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Contents CHEMICAL ENGINEERING WORLD RNI REGISTRATION NO. 11403/66 Chairman Publisher & Printer Chief Executive Officer
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VOL. 52 | ISSUE NO. 10 | OCTOBER 2017 | MUMBAI | ` 150
NEWS Industry News
6
FEATURE Equipments and the Chemical Process Industry - by N Radia, COO-Soda Ash Operations, GHCL
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Sulfur Plant Management in a Petroleum Refinery - by Debopam Chaudhuri, Process Design Engineer, and Srinivasa Oruganti, Department Manager - Process , Fluor Daniel India Pvt Ltd
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Hexane as a byproduct of Isomerization Unit Using a Top Dividing Wall Column - by Kondapalli Shreya Chaudhary, Chemical Engineer, and Prateek A Shanware, Chemical Engineer Bharat Petroleum Corporation Limited, Mumbai Refinery 28 Wireless Network: The Next Generation Communication, Methods of Field Instruments - by Sugata Bandyopadhyay, Consultant (Instrumentation & Control), and C Sailaja General Manager (Instrumentation & Control) TATA Consulting Engineers Ltd.
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Thermal Energy Storage with Phase Change Materials - by Kapil Gulati, Research Scholar; Sohan lal, Assistant Professor; and Sanjiv Arora Professor and Chairman, Chemistry Department, Kurukshetra University
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Developing Trends & Technologies in Petrochemicals and Plastics - by Pranjal Kumar Phukan, Senior Manager (C&P), Brahmaputra Cracker and Polymer Limited
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MARKETING INITIATIVE Condition monitoring for mobile equipment Automatic control loop tuning
56 56
PRODUCTS
64
EVENTS
72
PROJECT UPDATE
73
BOOK SHELF
74
AD INDEX
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INTERVIEW “Increased globalization, s u s t a i n e d m a r k e t opportunities and the emergence of Indian leaders are combining to create an exciting period for specialty - M S Vijayan, Joint Managing Director, Resil Chemicals Pvt. Ltd.
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The Publishers and the Editors do not necessarily individually or collectively identify themselves with all the views expressed in this journal. All rights reserved. Reproduction in whole or in part is strictly prohibited without written permission from the Publishers. Jasubhai Media Pvt. Ltd. Registered Office: 26, Maker Chambers VI, 2 Floor, Nariman Point, Mumbai 400 021, INDIA. Tel.: 022-4037 3737 Fax: 022-2287 0502 E-mail: sales@jasubhai.com nd
4 • October 2017
Disclaimer: The Editorial/Content team at Jasubhai Media Pvt Ltd has not contributed to writing or editing “Marketing Initiative.” Readers would do well to treat it as an advertisement.
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Chemical Engineering World
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CEW Industry News ABB Releases the PGC5000 Gas Chromatograph Oven with an Integrated Controller New York, USA: ABB’s Measurement & Analytics business unit announces the release of the PGC5000 gas chromatograph oven with an integrated controller, the newest addition to the PGC5000 process gas chromatography product portfolio for the chemical, petrochemical and refining industries. Shelter space and the overall initial investment in analytical equipment can be expensive. The PGC5000 oven with an integrated controller offers a low initial investment solution by integrating the single board computer (SBC) directly into the PGC5000B or PGC5000C gas chromatograph ovens. This not only eliminates the costs associated with one dedicated controller per oven architecture, but also reduces the overall size of the analyzer shelter, due to a significant reduction in the space required to house traditional process gas chromatographs. Coupled with three distinct user interface (UI) options, this product offering represents state of the art in process gas chromatograph architecture. The PGC5000 offers user interface flexibility in three distinct options. It offers Class 1, Division 2/Zone 2 (Division 1/Zone 1 also available) portable notebook PC with wireless or wired Ethernet connection to the ovens, or standard PC networked to the analyzer LAN with wireless or wired Ethernet connection to the ovens. The third interface option is a single PGC5000A controller that can control and serve as the UI for all ovens in a single shelter. The first and second UI options allow for the use of STAR, analyzer maintenance system software, and for each connected oven to be controlled and displayed on the same user interface. The PGC5000 is offered with an optional secure Wi-Fi wireless access point, with an adjustable transmission distance that limits the connection range to within the shelter. A single PGC5000A controller can connect to all PGC5000 ovens with integrated controller on the same network, using the logical address (analyzer tag name). The PGC5000 with integrated controller is available for all standard PGC5000B and PGC5000C ovens, including both the air bath and airless oven options. The new option also supports the full offering of detectors: flame ionization detector (FID), multiport and single port thermal conductivity detector (TCD) and flame ionization detector (FPD).
