work of ‘floating-head’ type shell-&-tube heat exchangers in petroleum refineries.

In 1975, I set up my first facility, Leo Engineering Works, to manufacture Shell and Tube Heat Exchangers. This company manufactured heat exchangers and parts thereof for both Esso and Burmah Shell petroleum refineries, now known as Hindustan Petroleum Corporation Limited (HPCL) and Bharat Petroleum Corporation Limited (BPCL) respectively.

These exchangers, which were made to TEMA-R specification, were mainly floating head types with Naval Brass tube sheets and Cu-Ni (70-30) tubes with Monel lining of channels and FTS covers.

During this enriching journey, I pioneered the development of Monel weld deposit on CS tube sheet blanks.

‘Make in India’ concept can be viewed in support of domestic consumption as increasing disposable incomes of citizens, through a multiplier effect, help increase demand of goods and services. Challenges associated with realising the ‘Make in India’ dream cannot be underestimated.

Chemical Engineering World

CEW Features

Shell-&-Tube Heat Exchanger (Refrigerant Condenser)

I decided to take my most defining plunge to manufacture world-class complex heat exchangers on a large scale, in 1987.

Along with Chetan Doshi and Khushroo Bulsara, I formed TEMA India Limited.

We started with a modest revenue of `18 lakhs (USD 100,000) in 1987. Over time, the company became one of the largest manufacturers of shell & tube heat exchangers in India and achieved many milestones.

world, based on technology from Lummus.

There were some challenges that the company faced as it looked to expand to the overseas market.

Board of Boiler and Pressure Vessel Inspectors (NB, R).

The Growth of TEMA India Limited

If I look back, I feel my inspiration is what drove me over the past four decades. Today, the nation has evolved and the government is incentivising established multinationals and budding Indian entrepreneurs alike, to manufacture in India. We believe that an increased thrust on R&D and setting up a full-fledged R&D centre, to improve production efficiency and product attributes, can be prioritised to increase our competitiveness in the global market. In fact, in line with this philosophy, the company developed the aforementioned shrink ring (added steel on channel barrel) technology for screw plug heat exchangers. Existing incentives by the government towards R&D, such as related tax exemption etc, are expected to encourage R&D activity, which in turn should further improve the image of products manufactured in India.

The company was formed in the year 1987 and in 1997, it bagged its first large order, from MRPL, worth ` 43 crores (USD 12 million) for 56 exchangers. TEMA INDIA LIMITED has enjoyed investor confidence in form of investments by ACTIS and TATA CAPITAL in 2005 and 2013 respectively. The company was awarded a patent for ‘shrink ring’ (added steel on channel barrel) technology for Screw Plug Heat Exchangers in 2009 and in the following year, it became one of the largest manufacturers of shell-&-tube heat exchangers in the country. Along the way, the company has been awarded many prestigious orders by highly reputed Indian and overseas clients and EPC companies. Latest significant orders (in 2014) include order from Petrofac worth ` 60 crores (USD 10 million) for KNPC Clean Fuels Project in Kuwait, FPSO P74 Brazil order from EBR and order for HP/LP heaters for 660 MW & 800 MW power plants, totaling ` 99 crores (USD 16.3 million), for NTPC projects.

Compliance to Health, Safety and Environmental (HSE) standards is another area which globally renowned clients look for. Although, our operations do not involve dealing with sensitive and hazardous substances, a stringent in-house policy is followed. Ensuring implementation of HSE standards will encourage plant owners and EPC companies to increasingly use made in India products.

One of the most significant achievements was an award of a Patent for the Shrink Ring (added steel on channel barrel) technology pertaining to Screw Plug Heat Exchangers, used in Hydrocarbon Processing for High Pressure / High Temperature applications.

Another was production of the largest and the most complicated Helixchanger in the country and amongst the largest in the

48 • January 2015

Although Indian manufacturing quality is not perceived to be sub-standard, TEMA India Limited has had to go the extra mile to convince some of its first time global clients. It is another thing that after visit to our facilities and deployment of our heat exchangers, many clients became repeat customers. Today, the company has expanded its operations to three state-ofthe-art manufacturing facilities and caters to the global best oil and gas companies and world- class EPC companies. The manufacturing facilities have been certified to ISO 9001: 2008 standards and also by American Society of Mechanical Engineers (U, U2 and S) and National

Chemical Engineering World

  

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SPECIAL Guest Column

Urbanisation, Young Force, & Digital Capability Will Drive ‘Make in India’ Campaign: Rabindranath Burman According to Rabindranath Burman, Managing Director, ITT Corporation (India) Private Limited, ‘Make in India’ campaign has been launched at the right time as some of the industries have been moving away from China and looking for another destination in Asia Pacific region. In this article, he further highlights the major objectives behind the campaign and lists some points that a manufacturer and the government will have to focus on to make the campaign successful.

Rabindranath Burman Managing Director ITT Corporation (India) Private Limited

T

he slogan 'Make in India' versus 'Made in India' captures the distinction of an initiative that we are addressing today as one of the most-discussed topics - not only in India but globally.

The shift is toward building more internal capability and addressing local consumption domestically by increasing purchasing power, which will consequently spur development and drive global opportunities and recognition.

With current uncertainty in the global economy, growing domestic consumption and opportunity will be critical for thriving in today’s economic environment providing balance in the worldwide marketplace.

China’s success is a great example of this.

The Indian market should therefore be considered as an opportunity with potential that goes well beyond a discrete market or region.

Rapid urbanisation, the world’s largest young work force, and strong digital capability and infrastructure give India socioeconomic viability and make it an attractive investment on a global scale. As the global economy has shifted to the East, particular interest

52 • January 2015

in India has been driven by its status as the world’s largest democracy and its attractive production costs. These factors have not only stimulated the Indian economy but have attracted Foreign Direct Investment (FDI) as well.

The current scenario is that India's share of manufacturing in gross domestic product is around 16 per cent, compared to China's 34 per cent and South Korea's 31 per cent. World Bank President Jim Yong Kim sees this as positive. Kim said with many industries leaving China, India could well gain in the manufacturing sector, even as he suggested that the country's vibrant services sector must not be de-emphasised as it attempts to project itself as a global manufacturing hub.

"I think that the efforts that are being made right now to explore how competitive India can be are very important,” Kim said. “There are a lot of industries that are leaving China right now and they very well may come to India... I do not see any downside to it."

The World Bank, which will soon put out its growth forecast, has at present penciled in Indian growth increasing to 6.4 per cent in 2015, up from around 5.5 per cent.

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CEW

SPECIAL The major objective behind the 'Make in India' initiative is to focus on the heavy industries and public enterprises while generating employment, empowering secondary and tertiary sectors, and utilising the human resources present in India. To achieve success domestically and globally will require an effective partnership between the manufacturer and/or investment community and the government sector.

This partnership brings various requirements to manufacturers: • A complete commitment to worldclass quality.

• Cost-effective manufacturing and investment in continuous innovation.

• An understanding of global requirements for the natural environment, health and safety, with strict adherence to standards.

• Effective legislation relative to waste management and effluent treatment.

• Fair workplace practices for both white- and blue-collar employees to maintain a satisfied workforce and enhance its buying power.

• Upgrading manufacturing capacities while adopting globally accepted standards and practices to maintain global competitiveness.

For government, this will mean: • Creating an 'easy to do business with' climate.

• Single-window clearance and environment clearance must be made simple and effected with speed.

• Implementation of a simplified and unified tax structure across India.

• Emphasis on having the right talent by providing the appropriate education programmes and specialisations required by targeted industries.

• Simplified policies that can be revised efficiently according to need.

• Providing alternative feed stock to make operations more profitable.

• Most importantly, significant investments in India’s infrastructure.

54 • January 2015

The major objective behind the 'Make in India' initiative is to focus on the heavy industries and public enterprises while generating employment, empowering secondary and tertiary sectors, and utilising the human resources present in India.

Individual state governments will play an important role, as local geopolitical scenarios are key to attracting desired investments.

While India was earlier seen as a Basic Chemical industrial market, it has now earned its rightful spot as a manufacturer of Fine Chemicals as well. The Indian chemical industry is today Asia’s third largest industry, and holds the sixth rank globally in terms of volume. This segment is growing at an average rate of 12.5 per cent and contributes around 5 per cent to the country’s GDP. This has been made possible by the rise in per capita income, availability of a workforce with strong technical skills, and R&D investment.

a major contributor to the chemical Industry.

Having facilities across the world, we understand the chemical industry and have invested strongly in R&D, new technologies and highly engineered products. Our Goulds Pumps and Bornemann brands of industrial pumps are recognised as world class in the chemical industry, and are manufactured at advanced facilities around the world, including our Gujrat (Baroda) factory.

The chemical industry is comprised of Basic (a segment dominated by petrochemicals, and with petrochemicals applied in almost all industries, growth prospects of the segment remain strong), Specialty and Knowledge Chemicals, and caters to a wide range of end-user industries producing commodities such as pharmaceuticals, fertilisers, textiles, plastics, polymers, agrochemicals, paints and dyes, and more.

Keeping abreast of these segments while addressing the specialty chemical market, which is extremely customer-focused and calls for continuous innovation while remaining cost competitive, is imperative.

Recent remarks by US Secretary of State John Kerry concisely capture the value of doing so, as he noted the 'Make in India' programme is a 'win-win opportunity for the world.'

ITT Corporation, a global US-based corporation focused on engineering excellence through many decades, has been

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SPECIAL Guest Column

Fluid Controls Targets Growth through People and Process Fluid Controls Private Limited (FCPL) was founded by Dr Y E Moochhala, a Mechanical Engineering Doctorate from North-western University, USA. After receiving his doctorate, Dr Moochhala worked in the USA for a number of years before deciding to return to India in 1974 to fulfil his vision of founding a world class organisation in the country which would manufacture products to the highest quality standards, be innovative and contribute to the development and growth of the country, writes Dr Tansen Chaudhari, Chief Operating Officer, Fluid Controls Private Limited.

F

ourty years later, the founding principles of the company to 'Make in India' have been taken forward by a new generation of managers - the Fluid Controls vision today is 'To be a global leader in the field of fittings, valves, and allied application solutions'. And, to drive this vision, we have instilled IntegrityReliability-Innovation as our value system.

Continuous improvement and innovation – which we believe leads to continuing excellence - is one of the corner-stones of our organisation. Internally, over the past few years, we have been streamlining and re-engineering our processes, and this means that we constantly question the way we execute all activities relating to our business.

FCPL has recently launched Lean Six Sigma, and though we have some way to go, we have already begun to reap the benefits of this approach. Most importantly, we now have a common understanding of performance. Of course, as one starts to streamline internal performance, it automatically gets reflected externally. Therefore, over the past few years, our approach to our customers and their needs has also changed. Instead of simply selling a product, we now work with 56 • January 2015

our clients to offer solutions. Our motto of 'continuing excellence' means that we work towards annual and long range plans.

This means that we focus on people and processes, responsibility and accountability and tangible deliverables. Because of this, our performance over the past years has exceeded our expectations.

Fluid Controls existing product offerings (as shown in the figure) ie, double ferrule compression fittings, valves and manifolds, clamps and flanges, etc. spread out various segments such as petrochemical, oil and gas, railways, process, steel, cement, chemical, etc. We offer these products which work in very high pressure environments.

With a heritage of forty years, a culture of product development, design and manufacturing, and with a clear vision, FCPL today is one of the most experienced companies in India. Our major growth drivers are: • Brand, Culture and Talent Management: We all appreciate the fact that once an organisation starts growing, one needs to build an organisation culture to sustain growth. We have put in a lot of efforts toward this such as team building, leadership trainings, review mechanisms,

employee succession growth planning.

and

career

• New Product Development and Technology: Though we have a rich product heritage, I must add that we were not systematically focused on new product development based on changing industry needs. In the past few years, based on our ‘Vision and Mission’ statements, we have put in place a product development plan and a dedicated R&D team who are frontline drivers. Also, we are using the best in class technologies available as a path to achieve new developments.

Emphasis on experimental validation of product performance has helped us 'walk the talk' through our product performance.

• Re-engineering and Market Segmentation: We understand that positioning our existing products for a specific market segment is very important. In order to meet specific produce expectations, we have improved and re-engineered our products. We are also focusing on re-engineering design and material parameters of our existing products for an optimal performance.

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Our plants are a tribute to our economical processes, comprehensive services, technology portfolio, experience and unique working methods. Energy-efficient, environment-friendly and operationally reliable, they stand out for their product quality, high yields and safety considerations. And they come backed by the technological competence of ThyssenKrupp Industrial Solutions-Process Technologies, Germany and its group companies.

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600 reference plants covering 4 decades

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Plants for Fertilisers, Petrochemicals, Refinery Units, Caustic Soda-Chlorine, Inorganic Chemicals, Metallurgy, Low Temperature Storages and Industrial Plants

ThyssenKrupp Industrial Solutions (India) Private Limited (Formerly Uhde India Private Limited) Head Office:- Uhde House, L.B.S. Marg, Vikhroli (W), Mumbai - 400 083, India.

Tel.: +91-22-4047 8020, Fax: +91-22-2578 4327, E-mail : tkisindia@thyssenkrupp.com Pune Office:- Dugal Plaza, Prem Nagar, Bibwewadi Road, Pune 411 037, India.

Tel.: +91-20-6608 1100, Fax: +91-20-6608 1300, E-mail : tkisindiapn@thyssenkrupp.com

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ThyssenKrupp Industrial Solutions (India)

CEW

SPECIAL • Product and System Certification: Apart from ISO 9001:2008, Fluid Controls has obtained PED certification, type test certification for its double ferrule fittings for fractional sizes up to 1” as per ASTM F1387-99 (2005 & 2012), and a host of other product performance certificates to international standards.

We are also in the process of acquiring new product certifications for CNG, high temperature high performance products amongst others.

The Fluid Control industry in India has experienced moderate growth over the past decade.

With our Prime Minister’s 'Make in India' initiative and support, we envisage a 20-30 per cent growth for us, both with our existing product range and with the new products we propose to introduce. The challenge in an industry, which is increasingly competitive, is the 'quality vs cost' debate. To 'Make in India', a company has to not only be cost competitive but also offer world class and world quality products. Keeping this in mind we, the team at FCPL is working towards implementing product optimisation, supply chain processes and stringent testing standards to enable us to offer clients quality at a competitive price.

We see 'Make in India' not just as a programme to manufacture cost competitive

With our Prime Minister’s “Make in India” initiative and support, we envisage a 20-30 per cent growth for us, both with our existing product range and with the new products we propose to introduce. The challenge in an industry, which is increasingly competitive, is the “quality vs cost” debate. and world quality products, but also as an initiative to explore creativity and research and development. In our organisation, every idea counts and we systematically review new development suggestions.

Our R&D approach is three-fold: out-of-box products, new products within our field, and minor-edits of our existing product portfolio. We have a clear five-year product development plan and strategy which we periodically review. In conjunction with our plan, we have a dedicated R&D team which keeps product design and the re-engineering moving constantly.

Encouragements received from Indian techno-giants like NPCIL, BARC, the Indian Navy, Railways, NTPCs, ISRO, ONGC, etc. have been of tremendous assistance in guiding us to develop new product designs.

In order to accelerate growth and development, we have installed and are using the latest Solid Modelling and Finite Element Analysis methods to virtually subject a product to near-reality conditions.

This helps reduce the single prototype development time. Also, lot of creativity

can be added in the define phase of the problem itself.

We have also set up a state-of-the-art laboratory which can perform stringent tests to ensure that our developments meet world standards.

At FCPL, as we are competing with ourselves internally as a part of continuous improvement, I feel we are ready for any type of competitive threat and also believe that we can become a global player offering products made in India which can compete with industry leaders.