Wacker Polymers to Raise Prices for Dispersible Powders Munich, Germany: Wacker Polymers is to raise its prices for dispersible polymer powders of the VINNAPAS, VINNACEL and ETONIS brand. Effective November 1, 2017, prices will be increased by seven percent, or as customer contracts allow. This measure has been necessitated by the continued increase in costs. The price adjustment enables Wacker Polymers to continue providing customers with a wide-range of innovative quality products, supply security and comprehensive technical, sales and customer support services. Dispersible polymer powders of the VINNAPAS, VINNACEL and ETONIS brand are used in a broad variety of modern construction and infrastructure applications. 6 • October 2017
Dow, DuPont Merger Successfully Completed Midland, USA: DowDuPont has announced the successful completion of the merger of equals between The Dow Chemical Company and E.I. du Pont de Nemours & Company, effective Aug. 31, 2017. The combined entity is operating as a holding company under the name “DowDuPont™” with three divisions – Agriculture, Materials Science and Specialty Products. Shares of DuPont and Dow ceased trading at the close of the New York Stock Exchange (NYSE) on Aug. 31, 2017. Beginning today, DowDuPont will start trading on the New York Stock Exchange under the stock ticker symbol “DWDP.” Pursuant to the merger agreement, Dow shareholders received a fixed exchange ratio of 1.00 share of DowDuPont for each Dow share, and DuPont shareholders received a fixed exchange ratio of 1.282 shares of DowDuPont for each DuPont share. The Board of Directors of DowDuPont comprises 16 members – eight directors formerly on the DuPont Board and eight directors formerly on the Dow Board. There are two lead directors: Jeffrey Fettig, who previously served as the lead independent director for Dow; and Alexander Cutler, who previously served as the lead independent director for DuPont. Liveris serves as the executive chairman of the Board and Breen also serves on the Board. Three Advisory Committees have been established by the DowDuPont Board, chartered to generally oversee the establishment of each of the Agriculture, Materials Science (Dow) and Specialty Products divisions in preparation for the separations. Additionally, each Advisory Committee will develop a capital structure in accordance with the guiding principles set forth in the Bylaws, and designate the future chief executive officer and leadership team of its respective intended company.
Praj Sets Industry Benchmark in the Green Procurement Practices Pune, India: Praj Industries, a global process solutions company, has secured Procurement Excellence Award in the category of “Best Green Procurement Initiative of the Year”. Mr. Girish Rishi, CEO of JDA Software and chief guest of the function, presented this award to Praj officials at the 11th Express Logistics & Supply Chain (ELSC) Conclave held in Mumbai. ELSC is one of Asia’s largest end-to-end logistics & supply chain conference. It includes workshops, interactive panel discussions, expert speakers from the industry, case studies, etc. Standing true to Praj's ethos of sustainability, Praj’s supply chain management team started Green Procurement initiative in 2015 with the aim of raising quality standards of the biochemical processing industry. The initiative is based on core themes of enhanced legal compliance and safety at work, reduction in greenhouse gas emissions and natural resources like water, energy and paper, efficient operations, waste management, including wastewater treatment. Starting with 6 suppliers in the maiden batch, today, more than 100 suppliers ranging from mid-sized companies to SME enterprises are at various stages of green certification. Praj has ambitious plan of involving 100% of its tier I suppliers in the green procurement program by 2020. Chemical Engineering World
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CEW Features
Equipments and the Chemical Process Industry The use of potent chemicals to generate reactions in raw material and convert them into finished products aptly sums up the chemical process industry. Any lapse in the selection, monitoring, maintenance, and institution of safeguards in the chemical process industry carries the risk of causing long term and often irreversible damages to humans and the environment including flora and fauna. This article will focus on equipments used in the chemical process industry and emphasize on why selecting the right equipment is critical not only in productivity but also on ensuring safety. Equipment Selection Selection of the right equipment is the key to an efficient and safe operation. Due diligence must be taken in equipment selection to avoid any undesirable outcome in the various stages of operations. Equipments can be divided into proprietary & non- proprietary. Equipments such as pumps, compressors, filters, centrifuges & dryers, cooling towers, Mixers, Agitators, valves, furnaces etc that are designed and manufactured by specialist firms and are available for purchase off the shelf constitutes proprietary equipments. These equipments are available in standard sizes and come in different capacities. Non-Proprietary equipments on the other hand includes but is not limited to chemical reactor, vessels, multistage separators such as fractionators and other special equipment not amenable to complete standardization. These equipments are custom designed for particular processes like reactors, distillation columns, and heat exchangers. There are several considerations during the equipment selection and design process for the overall satisfactory performance and reliability of the equipment. Some of the more important points to be considered are: 1. Ease of operation and control & types of process controls 2. Optimum processing conditions & design of equipment 3. Availability of trained operators to operate the equipments. 