We strongly believe that the 'Make in India' initiative, translated into policy and programs at a national level, will help us towards achieving our vision of being an Indian company which is 'a global leader in the field of fittings, valves, and allied application solutions'.

Dr Chaudhari did his PhD in Mechanical Engineering from IIT Bombay and worked with General Electric (GE) globally for 10 years in various roles, starting from Research Engineer and Sales handling Profit and Loss. He holds 5 Global Patents to his credit, 12 international journal publications and many conference papers. He is GE Certified Lean Six Sigma Master Black Belt, a visiting faculty and board of studies member to many business schools and engineering colleges. Tansen has published 2 Lean Six Sigma books and associated with many volunteer organisations as a mentor. He can be contacted at tansen.chaudhari@fluidcontrols.com.

Fluid Controls Private Limited

J V Patel ITI Compound, B. Madhurkar Marg, Mumbai, India, PIN: 400 013 T: 91-22-43338000 F: 91 22 43338001 E: sales@fluidcontrols.com W: www.fluidcontrols.com 58 • January 2015

Chemical Engineering World

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January 28-31, Mumbai Hall 1 - Booth D11A

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SPECIAL Interview

With Make-In-India's Launch, Old is the New NEW!: Kevin M Shah The new government has set the stage for development and the industry needs to play the game well, says Kevin M Shah, MD, Kevin Enterprises Pvt Ltd (KEPL). In an e-interview with CEW, he further reveals that the process plant owner must inculcate and imbibe a culture to capture the potential of Indian home grown vendors and further have targets to locate, guide and develop at least a few such Indian vendors for mutual benefits.

Kevin M Shah Managing Director Kevin Enterprises Pvt Ltd (KEPL)

Harshal Y Desai 60 â&#x20AC;˘ January 2015

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lease apprise us of the recent development within KEPL? How has its performance been in recent few years?

Before we talk about the recent few years, it is important to recall the period just before that. Barring a few bruises in some very select sectors, India as a whole had pretty much escaped a major downturn post the 2008 global financial crises. Most local industries by then had expanded or were expanding their capabilities at that time.

Unfortunately, not being badly hurt turned out to be a bane in disguise, as the then ruling government became over confident and instead of taking advantage of the injured overseas economies and pushing our own already flourishing industry to greater heights, it took a sudden socialist turn and scored a self-goal. Policies on the land acquisition, environment, minimum employment guarantee scheme etc were churned out that eventually resulted in the undoing of our economy and retarded every sector, especially our process industry.

The last few years have thus been rather slow, and considering that, KEPL has done modestly well. In anticipation of a change in regime, we have further expanded our plant;

we annexed an adjacent plot and bought additional machines to expand our capacity.

Recently, we have made our marketing actives more aggressive. We also bagged some prestigious orders from overseas. We believe that now with a pro-business government at the centre indeed, a lot of de-plugging of stuck projects and simplification of policies will take place. We all can hope that this is the lull before the desired storm.

Which are the sectors that generate maximum revenue for the company?

What are the market drivers? Which countries, region or markets are on companyâ&#x20AC;&#x2122;s radar?

The business is about cyclical famine and feast. Being a capital goods manufacturer, most of our business comes from purchase by new grass root plants or major expansions with bulk going in petroleum refineries, fertiliser plants and petrochemical complexes and that honeymoon goes on till the world hits a glut. In an integrated world, one can subsume that for one to put up process plants - global prices, firm and friendly national policies and a low interest rate regime would be the key drivers.

This is because for any project to be viable, a plant having a minimum economic capacity or having a global scale and size, is a must and Chemical Engineering World

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for the functionalization of particles or the encapsulation of liquids to the stabilization of sensitive substances. We develop and Glatt Food, Feed & Fine Chemicals Process Technology offers fluidized bed and spouted bed technologies for the production and provide laboratory units and production plants. We support you from the initial idea to the installation of your system. value adding of granules and pellets. Processes may range from spray granulation of liquids, agglomeration of powders, coating

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SPECIAL that requires considerable investment with long term gestation period between breaking ground, to breaking even. We expect a total reverse of situation at home and by end 2016, India should be on the top of the list of fastest growing economies of the world. America and Canada are also the places to look out for, besides Middle East. With Russia having considerable equity in our process industry - and being isolated by the western world, Indian companies may want to explore there to fill the vacuum.

Will you please update us on the green engineering concepts adopted within KEPL’s facilities?

Implementation of global cooling practices is today as much a requirement as a fashion due to the increasing awareness. We are a sheet metal fabrication shop, in our own modest way; we are doing little things for dear mother earth. To just name a few, at our plant, the work stations are ergonomically designed to ease working while adequate personal protective gears are deployed for use thus reducing excess stress and strain on our workmen; we have implemented the use of less toxic paste for cleaning our weld joints, cutting fluids are recycled for use in machining process, while spent fuel such as machine oils are stored and returned to refiners for recycling; our factory roofing is fitted with translucent sheets that aid in illumination using natural sunlight, for the entire day a lot of electricity is saved; the roofing is fitted roof top fans that are selfrotating using wind force, this also helps us in saving valuable energy resource and we have installed bore well for water for nondrinking purpose, thus saving the energy cost of filtration. I personally do not use elevators even when my office in on 5 th floor. That way I save energy and steal some exercise!

What are your views on ‘Make in India’ campaign? Do you think India can go a long way increasing its manufacturing capabilities? What are the issues that can hinder the progress of ‘Make in India’ campaign?

‘Make in India’ campaign makes so much common sense. Can we even imagine that an 62 • January 2015

The scope for breakthrough or disruptive innovation looks difficult in mass transfer equipment business. Process plant buyer or owners in India, in their zeal to keep an arm’s length, have forgotten to have a handshake with vendors. Thus, they lack the culture to work with vendors to develop products jointly, which could be of mutual interest. independent developing nation like India, with itself in need for so many goods, still being import dependant? That too, after having so many people looking for jobs or having lower pay in comparison to the developed world's average daily wages! It is worth pondering that under what influence did our policy makers expect India to go from an agriculture-based economy to a knowledge-based one, while bypassing the manufacturing one. The ‘Make in India’ campaign - if correct incentivising laws and rightly priced finance is provided could well usher an Indian decade or two for the world to applaud.

While Information technology is also very important, the manufacturer of a physical asset or old economy gives several fold higher value addition besides creating jobs across the entire spectrum. In India, we were always sceptical if this common sense concept would ever be understood by the top guys in the government. Tables have turned now after this campaign of ‘Make in India’ has been launched and that too at the highest level, by the PM himself. The hindrance could now be at the lower levels. We will have to see if the 'babus' and some PSU officers have woken up to reality - now the 'old' is the 'new NEW'!

How research and development is being evolved within the company?

The scope for breakthrough or disruptive innovation looks difficult in mass transfer equipment business. Process plant buyer or owners in India, in their zeal to keep an arm’s length have forgotten to have a handshake with vendors. Thus, they lack the culture to work with vendors to develop products jointly, which could be of mutual interest. Same is not true, say for a company like Shell or BASF, who openly encourage vendors. Further, as a culture, we train our students and later managers at workplace

to be super conformists and that means risk taking appetite in such individuals is next to nothing. That leaves very little incentive for any developer. Most of the innovations have thus been limited with incremental improvements. We have recently signed a Memorandum of Understanding (MoU) with Engineers India Limited to make and testenhanced mass transfer products at their R&D centre at Gurgaon.

What are the growth targets of the company in the next five years?

What must be clearly understood about employment of capital goods in process industry like petroleum refineries, petrochemical plants, urea making fertilisers and pharmaceutical units is that a customer will not buy because you want to sell; there is no scope for impulse buying. It is a project driven economy which further depends on government policies and that may further be under election related or global pricing pressure from time to time. The root cause of the global financial crises was the unfounded and steep upward targets given by some extra wise guys at the top leading to an oxymoronic 'profit at any cost' type race and the subsequent world infamous burst outs and bail outs of businesses. Our efforts at KEPL are to be on the radar of the customer; ‘sales’ is then a possible effect. Having said that, this time, it seems like India is poised for a take-off on a flight to a better path and I am sure it will carry its citizens with it.

Kevin Enterprises Private Limited Plot No11, Street No10, MIDC, Andheri (E), Mumbai, India, PIN: 400093 T: 91 22 61478000 F: 91 22 61478001 W: www.kevincpp.com Chemical Engineering World

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CEW

SPECIAL Interview

Chem Process: ‘The Right Solution to Each Client’ Chem Process Systems (CPS) has been operating on a simple philosophy - to provide impeccable range of products to its customers that meet thier requirements the in the best possible manner, and this culture has helped the company increase its product range, enhance skills of the employees, incorporate product innovation and focus on customer satisfaction, believes Jayesh Parikh, Managing Director, CPS. As a ‘leading Engineering Solutions Provider’, the company helps its customers create value by delivering superior products and services. The company received ‘the Best SME Award’ by a reputed group in the year 2012 within just 10 years of its inception.

Jayesh Parikh Managing Director Chem Process Systems Pvt Ltd (CPS)

Harshal Y Desai 64 • January 2015

W

hich are the sectors that generate maximum revenue for the company? What are the market drivers?

Leading process manufacturers in the sphere of pharmaceutical, chemical, textile, power, water, and fertilisers use our products and services. Our established and growing global footprint providing end-to-end excellence from the design manufacturing and installation of original equipment to leading aftermarket service and support is the reason behind our success. Increasing requirements of clients for the latest and efficient products have been very conducive for CPS’s growth.

How do you evaluate Indian industry’s enthusiasm towards adopting Zero Liquid Discharge technologies or mechanism in their facilities?

The concept of Zero Liquid Discharge (ZLD) is being actively promoted by all the government and non-government organisations as it is indeed the need of the hour for better water and land preservation. Indian industries, which have been committed to moral and social values, are adopting and implementing the ZLD concept diligently, but still there are a lot many well-known companies and big industrial units who are a bit hesitant on implementing the

technology, due to some impractical and nontechnological market gimmicks. There have been many cases, where just for the sake of putting up a ZLD, these companies have opted for a low cost option with outdated and non-feasible technologies.

Are these solutions expensive?

The definition of expensive will vary from company to company and their basis of evaluation. Many small chemical manufacturers have adopted the ZLD concept as a part of their culture and many have adopted for the sake of abiding to the norms of pollution control. If you consider ZLD as a part of your manufacturing plant rather than a mandatory process then you will not find it expensive, but if it is considered to be an enforced issue, it is expensive.

What are your views on ‘Make in India’ campaign? To what extent SME sector – in its current capacities - can strengthen the campaign?

We believe in the concept. We have immense potential to make each and every engineering process in our country itself. How much time it will take to be self-dependent is still mysterious. Yes, SMEs have a huge role to play in strengthening this campaign. SMEs Chemical Engineering World

Advt New.indd 39

6/22/2011 7:32:04 PM

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SPECIAL are the backbone of our country and more or less all the giant companies are dependent on them. I believe that stronger the SMEs, stronger the economy.

The technological advances that have swept the globe in last couple of decades could not have been possible without the belief of an innovator and definitely would not have been a success without the acceptance of a user. It is just the trust we - as Indian technocrats - would like to have from our fellow professionals to make our ‘Make in India’ concept a reality rather than just a slogan.

What boost does the SME sector require from the government so as to become more efficient and capable to strengthen the campaign?

Companies, which have indigenously developed technologies and manufacturing facilities, need government attention and need its assistance. The government should insist on Indian suppliers and give them preference on the basis of their technological capabilities.

Technology wise, we are internationally acknowledged, but there are many other area including SME taxation support and certain

The government should insist on Indian suppliers and give them preference on the basis of their technological capabilities. Technology wise, we are internationally acknowledged, but there are many other area including SME taxation support and certain import and export incentive that need some motivation from the government. import and export incentive that need some motivation from the government.

How is the research and development is evolving within the company?

Innovation is in the heart of our business - whether we create new products or new processes that improve and develop customer service and competitive advantage.

We support innovation through our R&D test centre which has also been recognised by the Department of Scientific and Industrial Research. Our R&D centre along with our Pilot Test Centre helps us create value for our customers. We take pride in quoting that our way of business is inspired by research and not driven by economic statistics. And to take the technological perfection to the next limit, we have made it mandatory to incorporate research and development in every product or process development.

How do you handle the issue of corrosion?

Corrosion is an inevitable process in any thermo-chemical equipment, if not scrutinised during the basic studies of process. It is a very huge subject and you can debate for days together on without any results. But yes, in our case, we do check a lot of parameters, like compatibility of equipment material, certain chemical rules initially and after process, circumstances of operation, selection criteria and others to avoid or delay in corrosion as much as possible. We have been successful in avoiding the same to a great extent and - as experts from all around the world working on the issue and finding innovative solutions - we hope to overcome this issue in future.

What are the growth targets of the company in the next five years?

We do not set targets for company in terms of volume or turnover, but just focus on ‘Grwoth’.

Growth in terms of client base, growth in terms of client reputation, growth in terms of infrastructure, growth of each and every person of our team, growth in terms of satisfaction of performance, growth in terms of stability of financial condition. But, unfortunately growth has been still seen as a figure oriented aspect; so, looking at the market condition, customer awareness and product demand I believe that we shall at least be three times the company that we are today with respect to infrastructure and volume of business.

Chem Process Systems Pvt Ltd 15 Natraj Industrial Estate, Vasna Iyava Sanand Viramgam Highway, Sanand Ahmedabad, India, PIN: 382170 T: 91 2717 284148 - 49 - 50 F: 91 2717 284194 E: chem@chemprosys.com W: www.chemprosys.com 66 • January 2015

Chemical Engineering World

CEW

SPECIAL Interview

Raj Process Equipments: Confident of Sustainable Growth The motto of Raj Process Equipments & Systems Pvt Ltd (RPESPL) has always been to continue the growth momentum through constant research and development within the company, says Anil Pise, Managing Director, RPESPL. The company has recently bagged a contract for a 400-tons/day maize starch processing plant along with manufacturing of liquid glucose and Malto-dextrin.

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hich are the sectors that generate maximum revenue for the company? Which markets are on the company’s radar?

At RPESPL, Major share of the total revenue is generated with turnkey solutions wherein we provide end-to-end solution to our clients for their process needs. RPESPL is targeting on developing its market in countries including Nigeria, Jordan, Kenya, Argentina and Malaysia.

How are the second-hand equipment market and competition from China affecting the industry?

Yes, we do face some competition from the Chinese manufacturers, but due to our stringent quality norms and high production rates, we have been able to stay ahead in the game. As far as price is concerned, we do face some challenges from cheap manufacturers; however, our clients are happy with the quality that we ensure.

Will you please update us on the green engineering concepts adopted within RPESPL’s facilities?

We have already implemented green engineering at all our factory premises. We have stringent control over manufacturing of waste.

The company uses CNC cutting machines for precise cutting of sheets thus reducing the 68 • January 2015

wastage and scrap generation. Risk to human health is also ensured by our safety officers who are always on their toes to monitor the people and their practices. We also arrange safety awareness programmes frequently for our employees. Further, we are also in a process of implementation of OHSAS at all our manufacturing facilities. We have a fullfledged research and development laboratory, where our research team constantly develops new processes for our existing as well as new product range. To ensure the problem of corrosion, we make a material safety data sheet which enables us to choose the ‘Material of Construction’ as per the Material Compatibility Chart.

What are your views on ‘Make in India’ campaign?

'Make in India' campaign is launched to put India prominently on global manufacturing map and in turn, facilitates the inflow of new technology and capital, while creating the jobs for millions of youth. India can go a long way in increasing its manufacturing capabilities but on the other side, India’s make in India campaign will be constantly compared with China’s 'Made in China'.