4. Reliable methods for fabrication & adherence to international codes like ASME during fabrication of equipment 5. Appropriate material of construction 6. Strength and rigidity of components 8 • October 2017
7. Satisfactory performance of mechanisms 8. Ease of Maintenance and repairs 9. Safety requirements compliance in case of human failures, failures due to control systems, failure in utility systems, process streams, environmental events (wind, water. Earthquake etc.), Fire Hazard. 10. From point of view of fabrication machinability, weldability, malleability is considered relevant properties. 11. From mechanical properties point of view composition, structure, specific weight, thermal conductivity, expansibility, and resistance to corrosion need to be considered. 12. The layout and design of the equipment must aim to minimize the risk of errors and permit effective cleaning and maintenance in order to avoid cross contamination, built up dust or dirt and in general any adverse effect on the quality of product.
to be constantly monitored. Also adherence to preventive practices such as following proper start up procedures so as to eliminate damage due to thermal shock, maintaining proper log sheet during operation, analyzing process deviations and corrective actions on the same needs to be monitored.
Monitoring
Performance Indicators For Production And Maintenance
Continuous monitoring of equipment and plant is standard practice in chemical process plants. Monitoring is important in the chemical process industry as equipments are prone to deterioration and varying operating conditions also take a toll on these equipments. Standard operating procedures such as start up and shut down in a chemical process factory can significantly alter stream compositions and operating conditions that are much different than under normal operation and calls for constant monitoring. When a manufacturing plant is in operation, adherence to process such as material identification as per specification, heat treatment of high thickness material, proper welding of joints with qualified welder as per ASME standards, dimensional checking along with hydrostatic / pneumatic tests etc needs
Maintenance Management systems can come in handy in ensuring a comprehensive maintenance of the actual machines. An ideal maintenance management system must incorporate features such as, equipment data base up-to-date in SAP, maintenance scheduling, monitoring of preventive compliance, maintain equipment history, static vessel thickness, corrosion management, condition based monitoring which covers vibration measurement of rotary equipments, thermography of furnace, Dye penetrate tests etc.
Performance indication foe equipments deployed in the chemical process industry can be tracked on several indexes such as Finance - Budgeting from corporate level down to each cost Centre besides tracking and monitoring the actual, budgeted and forecast which can be updated throughout the year. Actual performance can also be tracked against targeted performance in the manufacturing process. Such tracking also acts as an enabler for continuous improvement initiatives. There are several proven performance measurement models such as DMAIC (Define, Measure, Analyze, Improve and Control) that can be adopted. OEE (Overall equipment effectiveness) and cost per unit production are other metrics that can be used to track performance. Performance tracking on the corporate side Chemical Engineering World
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CEW Features can be done through asset or capital based metrics like performance to share holder value, such as RONA (Return on net assets) or ROCE (Return on capital employed) Reliability of equipment can also be gauged by measuring MTBF for equipment reliability, ratio of unplanned work, inventory turn rates and store house effectiveness etc. Defects if any identified prior to failure are indicative of the effectiveness of programs. Programmed results can also be tracked through score cards. Gap analysis can also be carried out to identify areas where performance gaps exist (between current level and industry best practices) in area, availability, yield, quality, and cost. Maintenance reliability can be further checked using several KPI’s such as availability, utilization, mean time between failures (MTBF) etc. Significant returns can be achieved with focus on identifying performance gaps, greatest opportunities for improvement.
or hardware can also be used to prevent recurrence of a failure and conform to reliability principles. Reliability is observed when mean time between failures (MTBP) is large compared to mission time & it should be harmonized with cost issues. Alternate Equipments (Stand By Equipments) The purpose of maintaining standby equipments is to enable continuous operations/production. It minimizes interruptions in operations which help to sustain productivity and norms which in turn affect the cost of production.Standby equipments are mostly rotary equipments like pumps, fan, compressors, vacuum pumps etc... Being rotary equipments it involves bearing lubrication, bearing /impeller replacement after certain hours of operation, maintenance of associated electrical and instrumentation system. The equipment life depends on serviceability. Hence frequency of maintenance is higher than static vessels.
Reliability Dependability is the best indicator of reliability, which is an indicator of the probability that an item can perform its intended function for a specified interval under stated conditions. To track reliability in the business context, the annual cost of unreliability incurred by the facility can be quantified and measured. Downtime, cutbacks, and slowdowns are how failure is measured in most continuous process industries. Any improvement in reliability will have a positive impact on reducing the cost of unreliability and thereby generates more profit and get more business. Reliability of equipments used in the chemical process industry can be improved by following good maintenance practices, deploying best-in-class operating procedures etc. Reliability can also be augmented by adopting Total productive maintenance (TPM), a practice which ropes in production personal into appropriate maintenance tasks for both equipment and processes. It promotes effective use of equipment and loss prevention through preventive maintenance efforts with the involvement of all people from top to bottom in organization. Root cause analysis to define, segregate and identify problems with people, procedures, 10 • October 2017
Protective Measures Implementing protective measures are required to ensure safe operation of equipments such as piping systems. These measures could include engineering protections against possible failures such as thermal insulation, armor guards, barricades, and damping for protection against severe vibrations. Automatic shut off mechanism or flow controllers in the event of a piping failure such as block valves or excess flow valves can also be incorporated. Plant must minimize the potential harm to personnel and property in case of accidents arising out of: a) Human failure b) Failure of equipment or control instruments c) Failure of utilities or key process streams c) Environmental events (wind, water, earthquake so on). Examples of common safe practices are pressure relief values, vent systems, flare stacks, venting of steam in case excessive build up and release of fire water to area of fire, escape hatches in explosive areas, dikes around tanks storing hazardous materials, turbine drives as spares for electric motors in case of power failure. In chemical processing plants of any significant size, loss prevention reviews are held periodically by representative departments.
New Advancements Advancement in manufacturing is furthered by the use of advanced materials such as carbon fiber and grapheme to produce stronger, lighter, or more durable products having high corrosion resistance used in new generation large aircraft. And like wise by the development of genetically engineered crops, bio-remediation (microbes) to clean up spills etc in the field of Biotechnology. In Nano-technology, engineering and technology conducted at the nano-scale to produce products such as disease targeted drugs and lighter sporting equipment. Nano- technology also holds promise in the development of chemical sensors when reduced to molecular dimensions makes it possible to detect very low level of arsenic in drinking water. Highly intelligent platforms create the foundation for continuous optimization by visualizing operating processes at chemical plants in real time and this creates a basis for concrete and well supported decisions and helps to increase performance and reduce operating costs by 8 % and production increase by 10 %, this helps in achieving sustainable competitiveness. The development of green process have led to the production of low smoke candles, macro molecular hazard free paint coating additives, biologically derived diesel fuel, non-yellowing eye glass lenses using Iso sorbide poly carbonates etc. Development of smaller ( i.e. Intensified ) process equipment with production rates equivalent to those of current equipment can result in significant material utilization, reduced energy and capital requirements, and safer equipment design, intensification reduces size by taking advantage of small dimension effects of heat and mass transfer phenomena and by combining multiple unit operations into a single unit ( e.g. Reactive distillation).