India should constantly keep up its strength so as to outplace China’s supremacy in the manufacturing sector.

However, there are some gaps between foreign investment and policies in India that need to be bridged to accelerate the ‘Make in India’ campaign.

Governments need to work on swift project clearances, streamlining of the implementation procedures, revival of manufacturing which has significant backward and forward linkages, simplification of tax policies and administration, repeal archaic laws which hinder the expansion and entry of new firms, revamp of the dispute resolution mechanism by bringing a separate tribunal to deal with disputes related to foreign firms, and a policy of certainty, continuity and transparency.

What are the growth targets of the company in the next five years?

We are currently in discussions with many companies for technological collaborations for variety of products which are to be introduced to the Indian market. We may sign agreements with companies who are willing to have a manufacturing or technological joint venture with our company. We will also be launching our IPO very shortly.

Raj Process Equipments & Systems Pvt Ltd T: 9120 - 40710005.

W: www.rajprocessequipment.com Chemical Engineering World

CEW

SPECIAL Interview

Gopani Product: Offering “World’s Top Filtration Products” Even during the economic meltdown, Gopani managed to register remarkable growth in its business, says, Pathik Gopani, Managing Director, Gopani Product Systems.

In this interview, he further throws light on company manufacturing strength and its plans for future.

P

lease apprise us of your company’s performance in recent few years?

We have done pretty well in the past few years. In 2008, we acquired one of our competitors - Uniexcel Agencies & Services Pvt Ltd. And it took us about a year to merge the company with our existing set-up, and now both Gopani and Uniexcel work in tandem creating synergies to serve the markets.

Gopani has predominantly been providing services to manufacturing industries and water treatment industry with more than 1200 small and large water treatment companies as our customers. In India, we are playing a vital role. We specialise in offering filtration system that protects downstream equipment and we have been doing that job relentlessly with almost zero problems for our customers and for our customer’s end users. I would say past few years have been magnificent in terms of our performance.

has grown serving different industries and sectors, simultaneously.

Which sectors have generated maximum revenue for the company?

The biggest contributor in the last five years has been water treatment industry, oil and gas industry and process and chemical industries. We are also seeing an upward trend in power generation, mining, steel, pharmaceutical industry as well. It is not just any one industry, but our company

What are your thoughts on ‘Make in India’ campaign?

It is a great campaign. I believe countries which did not focus on manufacturing never grew. A phenomenal growth of China is a good example and so is rebound of US economy. Production today is the key to a country’s growth.

Production will provide more job opportunities to the people and generate revenue that can

70 • January 2015

What are the USPs of the products manufactured by the company?

We always see the market divided between two types of buyers; buyers who look for solutions and buyers who look for economy products. We are predominately looking at the buyers who look for solutions with premium quality products.

These buyers typically want to concentrate on their core competence without having to worry about process issues. Our product portfolio comprises of some of the world’s top filtration products for each vertical. Our filter cartridges, self-cleaning filters, micro-filtration and ultrafiltration membranes, filter media, filter aid from JRS Germany, solutions for process industries, and filter housings are all setting a bench mark for Indian Industries we serve. Our products are technologically updated.

be invested in research and development. It will make the country self-sufficient and help in saving valuable currency on trivial products.

It is a very good plan and the campaign must be driven forward relentlessly by the government.

What are your plans for future?

We are a company that is learning every day, growing every day. Our core competence will remain solution providing and churning out world-class products. We are currently targeting oil and gas applications in the world markets. We are actually refreshing our product portfolios to focus on end-user applications and according to us, exports and local industries both will drive our business.

We hope to build a world-class organisation with a world-class team with world class products - that is where we see ourselves in the near future.

Gopani Product Systems T: 91 79 26441972 – 26441951 F: 91 79 26442601 M: +91 98246 01857 E: pathik@gopani.com W: www.gopani.com Chemical Engineering World

CEW

SPECIAL Interview

Advance Valves: Manufacturer

A

Distinct

and

Significant

Indian pumps and valves manufacturers have earned accolades in the global market, says Pranay Garg, Director, Advance Valves. In this interview, he further rates the overall capabilities of Indian industry and highlights the sectors which will drive the growth of the organisation in the near future.

Pranay Garg Director Advance Valves

Harshal Y Desai 72 • January 2015

A

dvance Valves is serving domestic as well as international market with its wide product rage manufactured in India. Can we say that the company’s strategy is already in line with government’s 'Make in India’ campaign?

Absolutely! The core foundation of Advance Valves has been to bring technology to India, to manufacture items which have not been manufactured in India before. This is how we have continued to be the pioneer in the product range we have introduced since our beginning 30 years back, to till date being identified as the distinct and significant manufacturer for our range of valves. This recognition is well endorsed even globally, where we work with the most premium clients, who work on technology and product reliability from an organisation which is a dependable project partner. The vision set forth by our Prime Minister is all about coming on that same platform recognising the Indian potential, to be the source, and not just a source, but the chosen source of high end engineering.

How do you rate the overall capabilities of Indian industry in the sphere of valve manufacturing? Can we really become a one stop destination for valves users

worldwide? How well are the valves manufactured in India accepted worldwide?

India has matured significantly over the last decade or so as a manufacturing base.

Earlier there were 2 or 3 valve manufacturers like us who were known worldwide for their product capability. Today, many other Indian valve manufacturers are recognised across the globe as the preferred source. This is even excluding the internationally renowned names which have set shops in India recently. The original Indian manufacturers and the international manufacturers in India have today demonstrated to the world the capability of India to be a complete source for almost the full spectrum of valves for any high end process plant. The level of acceptance is also very respectable for the Indian manufacturing diaspora.

Do Indian manufacturers have advanced technology to meet entire demand for valves? It is opined by some leaders that there are some critical areas where India still has to import certain types of valves?

Please elaborate.

Today, the Indian manufacturers are capable and have demonstrated that they can fulfill more than 80 per cent of the variety of needs. For the remaining 20 per cent also, Chemical Engineering World

Value-added Liquid Transport Solutions DESMI has a large range of industry pumps for various industrial applications: Chemical Processing (adhesives, glycerin, Isocyanate, pastes, polyol, unsaturated polyester resin, polymer)

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DESMI Pumping Technology A/S (India Liaison Office) 413, Aditya Trade Centre, Ameerpet Hyderabad â&#x20AC;&#x201C; 500016 91- 8790122223 Email: srai@desmi.com

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CEW

SPECIAL there are segments for which India has supplied to some customers, and is working towards being recognised as an established source. This is sometimes restricted due to certain procurement practices in India, where the proven track record is considered to be the eligibility criteria. Since that can never be the case and the manufacturer faces the chicken and egg dilemma, often manufacturers like us establish success first outside India, and then bring that offering back into India.

Once we are able to break the shackles of this approach, by topping up ‘Make in India’ with ‘Buy in India’, there shall very soon be no domain which we would not be able to cover.

What is Advance Valves’ market share in India? Will you please share some numbers or statistics? Which are the sectors which will drive the growth of the organisation in the near future?

Advance Valves continues to be known as a distinct and significant manufacturer for its products. In multiple product domains, we are the largest manufacturer with market share above 50 per cent of the total Indian market. (This is based on independent surveys we have conducted in the market since no organised data is available in detail).

Advance is seeing growth in various petrochemical and oil & gas, and power generation domains, including offshore and LNG. Product upgradations to stay ahead in these areas are also being done in a much focused manner.

How intense is the deployment of research and development within the company?

Research and Development is a very core area at Advance Valves, and covers product, application and process. This is directly led by the Board of Directors, as the organisation’s investment into the future for sustainability and being ahead of the pack. In addition to dedicated resources and infrastructure, the time of the senior team and the organisation 74 • January 2015

We see China as a stabilising source for valves. There are a couple of reliable manufacturers who have emerged over the years. The bulk of manufacturers however are still surviving on being a low cost source.

This has worked in certain industries, but now buyers are selective and recognize India and China distinctly. spent on R&D is also targeted and closely monitored.

There is a lot of effort in the market on creating solutions to the customer needs.

This is how we are able to connect with the customers and work on technology for emerging needs.

most respectable clients in the oil & gas industry have accepted this capability of Advance Valves by partnering with us and choosing us as the sole source for their most prestigious projects repeatedly.

How do you see the competition from Chinese valve manufactures? Do Chinese manufacturers have better technologies than Indian valve manufacturers?

We see China as a stabilising source for valves. There are a couple of reliable manufacturers who have emerged over the years. The bulk of manufacturers however are still surviving on being a low cost source.

This has worked in certain industries, but now buyers are selective and recognise India and China distinctly.

In terms of technologies, the Chinese manufacturers - given the government support to manufacturing - have moved fast with easy access to capital and cost of capital. India - on the other hand - has grown slow and steady with its own indigenous efforts which are stable and significantly robust in some areas.

What are your plans for future?

Advance Valves is on a massive growth path. We have invested significantly in our infrastructure multiplying capacity to over 4 times in last 6 years. This year, we shall be growing by 50 per cent.

This growth is happening at the core of the organisation and not just at the top line. Be it in terms of the highest caliber of talent across levels, technology deployed within the organisation or be it in terms of being in front of the customer across the globe with our globally expanding network. The

Advance Valves 142 A & B, Noida Special Economic Zone Noida, India, PIN: 201305 T: 91 120 4796900 F: 91 120 4796948 E: global@advancevalves.com info@advancevalves.com W: www.advancevalves.com Chemical Engineering World

CEW

SPECIAL Company Profile

RCF: Committed to Indian Farmers

R

ashtriya Chemicals & Fertilizers Limited (RCF), a Government of India undertaking, is a leading fertiliser and chemical manufacturing company with about 80 per cent of its equity held by the Government of India. RCF manufactures and markets urea and complex fertilisers (NPK) along with a wide range of industrial chemicals. Government of India has accorded 'Mini Ratna' Status to RCF. The 'Ujjwala' urea and complex fertiliser 'Suphala' brands of fertilisers manufactured

by RCF carry a high brand equity and are recognised all over the country. RCF has countrywide marketing network in all major states. Besides urea and complex fertilisers, it also produces bio–fertilisers, micronutrients and 100 per cent water soluble fertilisers.

Apart from these products the company produces almost twenty industrial chemicals that are important for the manufacture of dyes, solvents, leather, pharmaceuticals and a host of other industries.

Since inception, RCF has successfully and safely operated two dozen chemical and fertiliser plants for the past four and a half decades at Trombay. It has operated plants at Thal for last twenty five year and maintained the quality of environment.

This itself has been a huge challenge and demonstrates the company’s commitment towards environment and concern about the neighbourhood. RCF has spent more than ` 400 crore over the years in various pollution abatement and environment improvement schemes. This includes massive drive for tree plantation under 'Chembur Green' Project. Complete transparency is maintained by the company in dissemination of environment related data 76 • January 2015

and information. Through four dedicated continuous Ambient Air Monitoring Systems located around the boundary of the factory, real time emission levels are displayed through an illuminated board placed at the entrance of the factory for public viewing. No wonder that the company is maintaining ISO 14000 accreditation for environment since a decade. Both the manufacturing units are accredited with ISO 9000 for quality and OHSAS 18000 for Occupational Health and Safety. Recycle and reuse of resources has been the basic philosophy of RCF. The company has set-up sewage treatment plant which is one of its kinds in the country. The plant treats some part of the huge sewage generated by Mumbai city, which otherwise would be drained in to the sea. The plant generates 5 million gallons (MGD) of pure water each day and saves the equivalent amount of potable water for the city.

RCF is poised for growth through implementation of major projects which will help reduce the demand supply gap in the country. It is engaged in developing a project for 1.27 million MT urea plant at Thal, another 1.27 million MT urea plant based on coal gasification at Talchar and scouting for joint ventures in countries with natural gas resources. RCF strongly believes in discharging its Corporate Social Responsibility (CSR) diligently. A host of CSR activities are undertaken by the company which includes adoption of villages, providing drinking water, providing schooling facilities and scholarship, special measures for SC/ST and under privileged, providing training to farmers etc.

R G Rajan, CMD, RCF Memorandum of Understanding (MoU) with Government of India. The performance is evaluated independently by the Department of Public Enterprise. RCF has consistently been achieving the best rating of ‘Excellence’ for past several years. The company has been placed in 'Top Ten' amongst all the Public Sector Units (PSUs) of India for two consecutive years, with respect to MOU performance. It is now poised to get 'Navratna' status. RCF has maintained a good financial position.

RCF Limited Priyadarshini Building Eastern Express Highway, Sion Mumbai, PIN: 400 022

RCF does what it commits. The commitment is translated in a written document – the

E: Please visit the website W: www.rcfltd.com Chemical Engineering World

CEW

SPECIAL Company Profile

Transflow Asia

T

ransflow Asia is an ISO 9001:2008 certified and a professionally managed company in the field of manufacturing PTFE lined steel pipes, fittings, and fluoro-polymer accessories for chemical, oil and petro-chemical, pharmaceutical, dairy and other processing industries meeting international standards. It has catered to several organisations in the past and has good relations with a number of satisfied clients.

The company's qualified and expert engineers give the innovative solutions to handle the high quality fluid, corrosion resistant piping and vessel problems. It assures its clients of purest raw material, and follows high quality standards as well as international standards like ASTM/DIN/ BS Transflow Asia blends extensive plastic molding with ASME section VIII code metal capability to bring its clients piping and valve system. The cmpany specialises in small to large diameter armed with various special techniques, ranging from unmatched floropolymer moulding and welding technology. Transflow Asia gives equal importance to each customer’s requirements whether large or small, and whilst using CAD equipment and the latest manufacturing technology, it remains small enough to be flexible. Clients can rely on the company and receive its full attention to each inquiry and order.

Transflow's wide range of products and equipment used for handling high purity, dangerous and corrosive media is the result of years of experience in the application on PTFE, FEP, and PFA lined products.

The company specialises in design and manufacture of high purity, corrosion and 78 • January 2015

release products for various industries all over the world. Customer satisfaction is essential to company's success. It is possible by understanding the requirements of client’s by providing the quality products and services in a timely manner. "We aim to remain a quality and desirable supplier by identifying our customer’s needs and expectations, and by delivering their required products in a timely manner. Our expertise are consistently monitoring and managing the quality and performance of products to achieve targets.

Continuously honing our employee’s skills and increasing their contributions through ongoing training, and process improvements. We are committed to providing a choice of applicable high quality solutions, for good value, in the products and services we deliver to our customers," the company states.

To ensure a consistent level of product quality across all operations, its quality programme is structured in accordance with industry standards. Its core expertise, and much of the work it does, involves processing of corrosion resistant and high purity fluoropolymers such as PTFE, PFA, FEP etc. as per the customer’s requirement.