Author Details
Mr N. Radia COO-Soda Ash Operations, GHCL Chemical Engineering World
De Dietrich Process Systems India Private Limited R-548/549, TTC Industrial Area, MIDC Rabale, Navi Mumbai - 400 701, Maharashtra India Tel: +91-22-6108 8989, Fax: +91-22-6108 8917 Email: sales@dedietrich.co.in, Website: http://in.dedietrich.com/
CEW Features
Sulfur Plant Management in a Petroleum Refinery The Crude slate is gradually widening. While at the same time the Sulfur specs and emission norms around the world are getting more stringent. In spite of the thrust for renewable and other alternate energy sources there will be a steady growth in fossil fuel in the coming decades. Hence there is an inherent need to have a closer look at the Sulfur Recovery Process in existing and new Refineries. Technology developments are being done at Licensors’ end, but Refiners are also looking for optimization in design with adequate flexibility in operation. Typically, while the refinery configuration gets finalized based on the available crude slates and the market demands of the products, a few important decisions need to be made regarding the Sulfur Recovery Unit. These are linked mainly with respect to SRU Plant capacity, configuration, technology and product management. This paper will highlight and discuss these issues; and provide means and methods in making these decisions early in the project lifecycle.
T
he environmental effects of burning hydrocarbon fuels have led most world governments and environmental bodies to impose stringent specifications on the sulfur content of hydrocarbon fuels. And these emission norms are gradually getting more and more stringent, requiring tighter specifications for hydrocarbon products. The chart on the right clearly demonstrates how in the last two decades the sulfur specifications have become tighter, while at the same time the crude slate is gradually shifting towards high sulfur crudes. This creates additional challenges to design and improve the treatment process of various distillates but also develop and implement better means and methods to recover that sulfur. Hence the proper design of a Sulfur Recovery Unit (SRU) becomes vital from the very initial stage of a project. From the very inception of the project, when the blueprint of the refinery is being prepared based on the available crude slates and the planned products as per the market demand, a few key decisions need to be made with respect to the design of the SRU. This holds good for Refineries planning to undergo a revamp either to cater to a wider crude slate or to meet the newer emission norms. An early and proper judgment of these important parameters provides a smoother path of engineering and beyond in the lifecycle of the project. This paper intends to discuss 12 • October 2017
these parameters and provides guidelines to find answers to these questions. The Sulfur Recovery Process: The following simplified flowchart demonstrates how sulfur travels in a Refinery starting from the crude oil till getting recovered as liquid sulfur. The sulfur compounds present in the crude ultimately gets displaced from the hydrocarbon phase as H2S and that
is captured by an amine solvent in the amine treatment units or gets dissolved in the water. The amine circulates in the Refinery in a closed circuit, capturing the H 2S from the hydrocarbon phase in various amine treaters. This rich amine (rich in H 2S) is then regenerated in the Amine Regeneration Unit (ARU) to liberate the H 2S gas and generating lean amine (lean in H 2S) to be circulated back to the various amine treaters. Similarly, the sour water generated from the various process units in the refinery is treated in Chemical Engineering World
CEW Features The sulfur produced in the Claus section of the SRU is cooled and liquefied in Sulfur Condensers, and collected as liquid sulfur in pits. This product sulfur needs to be degassed to remove dissolved H 2S before it can be sent as the final product. Beyond this simplified definition and description of the sulfur recovery process, there are numerous variations where a wrong decision made will lead to an un-optimized sulfur recovery process. This may ultimately lead to a bottleneck in the design of the entire refinery. The Technical Considerations: This section will discuss about the most defining parameters of the Sulfur Recovery Unit (SRU) and will assist in achieving the most optimized solution. the Sour Water Stripping Unit (SWSU) to liberate the H 2S gas. The combined stream of the H 2S rich gases from ARU and SWSU is then sent to the Sulfur Recovery Unit (SRU). Most SRUs at present utilize the modified Claus Process for recovering sulfur. In the modified Claus process the H 2S is burnt with sub-stoichiometric amount of air to generate SO 2, which in turn reacts with the unconverted H 2S to produce elemental sulfur. It is imperative to maintain the ratio of H 2S and SO 2 at 2:1 for maximum recovery of sulfur. The governing equations are: H 2S + O 2 = 2H 2S + SO 2 H S + SO 2 = 2H 2O + 2S 2 2 3
The reaction first takes place in a thermal reactor (Claus Furnace) followed by a series of (typically two or three) catalytic reactors. The unrecovered sulfur in the Claus tail gas may be further processed to achieve a very high degree of overall sulfur recovery. There are alternate processes available to recover the last bits of sulfur from the tail gas. And ideally, the final stream of gas after the tail gas treatment containing ppm levels of H 2S is finally burnt in an Incinerator furnace. 16 • October 2017
Chemical Engineering World
CEW Features The train capacity though is intrinsically related to the train configuration of the SRU as has been defined in the next section. 2. Train Configuration Sulfur Recovery Units in a Refinery almost always is designed in multiple train configurations. The main reason behind this is to have operation flexibility not only for SRU operation, but also for the entire Refinery.
1. The Plant Capacity This is one of the major decisions that need to be taken at the very beginning of any project; the plant capacity of the SRU. Once the overall mass balance of refinery is being set up based on all the available crude slates, the sulfur balance of the refinery may easily be calculated from the overall material balance of the sulfur. For that, typically, the worst feed (crude oil feed with the highest amount of sulfur) is selected, and a material balance of the sulfur is prepared based on the allowable product specification of sulfur. The overall mass balance provides with the ball park figure for the Sulfur Recovery Unit plant capacity. The above statements hold good even for a revamp project initiated by a change in crude slate and / or meeting tighter product specifications. Thus, a new hydrotreating facility or a conversion process for heavies to light and middle distillate initiates the requirement of increase in the sulfur handling capabilities of the existing 20 • October 2017
Refinery. In that case the sulfur balance happens over a smaller section of the complete refinery, and the determination of the plant capacity depends not only on this sulfur balance but also the plant capacity and configuration of the existing sulfur recovery units. A typical refinery example is provided in the table here. This considers a 9MMTPA refinery processing a mix of high sulfur crude and Low sulfur crude and generating a mixture of fuels and hydrocarbons for downstream processes. A mix of high sulfur crude and low sulfur crude in a ratio of 8020 is considered for sulfur balance as the worst feed with respect to the sulfur content. Based on the actual mathematical sulfur recovery capacity, the real capacity of the Sulfur Recovery may be selected by adding a margin. The margin typically is 10% or 15% over the calculated plant capacity. So for the selected plant capacity for this example will typically be 660 TPD, rather selecting a 600 TPD plant.
For a large and complex refinery with multiple crude distillation and downstream processing units, the SRU train configuration will in most cases be defined by the shutdown groups that is by the concept of the “mini-refinery”. Once the overall sulfur plant capacity has been determined, the sulfur plant capacity for the different shutdown groups is also calculated. And for each of the shutdown blocks, the sulfur plant capacity is compared, and that defines the single train capacity of the SRU. Based on the catalyst replacement cycle, the process units will need a planned maintenance shut down once every 3 – 4 years. The train configuration allows individual train of SRU to undergo planned shutdown along with the turnover of the “mini refinery” for catalyst change over, maintenance, etc. The train configuration of the SRU also takes into account the impact on the operating capacity of the refinery when one of the SRU train becomes unavailable due to operational upsets. To have a maximum operation capacity in many large refineries, the SRU trains are designed with a lot of operational margin by having spare trains and designing as 3 X 50% or 4 X 33% train configuration. A thorough economic evaluation is performed before installing such spare capacities in SRU trains by considering the availability factor of the SRU train and the economic loss of the refinery due to operation at reduced through-puts. And as a part of optimization, installing common Claus and Incinerator Air Blowers, or common Chemical Engineering World
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CEW Features oxygen as a feed to SRU would of course be the additional constraint for this change. Oxygen enrichment is also a viable option for new installations especially for cases where the plot space becomes very limited and where operational flexibility requires multiple trains with installed spare capacity. As oxygen enriched plants may be easily operated with air only, thus it provides a higher turndown operation with air only operation; and hence higher operational flexibility. tail gas treating units for two Claus Units may be considered before sacrificing the spare train concept. Hence, for the specific example provided in Table 1 in the previous section, the desired plant configuration would be to select either a 3 X 330 TPD or 4 X 220 TPD of SRU considering maximum operating margins. But if the decision is made based on economic considerations of installed costs, rather than operating flexibilities, then the preferred configuration of the sulfur plant would become either 2 X 330 TPD