Products Lined Pipes and Fittings ( CS / SS 304 / SS 316 ) • PTFE Lined Pipes • PTFE Lined Bends / Elbows / FEP Lined Headers • FEP/PFA Lined Tee / Cross / Reducer / Y Type Strainer / Instrument Tee • FEP /PFA Lined Sight Flow Indicator (Double Window) & full view sight glass with metal frame • PTFE Lined Flexible Hose Pipe & Metal Bellows

PFA / FEP lined valves ( CS / SS 304 / SS 316) • Ball Valve / Flush Bottom Valve • Butterfly Valve / Diaphragm Valve • Plug Valve PTFE Products • Bellows for high pressure and vacuum applications (size 1” to 14”) • Valve Bellows / PTFE ‘O’ ring • Distributors / Redistributors for Column • Tube sheet set for glass Heat exchanger (Up to 12” size ) • Bush / Rod / Sheets & customised products Glass lined Reactor Accessories • PTFE Nozzle Liners / Solid Bush for GLR Nozzles • PTFE Envelop Gaskets / Expanded PTFE Gaskets • PTFE Lined Dip Pipe /Feed Pipe / J – Pipes / Sparger • PTFE Lined Thermo Well • FEP Lined Man-way Cover Assembly • PTFE lined Agitator

Transflow Asia 3/2 Ganesh Industrial Estate, New VIP Ring Road, Near Raghukul School Lane Vadodara, Gujarat, India, PIN: 390019 T: 91 265 2516156 / F: 91 265 2516156 E: sales@transflowasia.com; transflowasia@gmail.com W: www.transflowasia.com Chemical Engineering World

CEW

SPECIAL Company Profile

Super Industrial Lining Pvt Ltd

E

stablished in the year 2008, Super Industrial Lining Private Limited (SILPL) is a distinguished organisation involved in manufacturing and exporting an impeccable range of Lined Pipes System, Fittings and Valves. It is an ISO 9001:2008 certified company engaged in offering Line Spacers, Lined Elbows, Lined Tees and Lined Concentric Reducer. Furthermore, the company offer Lined Reducing Flange, Lined Double Window Sight Glass, PTFE Lined High Pressure Bellows, PTFE Lined Dip Pipes and Spargers, Glass Lined Accessories, Hose Pipe and more. This present gamut is being fabricated by making use of premium quality alloy, stainless steel and other required raw material, followed by comprehensive R&D. Furthermore, product-line which the company offers is complied with the define parameters of the industry, signifying its high and unsurpassed standards.

SILPL is a part of the 150 crore group.

The company has now started focusing on exports and has already exported in regions like USA, UK, Middle East, Far East, South Africa, SF Asia and Australia. Under the astute guidance of Naresh Goyal, Managing Director, Super Industrial Lining Private Limited has been able to develop expertise in this domain. Owing to his visionary and motivated persona, SILPL have been able to gain more knowledge for staying ahead of the pack.

The company understand the divergent demands of the clients and made the offered product-gamut in multifarious specifications.

Product array which has been made available is being appreciated for its remarkable attributes such as longer service life, resistance against corrosion, 80 â&#x20AC;˘ January 2015

performance and high tensile strength. "We are looking for international tie ups, mergers and collaboration which would lead to our goal. We are present in all the four quadrants of the country in the form of regional offices, agents and distributors. We intend to have a global presence. The company intends to have an EOU unit especially for the exports, continuing the existing facility for the domestic sales. We have structured a sound infrastructure set-up at Gujarat, India. The set-up is accentuated with all new-fangled machinery and required amenities that enable us to meet production target by maintaining swift and safe rate of production. With the support of such infrastructure set up we are able to meet bulk demands of the clients without compromising on the quality within minimal time frame. With due consideration, we have made our set up connected with all the shipment modes so as to ensure timely and prompt delivery of the end products at the clients end," SILPL states.

Since its inception, SILPL has been serving its esteemed clients with the best-in-class product array and fair business policies, which have enabled us to rejoice the position of the most preferred organisation. With an aim to

cater to the divergent demands of its clients, the company has made the offered productarray in different specifications. Along with this, its clients can avail the best range, made as per their detailed specifications.

"We strive to maintain transparency in our business dealings by following fair business policies. Furthermore, we serve our clients with timely delivery, and flexible transaction modes. Owing to the aforementioned we have been able to live up to the expectations of the clients situated across the continent."

Super Industrial Lining Pvt Ltd Block No: 1401 A& B, Behind Elysium Pharma, Mahali Talav, Luna Patiya Taluka: Padra, Vadodara, Gujarat PIN: 391440 T: 91 2662 222 036 â&#x20AC;&#x201C; 37 E: navdeep@silcindia.com; info@silcindia.com; W: www.silcindia.com Chemical Engineering World

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SPECIAL Company Profile

Everest Blowers Pvt Ltd

E

verest started manufacturing Twin Lobe Rotary Air Blowers way back in 1980. Over the years the company has expanded its technological base, bringing a wide range of products. Its quality management system confirms to the quality management system standard - ISO 9001:2008. Facilities include in-house design, production, manufacturing, quality control, inspection and after sales services.

Sales operations within the company are taken care of by a network of direct sales representatives, distributors and agents. Everest has a complete marketing infrastructure all over India. In sales division, people have years of application experience and they are totally capable of helping company's clients determine their best hardware solutions.

"Today, Everest Blowers Pvt Ltd has a manufacturing capacity of over 600 blowers per month. Over the years the group has built 3 state-of-the-art manufacturing facilities for “Roots Blowers, Package Blower Systems, Vacuum Boosters, Vacuum Pumps and Package Vacuum Pumping Systems," says Daksh Malhotra of Everest Group.

"The ‘Make in India’ campaign is a great initiative by our Honourable Prime Minister and we are hoping that it will benefit the blower and vacuum pump industries as well. All the blower and vacuum pump manufacturing industries in India (organised sector) are under the Small and Medium Enterprises (SME) banner. If the industry is supported with proper policies for land, labour and taxation, it can achieve greater heights in the long run," Malhotra adds further.

82 • January 2015

According to him, Everest has also geared up and improved its manufacturing capabilities - right from design stages. The company’s R&D facility is approved from the Ministry of Science and Technology – Government of India. The company has also received the National Award from former Prime Minister Dr Manmohan Singh for ‘Excellence’ in R&D in 2014.

"Everest has tied up with South Korean manufacturers for bringing in a new technology of Vacuum Pumps (Dry Screw Type). This technology has been liberally accepted by Indian chemical and pharmaceutical sectors.

This helps in obtaining, 100 per cent solvent recovery and reduces wastage as well as discharge to the ETP’s etc. thereby reducing pollution. Chemical and/or pharmaceutical sector in India is growing and at this moment they are willing to invest in advanced technology and explore the options of new and improved methods for efficient manufacturing.

Everest Dry Vacuum Pumping Systems have been found to be very effective and efficient in both these sectors.

Everest also manufactures Mechanical Vapor Re-Compressors that is used to recover the latent heat from Waste Water, thereby reducing the fuel cost considerably.

If, through the “Make in India” campaign the Indian Manufacturers (Especially MSME) are given the right opportunities, it will definitely prove its mettle to strengthen the Indian economy. A focus on innovative design and high quality machine parts has earned Everest a reputation of excellent workmanship amongst its users. For nearly two decades, Everest has offered its customers quality and cost-effective machines, necessary to meet the changing technology. Our commitment to total quality management in both our products

Daksh Malhotra, Everest Group and services is the foundation upon which our future business is based.

Everest Blowers was incorporated with a determination and commitment to deliver total quality in its ever-increasing range of products and services. We aim at strengthening our technological base consistently so as to deliver a flexible and dependable product line to our customers.

We endeavour to provide robust quality in our products and services (before and after sales) that may ensure years of service in cutting edge and demanding applications.

Everest Group B-44 Mayapuri Industrial Area Phase-1, New Delhi, PIN: 110064 T: 91 11 45457777 E: daksh@everestblowers.com W: www.everestblowers.com Chemical Engineering World

NEW Digi-Sense™ Meters— designed for maximum productivity!

Digi-Sense® Professional Logging Infrared Thermometer, 50:1 Measure and log temperatures up to 1850°C

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403, Delphi-A Hiranandani Business Park Powai , Mumbai-76

4024

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CEW

SPECIAL Company Profile

DIP-FLON Engineering & CO

I

ndustry leader since 1987, a company with primary objective of implementing hi-tech engineered polymer processing, throughout 26 years, Dip-Flon has gained specialisation in its target of achieving polymer processing.

Certifications: Dip-Flon is an ISO 9001:2008 certified company and a member of DuPont’s PPN Network. It is approved by various TPI like EIL, UHDE, TATA Project, CE Certificate etc.

The Plant: The company’s manufacturing plant based in Chattral GIDC, Gujarat, spreads to about 3000 sq yards and employs about 100 people.

The Journey: Over the years, the company has learnt and strived hard to excel in quality of the products that it manufactures.

Dip-Flon has emerged as one of the leading processors and fabricators of PTFE Moulded & Lined Components Like Spool Pipes & Fittings, Ball Valves, Plug Valves, Diaphragm Valves, Flush Bottom Tank Valves, Ball Check Valves, Dip Pipes, Spargers, Feed Pipes, Spindles, Sight glass and Spares For Glass – Lined Vessels and Reactors/Equipment.

The Clients: Its products are used in various industries across the globe including chemicals, petrochemicals, refineries, food and beverages, textile, pharmaceutical, pulp and paper, fertilisers, mining industry and allied industries.

Equipped With Modern Machineries: Dip-Flon, equipped with modern machineries and hi-tech processing equipment, is backed by highly qualified 84 • January 2015

team of technocrats andtechnical experts, after constant research and development efforts supported by world best technical guidance of M/s DUPONT, the company has perfected wide range of PTFE components of superior quality with excellent result oriented performance for ensuring cost reduction both in production and maintenance.

Great in Achievments: Dip-Flon’s business achievements are based on its continuous efforts to up date and improve high innovation rate in processing PTFE moulded and lined products.

Great Processors: The company is processing all grades of fluorocarbon resins as per ASTM F-1545. Dip-Flon gives prime importance to quality and follows all the requisite quality standards starting from level of procurement of raw material till the final stage of production under the strict supervision of experts and inspections by qualified technical personnel to ensure that customer is served with best quality products and meet international standards.

PTFE Lined Products: The company is serving Indian industries since last 26 years. Dip-Flon has also launched PTFE Transfer moulding Technology with full indigenous efforts backed by in house research and development facility. It manufactures and supplies vide variety of Lined Pipes, Pipe Fittings and complete range of lining system processed with hitech advance technology and experience.

Its various processing plastics are as – FEP (Fluorinated Ethylene Propylene) FEP is a co-polymer of tetrafluoroethylene and hexaflouro propylene. It is suitable

for continuous service temperature up to 180 0C to 200 0C and retains the chemical resistance with dielectric strength of PTFE. PFA (Perfluoroalkoxy): PFA is newly developed fluoropolymer, which is a Co-polymer of tetrafluoroethylene and perfluoroalkoxy monomer. It has excellent mechanical strength and outstanding dielectric properties. It is unaffected by virtually all solvents and chemicals even at high temperature of 240 0C to 260 0C. Safety: Company’s products come with a guarantee of safety. “Dipflon believes in manufacturing products that are safe in nature.”

Innovation: We innovate. We Build. We discover. We at Dip-Flon believes in doing things with brilliance.

Quality: Nothing can match a good quality.

So do we believe, here at Dip-Flon.

Service: Good service is the only mantra of modern day markets. How can we remain backwards from modern trends.

Mukesh Parikh - Partner Dip-Flon Engineering & Company B-413, B.G. Tower,Outside Delhi Gate Shahibaug Road,Ahmedabad, PIN: 380004 Gujarat, India T: 91 079 2562 4003, 25624169, 25620554 F: 91 079 2562 5665 E: dipflon@dify.com; info@dipflon.com W: www. dipflon.com Chemical Engineering World

SE

SAMARTH ENGINEERS AN ISO 9001 : 2008 Certied Company

Specialist in · Pressure Vessels & Heat Exchanger · Process Equipment Design & Fabrication · Agitator Tanks · Distillation Column · Condensers

· Manhole

· · · ·

Blenders Storage Tanks Fabrication & Machine Work Manufacturing of Flow venture tube

Fabrication In Inconnel – 600 / 625 / 690 Aluminium Hastalloy Copper

Titanium S. S. Duplex Steel 300 & 400 Series Mild Steel Carbon Steel

Unit – I : J – 415, MIDC, Bhosari, Pune – 411026, Tel. No. : (020) 66300305.

Unit – II : Plot No. 4/18, Sector No. 10, PCNTDA, Bhosari, Pune – 411026, Tel. No. : (020) 66146033.

Unit– III : J-414, MIDC, Bhosari, Pune - 411026 Mobile : 98600 98706, 97663 26240, 7776025551 E-mail : sanjayraut21@hotmail.com | sanjayraut22@gmail.com Website : www.samarthengineers.com, www.samarthengg.in

CEW

SPECIAL Company Profile

Safety, Productivity & Visual Turnkey Solutions: BRADY Company India Pvt Ltd

B

rady Corporation is a global leader in providing complete solutions that identify and protect premises, products and people.

With 100 years of existence and expertise as a solutions provider, leading manufacturers from multiple industries, markets and geographic locations rely on Brady as an integral member of their development and manufacturing teams.

For safety and productivity in manufacturing and services workplaces, Brady India Client Services is a resource like no other. It brings its experts on-site to clients' facility to get to know thier unique needs.

Visual Workplace Production Service

Your par tner in safety

Only what’s right for your business

86 • January 2015

The company works together with its clients to develop a custom, comprehensive solution that will elevate clients' business in safety, efficiency and reliability – for today, and for the years ahead.

Lockout/Tagout Procedure Writing Service - Brady Link360 Platform This turnkey service is the most effective, stress-free way to create an OSHA-compliant lockout/tagout programme.

Clients can trust Brady's field engineers to take care of every detail, including: • Professionally evaluating clients' needs and equipment requirements • Creating visually-instructive procedures specific to clients' machinery, facility and employee safety requirements • Laminating and installing the new lockout/tagout procedures • Installing color-coded energy source ID tags • Collaborating with clients' team during the process, helping them understand how to successfully maintain the programme in-house

The company helps its customers select a manageable area of focus and evaluate their (customers') current state to begin your path to a world-class visual workplace.

Company's engagement specialist visits customers' location with the necessary tools and materials needed to create labels that meet their (customers') needs.

Brady work with its customers' team by printing the necessary materials for their employees to install, aiding with their Kaizen or lean event, or creating a model area for them to use as an example when updating the rest of their facility.

Visual Workplace Production Service Starting your visual workplace journey and not sure where to begin?

Let us set an example. From Kaizen and 5S events to creating model workplace areas, Brady engagement specialists come prepared with the printers and the supplies needed to fulfil your custom project specifications and labelling needs.

We are experts on labelling, tagging and signage, as well as industry specifications and requirements, and guide your team on what labels your facility requires and how they should look like.

Brady Company India Pvt Ltd No 76,77,78, Cyber Park, Electronic City, Hosur Road, Bangalore, PIN: 560 100 T: 91 80 66582960 - 2900 E: feedback_India@bradycorp.com W: www.bradyindia.co.in; www.bradyid.com Chemical Engineering World

CEW

SPECIAL Company Profile

G R Engineering Pvt Ltd

G

R Engineering Pvt Ltd (GREPL) was established in 1967 and has grown by leaps and bounds. The company started with its 1st unit at Andheri in Mumbai. It was promoted by its Chairman, D P Hariani. The full credit for establishing GR Group goes to him for he is a displaced person due to the partition of the country. He is not a qualified Engineer yet he established an engineering unit which requires a high degree of skill. The company started first by fabricating equipment for the pharmaceutical industry with projects of various types of mixer and blenders. Besides this, the company also manufactured gratings at the start of the unit.

It had expanded by establishing a very large unit at Bangalore in 1975 and another unit at Tarapur in 1987. Currently, GREPL has consolidated and has two units at Tarapur Industrial Area. Within the group, it also has GR Infrastructure which mainly owns a fleet of crawler and mobile cranes with the largest crane of 500 T lifting capacity. GREPL created this unit in 2005 to be able to give complete EPC solutions to our clients. Since the last decade, the company has been a market leader in the supply of Pressure Vessels and executing EPC jobs to Oil and Gas industry.

"We are one of the few companies who are capable of working throughout the country executing EPC job and also fabricating thick vessels in our own workshop. The core of the company that has helped this growth is the people who work at GR. Without the talent, it is impossible for any company to grow. Besides this, we have always innovated in our supplies to our customers. We were the 1 st company in India to fabricate and install mounded storage facility for the storage of LPG in a single mound for Gas Authority of India Ltd 88 • January 2015

(GAIL) at Uran in 1998. Our customers are the oil companies such as IOCL, BPCL, HPCL, GAIL, RIL. MRPL, CPCL etc. in India. We have supplied many types of equipment to overseas markets in the Gulf area and also European clients," reveals R D Hariani.

For the 1 st time, the company had executed the reactor and regenerator package for Hindustan Mittal Energy Ltd (HMEL) at Bathinda in 2011-12. This was a joint venture of Mittal Energy and HPCL. This was a prestigious job as prior to GR only one other company had executed this type of reactor regenerator package on a turnkey basis in India. Based on this experience and successful commissioning; the company was pre-qualified for quoting for the same package for BPCL Kochi. This order is in advance stage of execution.

The company is one of the major suppliers of heat exchangers to the oil and gas industry.

"We are capable of drilling tube sheets with thickness of 400 MM on CNC drilling machines.

We have a collaboration with ABB Lumus for design of Helix Baffle Heat Exchangers. We are currently executing a large number of heat exchangers orders for RIL and BPCL, the two major jobs currently in execution in the country. We are also quoting for various enquiries in Asia Pacific and in the gulf area.

In the past, we have supplied many heat exchangers to the nuclear power plants at various locations in India. We are attested and holders of U and U2 and R stamp issued by ASME. Our price and quality are comparable to anyone in the world," the company claims.

According to Hariani, India can certainly play a big role in ‘Make in India’ initiative of the government. "We are already producing high-end products for all the infrastructure

R D Hariani, Chairman, GREPL

companies which play a significant role in the lives of Indians. This is the reason why our products are well received in India and overseas markets. Manufacturing is an area which has been neglected in the past and it is certainly a welcome change that the government has put a stress on this industry which has a possibility of employing a large number of skilled and unskilled people. Our plans for the future are to grow by acquisition wherever the opportunity arises and to go in diversified products related to our industry that is our core business. For this reason we have acquired more land in Gujarat and will soon start manufacturing, these are located close to a port for ease of shipment of large equipment, to cater to export markets," he concludes.

G R Engineering Pvt Ltd Poonam Chambers, Dr Annie Besant Road Worli, Mumbai, PIN: 400 018 T: +91 22 24960551 E: grew@vsnl.com W: www.grengg.com Chemical Engineering World

Call us today!

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SPECIAL News

Long Live Water Heaters Replacing carbon steel with Outokumpu LDX 2101® stainless resulted in a significant reduction in waste and a longer useful life.

W

hen PVI Industries LLC chose Outokumpu’s lean duplex to replace carbon steel in their water heaters, the move resulted in a significant reduction in the manufacturer’s waste stream as well as a jump in the useful life of their water heaters.

“There is a huge movement for materials that follow a longer life principle. This parallels with PVI’s belief. In Outokumpu, I know we have a business partner who shares that core value,” says Chris Bollas, President, PVI Industries.

certified for water heater applications,” explains Bollas. “We believed the material was something that would accomplish our goals, because stainless steel does not require any coating or plating.”

A prototype, test Unit #1, was built in 2009 using Outokumpu’s lean duplex LDX 2101 and then underwent accelerated life testing. Using the results from this test, PVI approached the ASME seeking approval to use LDX 2101 in production water heaters.

The Outokumpu datasheets for the grade were part of this presentation.

PVI, based in Fort Worth, Texas, USA, specialises in medium to large capacity ASME water heaters for commercial and institutional buildings like hotels, schools, hospitals and stadiums. PVI water heaters can be as large as 11 meters (37 feet) by 2.5 meters (8 feet) and contain as much as 17,000 litres (4,500 gallons) of water.

In North America, potable water contains oxygen that creates iron oxide when it comes into contact with carbon steel.

Previously, PVI had been using electroless nickel plating to reduce corrosion in their water heater tanks.

Five years after development, Unit #1 is still operational. The company has since produced more than 3,000 units – and all but five are still in operation. The company now warranties standard duplex water heater tanks for up to 25 years.

The process was generating about 590,000 kilograms (1.3 million pounds) of waste per year.

Sustainability achieved moving to duplex which reduced PVI’s waste stream to nearly zero. The company’s efforts were recognised by the State of Texas at the 2014 Environmental Excellence Awards where PVI received the honour for Pollution Prevention.

“We are thrilled to be recognised in the largest industrial state in America as the number one

Duplex offers a solution “We identified a couple of duplex grades and found favourable characteristics in Outokumpu’s LDX 2101. But the grade was not yet 90 • January 2015

Despite all the benefits in using stainless steel over carbon, there is no change in the cost of the water heaters for customers.

The additional cost of the stainless steel is offset by the savings from no longer coating and plating the carbon steel material.

Outokumpu’s LDX 2101 results in a significant reduction in the waste stream as well as a jump in the useful life of the water heater.

green company in this area. We expect to carry the sustainable footprint forward for years to come,” says Bollas.

www.outokumpu.com Chemical Engineering World

CEW

SPECIAL News

The New Ferritic on the Block Quickly becoming a global hit product, the high-chromium ferritic grade Outokumpu 4622 is rooted in R&D excellence and collaboration. polishing. Hot water boilers are another potential application for the new grade. On the road, one potential solution is the decorative trims of cars,” Kela adds.

Juha Kela

L

aunched in October 2013, Outokumpu 4622 is the latest addition to the company’s ferritics portfolio. The new grade fulfils ASTM UNS S44330 requirements and EN standardisation is in the works.

Outokumpu 4622 is also the company’s first ever high-chromium grade, offering tangible benefits to Outokumpu customers. Senior Research Engineer Juha Kela explains that Outokumpu 4622 delivers improved performance in terms of corrosion resistance, strength and formability. This makes it a suitable alternative to common austenitic grades, such as 304(L) – and the superior performance of the new product has been proved in laboratory tests, too. Furthermore, 4622 has good chloride resistance even including resistance to stress corrosion cracking. “The product is a highly competitive and attractive alternative,” Kela believes. The newcomer can be used in a wide range of applications from home appliances and exhaust systems to process equipment and cladding panels. “Also pots and pans as well as kitchen utensils could utilise 4622 as the material is almost ridge free, which means less 92 • January 2015

Feel the Steel According to Kela, Outokumpu 4622 is a highchromium ferritic stainless steel for general use.

“Since there is no nickel in the product, it is less expensive for the customer than 304(L) – yet the corrosion performance level is identical to that of austenitic steel.” The grade 4622 also has better deep-drawability than 304(L) – meaning that material savings can be achieved as products can now be made from smaller quantity.

The hit product did not materialise overnight.

In fact, there is a five-year development project behind 4622, with intense collaboration between various parties. Funded by Finnish innovation and research agency TEKES, the project featured two Finnish universities and involvement from Outokumpu Tornio Research Centre (TRC). Furthermore, Outokumpu production departments were involved in the full scale production trials.

Smooth Collaboration Kela looks back and admits to being impressed by the speed of the R&D project – and the quality of the end product, of course. “It is motivating to see that we were able to create a really strong product that is a great fit for the market. The development of this grade started from market demand: we listened to our customers. Outokumpu can react fast to customer need, as the grade was on the market within three years,” Kela says, citing the project as a real success story.

Global Success How about those markets, then? According to Kela, Outokumpu 4622 has been making waves especially in Asia. “Countries like China, Australia and Taiwan have been interested,” he says. In Asia, there are rival products which have, however, been alloyed and processed differently – but the market is clearly familiar with the concept and eager to try the Finnish steel. And it’s not just the Far Eastern market that is heating up: Germany, Italy, Great Britain, Poland and South America are keen on the new product. After the launch, the interest level has been rising constantly and globally, Kela notes.

George Miech from Outokumpu’s Business Development team in Australia points out that Outokumpu 4622 can compete against Asian 304(L) sheet and coils, which are dominant in the Australian market. The 4622 grade is a good alternative to high-chromium ferritics already on the market by Asian producers. “The new grade is making its way to the market and I am glad to see it targeted as a substitute, for example, with galvanised materials over here.

Apart from just booking the material directly, the Melbourne Service Centre also offers further processing and adding value through cut-to-length and No. 4 polishing,” Miech says.

“We believe that 4622 represents a combination of high quality and competitive pricing that the customers respond to at this time,” concludes Kela.

www.steelfinder.outokumpu.com Chemical Engineering World

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CEW

SPECIAL Feature

Technological Advancements are Backbone of SS Techno: Shripad Khatav Shripad Khatav, Managing Director, SS Techno Limited, says that the company is ready for a take off. In a conversation with CEW this month, he further explains that the company has built strong infrastructure and it is now ready to promote its technologies and systems in overseas market.

Shripad Khatav Managing Director SS Techno Limited

S

tarted as a consultant with an investment of meagre ` 20,000 in the year 1997, SS Techno Limited has come a long way. The untiring efforts of Shripad Khatav, a technocrat turned entrepreneur, helped the company establish its ‘brand’ in the market and earned several awards including ‘Star SME Overall’, ‘Best Green SME’, and ‘Best SME for Innovation’ - in the category of small enterprise.

The company forayed into manufacturing heat and mass transfer systems for the chemical and food industry in the year 2001 and started manufacturing scrubbers, evaporators and dryers. Soon after this, it started focussing on turnkey evaporators and dryers for the food industry. SS Techno has supplied state-of-art milk powder plants, condensed milk plants, baby food plants handling up to 5 Lac Lit/day milk. Instant tea and fruit juice evaporators were the other systems the company supplied to many clients.

Harshal Y Desai 94 • January 2015

Increasing industrialisation already started attracting the attention of environmentalists and Khatav - a foresighted technocrat - saw a huge potential in the area of waste water management. By 2005 many state governments had revised the regulatory norms for waste water treatment which mandated the industries to have ZLD (Zero Liquid Discharge)

plants while setting up any new industrial facilities. SS Techno developed unique in-house technology for highly sophisticated Turnkey ZLD plants for various industries such as pharma, food, engineering, textile, paints, distillery and electronic hardware etc.

According to Khatav, its ZLD plants recover crystal clear water up to 90-95 per cent plus from the effluent. This water can be reused or recycled after secondary treatment, if required.

In some applications, the solid waste separated itself fetches attractive revenue as a by-product.

Khatav believes that stricter governments’ regulatory norms and social pressures for clean environment have turned out to be a boost to the business.

The company has developed inherent culture of innovation and continuously works towards improving existing applications and simultaneously developing new applications through research and development. It has inhouse softwares that keeps itself constantly abreast with the changing trends enabling the company to meet the challenging future demands of the industry. He attributes the success to strong team, who offer best solutions to the clients through meticulous implementation. The company has developed adequate infrastructure to cater to the growing Chemical Engineering World

CEW

SPECIAL demands and has three manufacturing facilities.

It has set up a new state-of-the-art facility in Chakan, Pune.

‘Waste Water Treatment’ remains the core of the business now. Khatav adds that the company is cutting down on its drying portfolio and focussing on turnkey evaporation technologies.

Research and Development 'Research and Development' is the core of the company - since its inception. According to Khatav, it is mandatory to develop systems in-house that can meet customers’ requirement in the best possible manner. The company, so far, has commissioned 160 ZLD evaporators.

He adds that solutions for waste water treatment need to be customised, since each stream of waste water has its own characteristics. One needs to study and evolve a totally tailor-made solution. He asserts that innovation-based on technology has always been at the forefront of SS Techno, which is its inherent strength and strong differentiator.

At present, the solids from the ZLD plants are disposed off as waste. “Waste is a product out of

ZLD Plant Chemical Engineering World

Research and Development' is the core of the company - since its inception. According to Khatav, it is mandatory to develop systems in-house that can meet customers’ requirement in the best possible manner. The company, so far, has commissioned 160 ZLD evaporators. place” Khatav says. The new focus of SS Techno has been on value addition to the solid waste from the ZLD plants. So far SS Techno has been able to identify and implement innovative uses and applications of solid wastes from Industrial wastewaters – such as fertilisers, binding chemicals, animal feed, fuel for boiler, raw material for other processes etc.

The major constraint in front of the Industry to install evaporators for ZLD plant is the operating cost… Steam is the main cost component. Evaporation operation in the industry is conducted generally using steam as the heat source. SS Techno has developed technologies, where system uses inherent process waste heat and steam is not required for evaporation process. “We have developed our own technology to utilise energy available in any form for ZLD plants to the reduce cost of operations - waste heat in flue gas, hot water, solvent vapours etc,” Khatav adds further.

According to him, this technology has been

tried by some other players as well, but not to the extent SS Techno is using it. The company claims to have established seven such plants so far and five more are under execution.

In a recent conversation with CEW this month, Khatav reveals that the company is now manufacturing an instant tea plant, which according to him, is the biggest instant tea plant based on evaporating and drying technology.

This is the fourth such plant the company is building in India. All the technologies involved in building the plants are developed in-house.

Overseas Market The company, without any marketing or promotion, could set up some plants in overseas market. According to Khatav, due to lack of resources, it could not promote the company in the international market. However, the scenario has changed now. The company boasts of a sound infrastructure and talented team of professionals. “We are now ready to compete in the international market as well, and we will start promoting our technologies and system in overseas market soon. Our technology is different, and we are hopeful that our systems will be widely acknowledged in the international market as well,” a confident Khatav reveals.

Some important orders are underway. The company is looking for overseas partners and agents. The company may also tie up with local players as well.

SS Techno Limited 502, Mayfair Towers, Shivajinagar Wakadewadi, Pune, PIN: 411 005 T: 91 20 66524431 - 32 - 33 F: 91 22 66524434 E: s.khatav@sstechno.com W: www.sstechno.com January 2015 • 95

CEW

SPECIAL Interview

Dipesh Engineering Works Targets 30% Growth According to Ketan Patel, Chief Executive Officer, Dipesh Engineering Works, the company has built infrastructure to produce greater volume of products at its facilities.

The company has increased its capabilities in handling medium sized turnkey projects.

P

lease apprise us of the recent development within Dipesh Engineering Works (DEW)?

Amongst many improvements within DEW the main commendable ones are improved work environment, strong commitment from all levels for on time delivery, and EHS.

operations have minimised paper usage. Our product designs also incorporate the green engineering concepts, for our clients. We also have added products for environmental treatment applications, which increased our revenues. Green Engineering has been an established facet at Dipesh Engineering Works.

Which are the sectors that generate maximum revenue for the company? What are the market drivers?

Our current market drivers are performancebased and High Risk equipment, where we have better capability then our competitors.

Our revenues are supported by combination of bulk fabrication orders and exotic metals fabrication.

What are your views on ‘Make in India’ campaign?

Yes definitely, India has a strong mix of capability in supporting the manufacturing boom both in terms of expertise and the reasonable costs. This in combination with the international volumes and financial support can trigger a very high growth rate, turning India into developed economy. Our PM Shri Narendra Modi has rightly targeted the possibility, and with his good and rapid governance, we hope both the Indian and international user and investor fraternity shall be benefited.

Is competition from China a threat?

For bulk items China does compete and acquires part of our business and also impacts the cost structure, however, leveraging on our quality and reliability of our products the impact is not big.

We get repeat order from our clients.

Please update us on the green engineering concepts adopted by DEW. Our team and company is gearing up for a higher level of HSE compliances and we have already installed professional pickling and passivation plus blasting and painting shops with necessary pollution controls and permissions. Most of our 96 • January 2015

What are the issues that can hinder the progress of ‘Make in India’ campaign?

In my opinion, the currency fluctuations, governance support from bureaucracy, continuity of motivation in Indian and international fraternity, and regional borders or religious issues, etc are major threats, which can hinder the ‘Make in India’ campaign. It is also important that the SME sector is encouraged.

How R&D is being evolved within DEW? How do you handle the issue of corrosion?

It is an ongoing process. We are targeting applications-based and clientele specific research, rather than a product-based approach.

Also, we have increased our capabilities in handling medium sized turnkey projects. As far as fabrication for corrosive applications are concerned, we have an enviable portfolio of Handling almost all metals, cladding and linings and have designed and set up a state-of-art Clean Room for the same.

What are the growth targets of the company in the next five years?

We are geared for 30 per cent plus growth. We have established the facilities to produce three times of current volumes.

Dipesh Engineering Works Sej Plaza, 1-3, 3rd Floor Junction of S V Road & Marve Road Near Nutan High School Malad (W), Mumbai, PIN: 400064 T: 91 22 40736736 E: sales@dipeshengg.net W: www.dipeshengg.com Chemical Engineering World

Chemical Engineering World

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CHEMICAL

ENGIN CHEMICAL 28-31 January

VOL. 49

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Chemical Engineering World

Products CEW Hastelloy C-276 (Corrosion & Heat-resistant Alloy) Bohra Metal & Alloys offers nickel chromium-molybdenum alloy with added tungsten, which exhibits excellent resistance to pitting and crevice corrosion, uniform corrosion and stress corrosion cracking, in wide variety of chemical process media and to reducing acid media in particular. It is well-suited for equipment handling strongly oxidising chloride media, including solutions containing ferric and cupric chlorides, hot contaminated mineral acids and formic and acetic acids. It possesses good resistance to corrosion when exposed to wet chlorine gas and to hypochlorite.

For details contact: Bohra Metal & Alloys 73 C P Tank Road, Mumbai 400 004 Tel: 022-22424755, 66394625 E-mail: bohrametal@hotmial.com / psbohra@hotmail.com or Circle Readers’ Service Card 1

Rotary Gear Pumps C Bole & Co offers range of positive displacement rotary gear pumps for handling oil and other semi-viscous liquids. Gear pumps are also available in SS-316 constructions incorporated with steam jacketed construction suitable for corrosive resins. Pumps can be supplied in SS-316, gun metal, bronze construction with heating/cooling jackets and with special mechanical seal which prevents leakage near shaft end.

Pump body made of 2 piece type, ie, only one joint in the body which reduces the maintenance cost. It has easily replaceable bushes with positive lubrication arrangements. It has proved more efficient due to suction and delivery in the line with the rotors. For handling all kinds of oils and other similar corrosive viscous liquids, pumps are supplied in CIMS construction. For viscous corrosive liquids and chemicals, pumps can be supplied in SS, gun metal or bronze construction with helical gears for smooth as well as efficient running and built-in relief valve for dependable and trouble-free pumping of viscous liquids.

For further details contact us : C Bole & Co 61 Narayan Dhuru Street Mumbai 400 002 Tel: 022-23424350, 23429641 | Fax: 91-022-23424040 E-mail: cboleco@yahoo.com / cboleco@hotmail.co or Circle Readers’ Service Card 2

Chemical Engineering World

January 2015 • 99

CEW Products

Combustible Gas Detector

Open Path Combustible Gas Detector

ESP Safety’s SGOES gas detector monitors concentration of hydrocarbon gases in environment. The SGOES is configured to report alarms when the gas concentrations in the environment reach three independently programmblle levels, expressed as a percentage of the lower explosive limit (LEL) in the air. As determined by application requirements, the SGOES is factory calibrated with one of eight hydrocarbon-based gases (typically methane or propane). Conversion factors are used to correct for gases other than the factory calibration gas. The optical (IR) sensor is not dependent on the presence of oxygen in a mixture of gases and therefore can function effectively in environments where the other sensor technologies cannot.

The TGAES hydrocarbon gas detector is an open path infrared gas detetion system that provides continuous monitoring of combustible hydrocarbon gas concentrations in the range of 0-1 LEL/m, 0-2.5 LEL/m, 0-5 LEL/m over a distance of 5 to 200 metres. Standard system outputs include 4-20 mA DC current output, with HART and RS-485 MODBUS communication. TGAES is capable of detectiong most hydrocarbon gases and vapours including methane, ethane, propane, butane, propylene and others. No direct electrical intercconnection between the two modules is required.

For details contact: ESP Safety Pvt Ltd A-21 Angel Building, Godrej Hill, Nr Khadak Pada, Kalyan (W) Maharashtra 421 301 E-mail: anjesh.mathur@esp-safety.in

For details contact: ESP Safety Pvt Ltd A-21 Angel Building, Godrej Hill, NrKhadak Pada Kalyan (W), Maharashtra 421 301 E-mail: anjesh.mathur@esp-safety.in

or Circle Readers’ Service Card 3

or Circle Readers’ Service Card 4

AutoCAD-based Plant Design Solution AutoCAD-based plant design solution allows generation of .ifv files for viewing and sharing CADWorx design models on the Apple iPad. Intergraph has released CADWorx 2015, the next-generation AutoCAD-based software solution for plant design and automation that has enhancements to CADWorx Design Review that allow the generation of .ifv files for viewing and sharing CADWorx design models on the Apple iPad using the free Intergraph FreeView app.

Intergraph CADWorx, an intelligent 2D and 3D plant design system, provides ease of use, flexibility, scalability and interconnectivity. The software offers piping and instrumentation diagram (P&ID) synchronization with the model plus intelligent modeling and automatic production of design deliverables such as isometric drawings and bills of material, enhancing organizational productivity throughout the engineering and design process.

Other CADWorx 2015 features include capabilities for routing of mitered elbows, skewed pipe design and male and female needle valves; custom field default values for models; new tables in the specification editor; and a new, more user-friendly ISOGEN interface. For a complete list of CADWorx 2015 enhancements, visit www.intergraph.com/cadworx2015/enhancements. Intergraph CADWorx & Analysis Solutions products allow design and engineering to share relevant information seamlessly, thereby maintaining accuracy and improving efficiency.

These include CADWorx Plant Design Suite, for AutoCAD-based intelligent plant design modeling, process schematics and automatic production of plant design deliverables; CADWorx DraftPro, a free solution for intelligent 2D design and layout; CAESAR II, the world’s most widely used pipe stress analysis software; PV Elite, for vessel and exchanger design and analysis; TANK, for the design and analysis of oil storage tanks; and GT STRUDL, one of the most trusted, adaptable and fully-integrated structural analysis solutions in the world.

For details contact: Intergraph Corporation 305 Intergraph Way, Madison, AL 35758, U.S.A. Tel: 1.256.730.2000, Fax: 1.256.730.2048 or Circle Readers’ Service Card 5

100 • January 2015

Chemical Engineering World

Products CEW Steam Turbine KEPL offers API steam turbine K-TUR in compliance with the American Petroleum Institute (API 611) specifications. K-TUR had been indigenously developed by KEPL an Indian company.

K-TUR is among the most efficient single-stage turbine with a wide spectrum of interesting features such as steam shields, blade-tip seals and reusable bearing liners. The steam Turbine uses profile blading, which helps in reducing the windage losses, thus improving its proficiency. K-TUR machine also has the facility of installing mechanical seals instead of the normal carbon rings.

Currently, the K-TUR turbine is available in two frames. Frame KT-B is for the power requirements up to 1-MW and frame KT-D is for the power requirements up to 3-MW. The K-TUR Drive Turbines are available in both condensing and back pressure configuration.

For details contact: Kirloskar Ebara Pumps Ltd Pride Kumar Senate Bldg Senapati Bapat Road Pune Maharashtra 411 016 Tel: 020-25600100 Fax: 91-020-25600351 E-mail: kelp@kepl.in.net or Circle Readers’ Service Card 6

Minivac Rotary Vane Oil Immersed High Vacuum Pumps These are oil immersed rotary vane type vacuum pumps with maximum vacuum of 0.05 mm Hg in single stage and 0.005 mm Hg in double stage. The assembly consists of main body with a rotor mounted eccentrically in it. The rotor is provided with two vanes opposite each other with spring inbetween, which push the vanes out against the inner wall of main body. As the rotor revolves, the vanes move in and out of the rotor and sweep the air twice per revolution.

All parts are precisely machined and ground for close tolerances for higher efficiency and performance. Robust in construction and fitted with inbuilt gas ballast and easy oil changing arrangement, Optional accessories like moisture trap, vacuum gauge with regulator, nonreturn valve, suction air filter, discharge oil mist filter can be provided.These are useful in many applications like distillation/refining/purification, impregnation/vacuum heat treatment, leak testing/filling, etc.

For details contact: Shree Siddhi Vinayak Industries Plot No: 19, Kashimira Indl.Estate, Post: Mira Dist: Thane, Maharashtra 401 104 Telefax: 91-022-28458372, 28457073 E-mail: response@minivacpumps.com or Circle Readers’ Service Card 7

Chemical Engineering World

January 2015 • 101

CEW Products

Diaphragm Vacuum Pumps & Compressors Diaphragm vacuum pumps and compressors are a quiet source for vacuum and pressure. These pumps are portable, quiet and oil-free and offered with single/three-phase motors.

The diaphragms are available in various options of materials like EPDM, Neoprene, Viton and Tefloncoated Neoprene Rubber.

Its aluminium construction makes it lightweight and compact.

These vacuum pumps are available in the range of 10 to 75 LPM with a maximum vacuum of 27” Hg and pressure of 60 PSIG. The choice of series and parallel connection in doublestage models gives selective advantage of flow and vacuum/ pressure. Chemical-resistant models are supplied with flameproof motors. These are useful for various applications like pollution control equipment, laboratories, flame photometer, plastic welding machines, agitation of chemicals, aeration, oil spray painting, etc.

For details contact: Sri Vishnu Pumps Mfg Co 19A, Plot No: 19, Kashimira Indl Estate B/h Kashimira Police Station Post: Mira, Dist: Thane, Maharashtra 401104 Telefax: 91-022-28458372, 28457073 E-mail: vishnupump@rediffmail.com

S i n g l e S t a g e L i q u i d R i n g ( Wa t e r - R i n g ) Vacuum Pumps Minivac liquid ring vacuum pumps can handle hot and saturated vapours/dust particles/fiber and foreign matter with seal water.

These are directly coupled vacuum pumps and supplied with standard accessories like common base plate/vacuum and pressure gauges/drain valve/non-return valve.

It has a maximum vacuum of 710 mm of Hg and capacities ranging from 50 to 440 m 3/hr.

Available in wide choice of materials like CI/partial phosphor bronze/complete phosphor bronze/partial SS-316/complete SS-316.

It finds application in distillation, evaporation, filtration, drying, vacuum impregnation, crystallization solvent recovery, sizing for PVC pipes, brake testing, etc.

For details contact: Shree Siddhi Vinayak Industries Plot No: 19, Kashimira Indl Estate Post: Mira, Dist: Thane, Maharashtra 401 104 Telefax: 91-022-28458372, 28457073 E-mail: minivac@rediffmail.com

or Circle Readers’ Service Card 8

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Electro-deionization PrajHiPurity Systems (formerly Neela Systems), Praj Group Co, offers new models of its ‘Glacier’ Water System used to generate pure, sanitized water for pharma and biotech applications. Advanced features have been added to this system like ‘one touch’ sanitization operation, complete plug and play operation, easy access for O&M with reduced footprint. It can be remotely monitored on request. Glacier is a fully standardized and automated RO+EDI combination. It is a skid-based system for generation of purified water. Glacier takes complexity out of purification. It can be configured to specific requirements for purification of thousands of litres of water without any operator intervention. The Glacier can be made in varied capacities ranging from 500 to 5,000 LPH in convenient steps. This time-tested purification module consistently delivers purified water as per USP and EU Standards. It has built-in variants to suit automation levels as required.

For details contact: Praj HiPurity Systems Ltd (formerly Neela Systems Ltd) Solitaire Corporate Park, Unit No: 1211, 1 st Floor, C S No: 131A-1/A, Guru Hargovindji Marg Andheri (E), Mumbai 400 093 Tel: 022-40888444, 40888372 | Fax: 91-022-28747129 E-mail: info@prajhipurity.net or Circle Readers’ Service Card 10

102 • January 2015

Chemical Engineering World

Products CEW Centrifugal Air Blowers Vacunair Engg Co Pvt Ltd offers centrifugal air blowers in capacity up to 75,000 m 3/hr and pressure up to 1,500 mm WG. This energy savings with fans utilises variable inlet vanes; high pressure atomisation/combustion air as per specific requirement to suit burners; highly efficient design impeller fabricated in aluminium/MS riveted high strength construction fitted with hub; minimum overhung and weight design for low starting inertia; impeller dynamically balanced; different drive for direct coupled/directly mounted on motor shaft/vee belt; etc. Optional accessories like inlet/ outlet silencer, air filter, air control devices can be supplied. Other application includes cooling, conveying, air knives, fluidizing system, glass blowing, drying and various process system.

For details contact: Vacunair Engg Co Pvt Ltd Nr Gujarat Bottling Rakhial,Ahmedabad, Gujarat 380 023 Tel: 079-22910771, 22910772 | Fax: 91-079-22910770 E-mail: info@vacuunair.com or Circle Readers’ Service Card 11

Catalogue for the Scientific and Process Industries Cole-Parmer released its 8 th annual catalogue for the scientific and process industries. The company has also released its 3rd annual catalogue dedicated to the food and beverage industry. The new 2014/15 India catalogue has numerous unique and new products, as well as returning favourites. It offers a full selection of products and services to enhance efficiency and produce best practices. Users can select from highly efficient laboratory essentials, lab equipment, fluid handling, and process equipment and find exactly what they need for their application from research and development to pilot plants to scale-up.

The catalogue also has convenient dual pricing featuring custom duty exempt prices and prices in rupees, making it handy for users to set up supply contracts. The catalog includes a wide portfolio of products to address customers’ demanding manufacturing and process application needs. It features the recently introduced Masterflex pumps with anti-drip functionality, the Digi-Sense line of precision measurement Instruments, Cole-Parmer mixers and stirrers, analytical instruments for the food and feed line, lab filtration, cold storage solutions, new safety consumables and much more. Find these and many other innovative products in the 2014/15 India Catalog from Cole-Parmer. To request a FREE catalogue, call 022-67162222, e-mail at response@coleparmer.in or visit www.coleparmer.in For details contact: Cole-Parmer India Pvt Ltd 403-404, Delphi - B, Hiranandani Business Park, Powai, Mumbai 400 076 Tel: 022-67162253, 67162222, 67162229 | Fax: 91-022-67162211 E-mail: response@coleparmer.in / info@coleparmer.in or Circle Readers’ Service Card 12

Chemical Engineering World

January 2015 • 103

CEW Products

Inconel 625 (Corrosion & Heat-resistant Alloy)

New Monitoring System

Originally developed for high-temperatue applications, this nickel-chromium-molybdenum alloy is now widely used in the chemical processing industry. Its high mechanical strength and good resistance to acids and alkalis permit the manufacture of thin alied components with good heat transfer characteristics. Its excellent resistance to pitting, corevice and intercrystalline corrosion, and its virtual immunity to chloride-induced stress-corroison cracking, make this material ideal for the manufacture of components exposed to seawater and subjected to high mechanical stresses.

Further applications include scrubbers and other components in flue-gas desulphurisation plants of fossil-fired power stations where corrosion problems are particularly severe.

The system works by creating an overpressure in the enclosure preventing any surrounding explosive atmosphere from entering. The internal pressure is controlled with a unique pressure switch unit, QUINGUARD, Control panels, enclosures, cabinets, etc. The main advantage of the Overpressure System 2.0 is that all components in such housings or switching cabinets can be off-the-shelf standard materials, with regulation components up to HMI’s or other computer units.

For high switching loads above 5 amps you need to use their certified range of Contactors (SC Series). These contactors can be fitted directly in the panels or enclosures like all other standard components. Different ratings can be selected up to a switching capacity of 540 KW/1,000 A.

For details contact: Bohra Metal & Alloys 73 C P Tank RoadMumbai 400 004 Tel: 022-22424755, 66394625 E-mail: bohrametal@hotmial.com psbohra@hotmail.com

For details contact: Quintex GmbH I Park Tauberfranken 13, Lauda-Königshofen Baden-Württemberg 97922 Deutschland, Germany Tel: +49 (9343) 6130-118 | Fax: +49 (9343) 6130-105 E-mail: anja.budow@quintex.info

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Supertor Supertor is a pump like machine to handle slurries and liquids. It can grind, mix and pump in one operation. It is developed from a centrifugal pump with an inclined disc which is at an angle to the shaft instead of a normal impeller. This creates strong turbulence which causes the acceleration of the medium in both axial and radial direction, resulting in pumping and intense mixing of the medium. Notched teeth in the rotor disc mesh with teeth of stator to effect disintegration or crushing.

There is just a gap of 0.5 mm between stator and rotor. The multiple movements cause thrust and shear stress, and can create intensive mixing and conveyance depending on properties of material.

A unique feature is the ability to reduce particle size to controlled sizes with standard distribution across the medium. With the Supertor a variety of processes can be performed pumping, homogenization, emulsification, disintegration, increasing rate of reaction by intense mixing, impurities dissolution during cake washing, rapid dissolution of difficult to dissolve solids, extraction, reduction of agglomerates, grinding, deflaking, crushing, shredding, mixing, etc. Two models are available, viz, size 22, size 25 with stuffing box or mechanical seal design. It is a high shear machine. Both head and flow rates depends upon fluid being handled, its density, viscosity, solid content, etc. Typically size 22 Supertor can give flow of 5-7 m 3hr. and size 25 more than 7 m 3/hr. Industries served are pigment, dyestuff, pharma, detergent, spices, rubber, adhesive, silica, paper and pulp, etc.

For details contact: Dalal Engineering Pvt Ltd Kavesar Village, Nr Suraj Water Park Thane-Ghodbunder Road, Thane (W), Thane, Maharashtra 400 615 Tel: 022- 25976201, 25976202, 25976205, E-mail: sales@dalalengineering.com or Circle Readers’ Service Card 15

104 • January 2015

Chemical Engineering World

Products CEW iSense Software for the ISM Technology Mettler Toledo offers a new version of its iSense software for the Intelligent Sensor Management (ISM) technology with valuable features. Mettler Toledo’s digital sensor technology ISM, has transformed the way analytical sensors are handled and maintained from first installation to end of life. ISM offers a level of performance and convenience that is not available with other systems. iSense, the accompanying software for ISM, streamlines all sensor activities. It provides valuable features such as sensor calibration away from the process, electronic documentation, instant evaluation of a sensor’s health, and predictive information on when maintenance will be required. The latest version of iSense enables seamless management of ISM sensors and delivers exceptional usability. ISM and iSense have been designed to be adaptable to your current needs and your future ones. Planned developments, such as a mobile app that provides a quick sensor check on the go, mean that ISM will remain at the forefront of analytical measurement technologies.

For details contact: Mettler-Toledo Ingold Inc 900 Middlesex Turnpike, Building 8, Billerica, MA 01821, U.S.A. Tel: +1 800 352 8763 | Fax: +1 888 687 7687 E-mail: santare.rukaite@mt.com or Circle Readers’ Service Card 16

Next-generation Capping Heads The new, extremely wear-resistant ROBAcapping head with plastic/SS linear guide reduces service and maintenance costs to the absolute minimum.

With the ROBA-capping head, the hysteresis technology not only provides contactless and therefore wear-free torque transmissions: It is also impact-free and low-vibration, and thus guarantees a longer plant lifetime.

The capping heads also feature a high torque repetitive accuracy of +/- 2%. With their continuous and impact-free closing torque, they are therefore the optimum choice for the application of plastic screw caps with preformed threads. They are better suited for the task than permanent magnet couplings with intermittent torque in slip operation, which in part “hammer down” the screw caps and make them hard to open. With the ROBA-capping head, the limit torque can be easily and continuously adjusted, and can be read off directly via a scale. The enclosed construction also makes the capping heads resistant to dirt and aggressive media. It is possible to adapt the head pressure easily according to the customer requirements.

For details contact: Chr. Mayr GmbH + Co KG Eichenstraße 1, 87665 Mauerstetten, Germany Tel: +49 8341 / 804-232 | Fax: +49 8341 / 804-49232 E-mail: hermann.bestle@mayr.de or Circle Readers’ Service Card 17

Chemical Engineering World

January 2015 • 105

Petroleum Istanbul

ChemTECH Chennai 2015 Dates: 10-12 December 2015

Dates: 2-5 April, 2015

Venue: TNTPO, Exhibition Ground, Chennai

Venue: Tuyap Fair Convention & Congress Centre, Istanbul, Turkey

Details: World meet of chemicals, petrochemicals, pharma

Details: Trade fair for Petroleum Upstream and Downstream

and process industry in India encompassing exhibition and

Equipment, Technology and Services

conferences.

Organiser: Hannover Messe International Istanbul Limited

Contact: +91 22 40373636

Contact: +90 216 466 74 96

Email: sales@jasubhai.com

Email: petroleum@efo.com.tr

Website: www.chemtech-online.com

Website: www.petroleumistanbul.com.tr

Watertech India 2015

China International Exhibition for Coating & Paintss

Dates: 2-4 September 2015

Dates: 13-16 Mar 2015

Venue: Pragati Maidan, New Delhi

Venue: Beijing, China

Details: International Trade Fair for Water & Wastewater

Details: One of the leading trade fair for Coating & Paints

Treatment & Management

industry in China

Organiser: Messe Frankfurt Trade Fairs India Pvt Ltd

Organiser: Sinostar Internationl Ltd

Contact: +91 22 6757 5940

Contact: +852 2865 0062

Email: nidhi.agrawal@india.messefrankfurt.com

Email: info@sinostar-intl.com.hk

Website: www.watertechindia.com

Website: www.sinostar-intl.com.hk

World PetroCoal Congress

Chem Bio Finland 2015

Dates: 15-17 February 2015

Dates: 18-19 Mar 2015

Venue: Convention Centre-NDCC, New Delhi

Venue: Helsinki, Finland

Details: On sustainable usage of the non-renewable

Details: Exhibition for the chemical, laboratory and

resources

biotechnology products and services

Organiser: Energy and Environment Foundation

Organiser: The Finnish Fair Corporation

Contact: +91 11 2275 8149

Contact: +358 40 450 3251

Email: punit.nagi@ee-foundation.org

Email: sales@messukeskus.com

Website: www.worldpetrocoal.com

Website: www.messukeskus.com

Chemspec India 2015

Middle East Coatings Show 2015

Dates: 16-17 April, 2015

Dates: 9-11 March 2015

Venue: Bombay Convention & Exhibition Centre (BCEC), Mumbai

Venue: Dubai International Convention & Exhibition Centre, UAE

Details: Event for the Indian fine, custom and speciality

Details: An event for raw materials suppliers and equipment

chemicals community

manufacturers

Organiser: Quartz Business Media Ltd

Organiser: DMG Events â&#x20AC;&#x201C; ME & Asia

Contact: +91 99 204 74017

Contact: +971 4 4380355

Email: rohit@chemicalweekly.com

Email: info@dwtc.com; chrishamilton@dmgeventsme.com

Website: www.chemspecevents.com

Website: www.coatings-group.com

106 â&#x20AC;˘ January 2015

Chemical Engineering World

Project Update CEW New Contracts/Expansions/Revamps The following list is a brief insight into the latest new projects by various companies in India.

• CHEMICALS 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 clearance and the completion date is yet to be finalized.

Shimoga Life Sciences is planning a 300-400-TPA synthetic organic chemicals and herbal products manufacturing project at a cost of ` 50-million in village: Attivaram, district: Sri Potti Sriramulu Nellore, Andhra Pradesh. The project is waiting for environmental clearance. Work on the project will start after receipt of environmental clearance.

DCM Shriram is planning an expansion of its chlor alkali manufacturing project from initial 450-TPD to 915-TPD in Jhagadia, district: Bharuch, Gujarat;. The project will come up along with an expansion of its power project at a total cost of ` 5,340-million.

The Board of Directors of the company at its special meeting held in October 2014 have approved the project.

India GCI Resitop, a subsidiary of Gun Ei Chemical Industry Company, is planning a resin-coated sand and phenolic resin manufacturing project in Oragadam, district: Kanchipuram, Tamil Nadu. Land acquisition is in progress. The project is planned for completion in 3 years from zero date.

Bhuruka Gases, belonging to the Bhuruka Group, is planning a compressed oxygen project in district: Pune, Maharashtra. The project is in initial stage. Land is yet to be acquired.

Vasudha Pharma Chem is planning a chemical manufacturing project in village: Atchutapuram, district: Visakhapatnam, Andhra Pradesh. The project will be spread over 26-acre of acquired land. Work on the project commenced in August 2014 and is planned for completion in 2016.

Sayona Colors, belonging to the Sayona Group, is planning an expansion of its dyes and colours manufacturing project in Navrangpura, district: Ahmedabad, Gujarat. The project will involve capacity expansion of products like synthetic organic dyes, food colours and cosmetic colours. The project is waiting for international collaboration.

Vensun Laboratories is implementing a 200-TPA chemicals manufacturing project titanates esters and its derivatives, phosphate esters and its derivatives, organic chelates and its derivatives, ammonium chloride, in MIDC, Chincholi, district: Solapur, Maharashtra.

The project is waiting for environmental clearance. Civil work is in progress. The project will be spread over 2-acre of land. The project entails an investment of ` 40-million.

Consultant and equipment supplier have been appointed.

Punjab Chemicals & Crop Protection is planning a thiamethoxam manufacturing project in village: Kolimajra and Samalheri, district: Mohali, Punjab. The project will come up at the company’s existing plant premises. The project is in planning stage.

SK Solvochem Private Limited is planning a 1,500-TPA synthetic organic chemicals manufacturing project - dye and dye intermediates, bulk drug and intermediates excluding drug formulations, synthetic rubbers, basic organic chemicals, other synthetic organic Chemical Engineering World

January 2015 • 107

CEW Project Update chemicals and chemical intermediates, at a cost of ` 20-million in village: Nimbua, district: Mohali, Punjab. The Public hearing was held in January 2014. The project is waiting for environmental clearance.

Nuray Chemicals is implementing a ferric citrate-manufacturing project at the existing unit in SIDCO Industrial Estate, Kakalur, district: Tiruvallur, Tamil Nadu. Civil, mechanical and engineering work is in progress. The project is scheduled for completion in Q4 2014. Equipment is already available.

• MINING Barmer Lignite Mining Company, a JV between Rajasthan State Mines & Minerals and 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.

The project cost is estimated to be ` 18,000-million inclusive of a new lignite mining project at Jalipa mines. The project is waiting for environmental clearance.

• NON-CONVENTIONAL ENERGY Shri Shivsagar Sugar & Agro Products is planning a 18-MW bagasse-based co-generation power project in village: Udpudi, district: Belgaum, Karnataka. The project will come up in the existing 150-acre sugar plant premises. The project is planned for completion in 12 months from zero date.

Coal would be transported by rail for the entire route from mines to power plant site. Clearances for the project are received from Airports Authority of India and Archaeological Survey of India, Health & Family Welfare Department and Fisheries Department, GoK. The project is waiting for environmental clearance. Work will commence after receipt of clearances from MoEF. Birla Corporation is planning a 50-MW captive power project in district: Nagaur, Rajasthan. The project will come up as a part of its integrated cement project. Land acquisition is in progress.

Further details of the project are yet to be finalized.

ARS Metals is planning a 8-MW waste heat recovery-based captive power project in Naidupet, district: Sri Potti Sriramulu Nellore, Andhra Pradesh. The project will come up as a part of its 4-phase greenfield integrated steel project in the same location, which is also in planning stage. The power generated will be used for the upcoming greenfield integrated steel plant. The project is waiting for environmental clearance. 58-acre of land has been allotted by APIIC for the project. The entire project is planned for completion in 30 months from zero date.

Adani Power Rajasthan is planning an expansion of Kawai coalbased thermal power plant in Kawai, district: Baran, Rajasthan.

The capacity will be augmented from 1,320-MW by addition of 2x800-MW. The project is waiting for environmental clearance.

Siddheshwari Paper Udyog is implementing a 6-MW rice huskbased captive power project in Kashipur, district: Udham Singh Nagar, Uttarakhand. The project is coming up with an expansion of its kraft paper-manufacturing unit. Civil work is nearing completion and machinery has been ordered.

Anantha Power Projects is planning a 3x2.6-MW hydro electric power project at village: Mohanpur, district: Rajnandgaon, Chhattisgarh. The company is in final stage of placing orders for machinery. Clearances have been received. Work on the project commenced in September 2014 and is planned for completion in September 2015.

The Jeypore Sugar Company Limited is planning an expansion of its bagasse-based co-generation power plant from initial 0.5-MW to 8.5-MW in village: Chagallu, district: West Godavari. Andhra Pradesh. As of January 2014, the project will come up along with a new 120-KLD grain-based distillery. The project is waiting for environmental clearance.

Astrix Laboratories is planning a 5-MW coal-based captive power project in village: Gaddapotharam, district: Medak, Telangana. The project will come up along with a modernization-cum-expansion of its API manufacturing project. The estimated cost of the total project is ` 600-million. The project is waiting for environmental clearance and is planned for completion in 2 years from zero date.

• THERMAL POWER Raichur Power Corporation, a JV between Karnataka Power Corporation and Bharat Heavy Electricals, is planning a 800MW coal-based super critical power project in village: Edlapur, district: Raichur, Karnataka. The estimated cost of the project is ` 88,062.3-million. This is an expansion of the Raichur TPP by addition of 800-MW and would generate 5,957 MU of energy annually. According to MoEF sources, 382-million tonnes of coal to KPCL has been allocated in Deocha-Pachami Coal Block in West Bengal which has a total reserve of 2,012-million tonnes.

The blended coal 2.92-MTPA (indigenous coal of 2.044-MTPA (70%) and imported coal is 0.876-MTPA (30%)) will be used for the proposed TPP. Edlapur TPS is proposed to be commissioned in 51 months from zero date. Imported coal would be utilized.

Neyveli Lignite Corporation is planning 4,000-MW Sirkali thermal power project in Sirkali, district: Nagapattinam, Tamil Nadu. The project will spread over 1,221.82-hectare of land. Phase-I will consist of 1,980-MW and the estimated cost is ` 144.82-billion.

Phase-II will consist of 2,020-MW. Action has been initiated for preparation of FR for coal jetty and marine EIA study. The company is to expedite the issue of administrative sanction for acquiring land. Letter of award (LOA) for consultancy services for the preparation of feasibility report (FR) has been issued to Tractebel and preparation of FR is in progress.

108 • January 2015

RKM Powergen is planning a 4x660-MW coal-based thermal power project in district: Datia, Madhya Pradesh. The project is waiting for environmental clearance and coal allocation.

Chemical Engineering World

Ad Index CEW Sr. No.

Client’s Name

1

Accent Techno Solutions

2

Page No

Sr. No.

Client’s Name

Page No

Front Cover

16

Eureka Forbes Ltd

49

Ani Engineers

87

17

Everest Transmission

77

3

Arvind Anticor Ltd

85

18

Evergreen Technologies Pvt Ltd

51

4

Atomic Vacuum Company (Exports)

Inside Cover I

19

Flexim GmbH

5

Avcon Controls Pvt Ltd

79

20

Forbes Marshall

19

6

Beda Flow Systems Pvt Ltd

69

21

Glatt (India) Pharma Engineering Pvt Ltd

61

7

BHS-Sonthofen (India) Pvt Ltd

99

22

Gopani Product Systems

8

Bonfiglioli Transmissions

53

23

Hi-tech Applicator

7

9

Chemlin Pumps & Valves Pvt Ltd

93

24

HRS Process Systems Ltd

9

10

Cole-Parmer India

83

25

ImageGrafix Engineering Services Pvt Ltd 101, 103, 105, 107

11

Dalal Engineering Pvt Ltd

15

26

Integral Process Controls India Pvt Ltd

41

12

De Dietrich Process Systems India Pvt Ltd

21

27

Intek Engineers

13

13

Desmi Pumping Technology A/S

73

28

Jitamitra Electro Engg

93

14

Edwards Vacuum

33

29

Kevin Enterprise Pvt Ltd

55

15

Emjay Engineers

59

30

Kirloskar Brothers Ltd

Chemical Engineering World

Inside Cover

Back Cover

Inside Cover II January 2015 • 109

CEW Ad Index Sr. No.

Client’s Name

Page No

Sr. No.

Client’s Name

Page No

31

KSB Pumps

17

46

Sharplex Filters (India) Pvt Ltd

65

32

Lubrizol Advanced Materials India Pvt Ltd

67

47

Shavo Technologies Pvt Ltd

31

33

Mist Resonance Engg Pvt Ltd

45

48

Shri Vishu/Shree Siddhivinyak

91

34

NNE Pharmplan (India) Pvt Ltd

37

49

Super Industrial Lining Pvt Ltd

5

35

Outokumpu India Pvt ltd

39

50

Suraj Ltd

89

36

PPI Pumps Pvt Ltd

81

51

Tecnimont ICB Pvt Ltd

29

37

R K Dutt Concerns

83

52

ThyssenKrupp Industrial Solutions (India) Pvt Ltd

57

38

Rajdeep Engineering Systems (Pune) Pvt Ltd

87

53

Uni Klinger Ltd

71

39

Rasaii Flow Lines Pvt Ltd

75

54

UNP Polyvalves (India) Pvt Ltd

43

40

Rashtirya Chemicals & Fertilizers Ltd

25

55

Venus Trading

89

41

Ravel Hiteks Pvt Ltd

89

56

Zeeco Inc

27

42

Samarth Engineers

85

43

SAP-Vcentric

11

44

Seal Excel (India) PVt Ltd

81

45

Shanbhag & Associates

63

110 • January 2015

Chemical Engineering World

Book Shelf CEW Internal Corrosion of Pipelines Editors Pages Publisher

: Anil Bhardwaj, Baldev Raj : 372 (Paperback) : Narosa Publishing House Pvt Ltd

About the Book : Internal Corrosion of Pipelines dwells upon various factors responsible for internal corrosion of pipelines, which include corroding gases like O 2, CO 2, H 2S; different types of bacteia; environmental factors such as temperature and pressure; aqueous chemistry including salinity, buffer ion concentration, ionic composition and pH; flow regimes in case of multiphase flow etc. Mechanism, cause and effects have been explained in user-friendly language with apt case studies and examples. Internal corrosion of pipes in seawater environment is a very specific issue relavant to coastal, offshore and shipping industry.The options of corrosion resistant materials and corrosion control have been eloborated which can vary depending upon requirement of industry, temperature and flow conditions. Two types of pipeline systems are common to most chemical process industries, viz cooling water and firewater. They are essential for efficient and safe operations of a chemical process plant. The environmental and flow condition are different for these lines and unique corrosion control measure, including specific material of construciton, for these two categories of lines have been dealt in this book in separate chapters. Certainly, this book will be a treasure for all those involved with pipelines in variety of environments of various industries.

Modern Welding Technology Author Price Pages Publisher

: Howard B. Cary, Scott Helzer : USD 153.18 : 736 (Paperback) : Prentice Hall

About the Book : This well-respected, introductory welding text contains coverage of the latest codes, materials, and processes necessary to become proficient in an ever more complex industry.

The technology of welding is growing and the book’s focus on arc welding processes and the use of steel in construction reflect those changes, while continuing to provide a comprehensive coverage of basic principles and theory.

The Future of the Chemical Industry by 2050 Author: Price Pages Publisher

: : : :

Rafael Cayuela Valencia USD 80.75 331 (Hardcover) Wiley-VCH

About the Book : Discussing the technological supremacy of the chemical industry, including pharmaceuticals, and how it will adopt a leading position to solve some of the largest global challenges humans have even seen, this book details how the industry will address climate change, aging populations, resource scarcity, globality, networks speed, pandemics, and massive growth and demand. Following a detailed introduction to some of the megatrends shaping our world over the forthcoming decades, the book goes on to provide several scenarios of how the world could look by 2050, including ‘business as usual’ and a ‘sustainable’ one.

Chemical Engineering World

Thermochemical Processing of Biomass: Conversion into Fuels, Chemicals and Power Authors Price Pages Publisher

: Robert C. Brown, Christian Stevens : USD 88.99 : 350 (Hardcover) : Wiley

About the Book : Thermochemical pathways for biomass conversion offer opportunities for rapid and efficient processing of diverse feedstocks into fuels, chemicals and power. Thermochemical processing has several advantages relative to biochemical processing, including greater feedstock flexibility, conversion of both carbohydrate and lignin into products, faster reaction rates, and the ability to produce a diverse selection of fuels.

Thermochemical Processing of Biomass examines the large number of possible pathways for converting biomass into fuels, chemicals and power through the use of heat and catalysts. The book presents a practical overview of the latest research in this rapidly developing field, highlighting the fundamental chemistry, technical applications and operating costs associated with thermochemical conversion strategies.

Bridging the gap between research and practical application, this book is written for engineering professionals in the biofuels industry, as well as academic researchers working in bioenergy, bioprocessing technology and chemical engineering.

January 2015 • 111

CEW Interview

Interview CEW

From Corrective Actions to Proactive Approach In the year 2012, India incurred estimated losses of USD 67 billion due to corrosion.

The government could have saved USD 22 billion, if it had the correct action plan in place. “In India, though large scale corporations from public as well as private sectors have corrosion prevention programmes in place, there is still a long way to go for the medium and small scale sector which is still oblivious to a great extent of threat of corrosion,” shares Dr Samir Degan, MD, Osnar Chemical Pvt Ltd and Chairman, NACE International Gateway India Section (NIGIS), in an exclusive interaction with Mittravinda Ranjan. Edited Excerpts.

112 • January 2015 World Chemical Engineering

January 2015 • 112

Interview CEW

H

ow do you see the perception towards corrosion prevention and mitigation strategies implemented in India vis-à-vis other developed nations?

Corrosion is a serious business. Like other natural hazards such as earthquakes or severe weather disturbances, corrosion can cause dangerous and expensive damage to everything from automobiles, home appliances and drinking water systems to pipelines, bridges and public buildings. Though developed nations like the USA realised the importance of addressing this issue much earlier, in India the perception towards it has changed gradually over the last two decades after the inception of NIGIS in 1992. NIGIS has been working consistently towards creating greater awareness about dealing with the threat of corrosion and the organisation made significant impact since then.

If you ask me, it is about the mindset!

The industry has relented to accept the fact that corrosion is an issue that affects the overall profitability of a company in the long run. Earlier the problems were going unnoticed but the scenario has significantly changed now.

Coming to India story, we are in the tropical environment which is humid and warm and supports corrosion process.

The higher the temperatures, faster are chemical reactions and the process of corrosion. Warm environment creates a more conducive environment for corrosion.

If you look at the large public and private sector organisations they factor corrosion as the part of their design stage. They look at various ways to address the issues which are generally not the case with the smaller set ups, where they address the issue only when it ariese and forget it till the time the incidents or accidents happen again. Unlike weather related disasters, however, corrosion can be

controlled, but at a cost. It is estimated that a third of this cost can be saved by current technologies and awareness of the problem.

Are there any numbers you could share with our readers on losses incurred due to corrosion?

According to the NACE International’s 2002 US Corrosion Study, the direct cost of corrosion is USD 276 billion - on an annual basis, which represents 3.14 per cent of the US Gross Domestic Product (GDP). Extrapolating this figure globally the cost of corrosion is over a trillion US dollars.

As per the 2012 GDP figures, corrosion cost India around USD 67 billion. As a nation, we could have saved around USD 22 billion, if we had taken appropriate preventive measures.

The extent of corrosion impacting a nation varies depending on the population of country and available infrastructure. It is very difficult to have the exact data and the numbers that we read are based on the data that is extrapolated.

NACE has now embarked on a global study, IMPACT - International Measures of Prevention, Application and Economics of Corrosion Technologies, to determine the financial and societal impacts of corrosion on several industry sectors.

The study will include global data form the world’s largest economies including India and emphasis on public safety and the environment; economic models focused on costs, industry best practices and case histories; and correlate data to the real world consequences of corrosion failures.

From the global standards, how do you rate the corrosion control technologies in India?

In the field of surface treatments, both, coating protection and cathodic

protection, there have been significant advancements in technologies, globally, and we have been conducting technical courses and certification programmes for the working professionals to address corrosion specific issues.

Material selection is attracting lot of attention, particularly in the Middle East as the companies have started realising material selection as one of the most critical area for longer asset life. At NACE, we are running special certification courses to enable the professionals choose the best materials of construction for their assets.

As far as technologies are concerned, we are at par with any developed country, the challenge is the approach taken towards adoption of those technologies. Many large corporations have integrated corrosion prevention plans in their operations and they more proactive address the issue. But as we talked earlier, there is a serious lack of awareness about advanced technologies among the small players and there is lot of space for new corrosion protection technologies.

You pointed out lack of awareness and willingness to implement technologies as the biggest challenge. At NACE, how are you trying to bridge the gap?

Worldwide, NACE has been primarily driven by the oil and gas industry where they comply with our standards followed by infrastructure, defence, power and chemicals and petrochemicals sectors.

In India, large players like ONGC, GAIL and Cairn India and refiners from both the public and private sectors have been extremely supportive to our endeavours.

They already have corrosion mandates and are investing heavily to tackle corrosion which also includes training their professionals for certification

NACE has now embarked on a global study, IMPACT - International Measures of Prevention, Application and Economics of Corrosion Technologies, to determine the financial and societal impacts of corrosion on several industry sectors.

Chemical Engineering World

January 2015 • 113

CEW Interview Currently, we are working on the modalities, which is likely to be in place by April this year. We also had another very positive round of discussions with the US Commercial Services Department and are working further on the plan. courses run by us. But as far as India’s chemicals and petrochemicals sectors is concerned, industry is yet to realise the criticality to address the issue of corrosion and necessity of an action plans in place.

In your view, to what extent well integrated corrosion prevention strategies support the ‘Make in India’ vision of our Honourable Prime Minister?

Honourable Minister for Chemicals and Fertilisers Ananth Kumar participated in the Corcon 2014 and appreciated NIGIS’s approach and its idea to bring experts from the world together to address the issue of corrosion. Prime Minister has laid great emphasis on ‘Make in India’ with zero defect and zero effect on environment and corrosion management will facilitate the manufacturing sector to enhance its competitive edge in the global market. He also emphasised on adopting a proactive approach which we strongly believe is absolutely in-sync with the current global trends and will go a long way towards enhancing the competitive advantage India already has in manufacturing.

Kumar also made some very key announcements regarding corrosion control and there were some serious discussions with the US Commercial Services department as well during CORCON 2014. What is the progress NIGIS has made so far on both these fronts?

I am humbled to say that we have been able to make significant impact with the last edition of CORCON as we were able to draw the attention of the concerned government authorities viz Ministry of Chemicals & Fertilizers and Department of Industrial Policy & Promotion (DIPP), Ministry of Commerce and Industry and engage them directly in a dialogue with the US Commercial Services Department to jointly address the issue through knowledge and technology transfers.

114 • January 2015

The Honourable Minister himself has proposed setting up a nodal agency under the Ministry of Chemicals and Fertilizers in concurrence with NACE to create awareness across the other industries.

Currently, we are working on the modalities, which is likely to be in place

by April this year. We also had another very positive round of discussions with the US Commercial Services Department and are working further on the plan.

The Minister also announced signing of Memorandum of Understanding (MoU) between NACE and Central Institute for Plastics Engineering & Technology (CIPET) to conduct various skill development programmes and running certification courses to train people at the bottom of pyramid and also running intensive 3-6 months training programmes for industry professionals to equip the industries to integrate corrosion maintenance as the integral part of their maintenance activities. I had a discussion with the Director of CIPET last month in Chennai and we are looking forward to soon formalise the agreement to work on the detailed plan to present to the ministry.

Apart from this as I mentioned earlier that we are running various programmes successfully all across India through our section and have been receiving strong positive response towards the certification programmes.

In a nutshell, what would you like to propose to make the much desired impact to address the issue of corrosion in India?

One must understand that corrosion can never be stopped - it can only be prevented and mitigated by taking correct actions. In my view, a holistic approach encompassing all stakeholders is required to seriously address the challenge of corrosion prevention. Today,

there is severe lack of awareness which can be created if students are taught about corrosion right from the school levels. Sadly, Corrosion, which is actually a highly specialised field, is not even taught as a part of curriculum in the engineering colleges.

The bigger challenge is developing the mindset where the industries need to understand spending on corrosion prevention technologies as a long term investment instead of unnecessary expenditure which can help the organisations in multiple ways to improve their overall performance. A top down approach where the management understands and decides to include corrosion control as an integral part of the HSE exercise, in my opinion, can go a long way. This would mandate the organisations towards taking proactive approach rather than taking corrective actions after they incur huge losses due to any incident.

A strong regulatory policy supported by, regular corrosion audits will mandate the industries for having regular maintenance checks. Moreover, this would also enable industries to have longer asset life, avoid any unprecedented shutdowns caused due to corrosion, improve overall performance and significantly improve the top and bottom lines.

At NACE, we have been trying to create greater awareness across the industries to combat corrosion in India and I think we have been able to make a small dent.

In the years to come, we are hopeful that with the support from the respective authorities we will further be able to reach out to wider industry base and make the difference!

Chemical Engineering World

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Kirloskar Brothers Limited (KBL) offers a wide range of process pumps and pumping solutions that are required by process industries along with water supply demands. It covers all the segments including Engineering Steel, Paper & Pulp, Textile, Sugar, Chemical, Food and Beverages, Cement, Mining, Pharma, Automobile.

s & Defence NEED GENUINE SPARES? We understand that in the Pharma industry to handle toughest effluents and deliver optimal performance, it is important to reduce multiple downtime and pump breakdown that are caused due to spurious spares.For the same, we have set up a network that ensures quick turnaround for our genuine spares so that the performance of your pumps is not compromised.

To know more about genuine spares call us at: 1800-10-34443

A Kirloskar Group Company

Mark of genuinity

R.N.I. No. 11403/1966 Date of Publication: 29 th of every month. Postal Registration No: MSC/095/2015-17 Posted at Patrika Channel Sorting Office, Mumbai 400001, on 29th & 30th of every month. Total Page No.:116