or 3 X 220 TPD. The plant configuration on whether to have 2 trains or 3 trains would mainly be defined by the “mini refinery” concept. For the said example above though, the data is for a single crude train, hence having a single train of SRU with the required capacity will have no operation flexibility, while designing it for a 2 X 660 TPD configuration will attract a lot of unnecessary installation cost. Thus the prudent option for this scenario would to select a 2 X 400 TPD sulfur plant configuration which will allow for a refinery operation at 70% capacity even with one SRU train operating with optimum additional installation cost. For revamp projects, the easy solution is to add one or more SRU train in line with the existing capacity of the SRU trains. But in most occasions, the new SRU train configuration is defined by the available plot space and the overall refinery operational flexibility. Though in many 22 • October 2017
cases, modifying to oxygen enrichment technology may provide an even simpler and cheaper option for revamp; as has been discussed in the following section. 3.Technology Selection The alternate option of Oxygen Enrichment process is gaining importance for retrofitting and revamps sulfur plants as it provides the easiest way to increase the sulfur plant capacity as is evident from the table here which shows how oxygen enrichment allows increment in acid gas handling capability of an SRU theoretically. Oxygen enriched operation reduces the amount of nitrogen entering the process and hence allows acid gas to replace it while keeping the total through put of gases same; and hence the pressure drop in the system similar. This drastically increases the plant capacity as the extent of oxygen enrichment increases. For revamp units, shifting from a standard straight through process to low-level oxygen enrichment technology (oxygen < 28%) will significantly increase the plant trough put (10 – 30%) with hardly any other modification in the entire plant. Utilizing medium level (28 – 45%) or high level (> 45%) oxygen will increase the plant capacity quite drastically (up to 75% for medium and up to 150% for high); but it also will lead to considerable modifications in the existing plant (new burner designs, and additional equipments). But in any case the capital investment will be a very small percentage of installing a new train of SRU (around 20%). The requirement of managing the
Available Processes: COPE by Air products and GAA-Fluor; Oxy Claus Process by Air Liquide; SURE single combustion, SURE double combustion and SUREMAX by Worley Parsons. 4.The Target Recovery with Tail Gas Treatment for SRU Typically all medium to mega refinery complexes target a recovery of more than 99% of the sulfur in SRU to meet the stringent SOX emission norms. The straight through Claus Process, even with three catalytic reactors can at max achieve a sulfur recovery of 95-97.5%. So at present the tail gas treatment has become inevitable in all present Refinery SRU, irrespective of the plant capacity. Three main methods of tail gas treatment presently available on a commercial scale are: • Sub Dew Point Process – This typically utilizes an alumina based catalytic reactor for the conversion of sulfur compounds, H 2S and SO 2 to sulfur. The reaction happens below the sulfur dew point temperature which increases the yield of the sulfur. The catalysts are typically regenerable upon heating. Available Processes: CBA (Cold Bed Adsorption) from Amoco, MCRC from Delta Hudson, Sulfreen from Lurgi, Clinsulf SDP from Linde, Clauspol from Prosernat. •
Selective or Direct Oxidation Process – This utilizes a direct and selective Chemical Engineering World
CEW Features reasons that the more important process units naturally demand deeper insights and more concerted efforts from all parties. But if neglected the bottlenecks in SRU design may lead to hindrances in the overall refinery performance and operation. A proper balance of the sulfur across the refinery followed by selection the train configuration and operational capacity margins set the path for unhindered refinery and SRU design and operation. For revamp projects as well, technology selection, and possible pathways for increasing the target recoveries will provide ways to avoid adding new trains of SRU and hence saving significant project costs.
•
•
conversion of the residual H 2S in the Claus off gas using a special catalyst (alpha alumina or silica extrudate) in an oxygen rich environment. Available Processes: SuperClaus from Jacobs, BSR Selectox & BSR/ HI-Activity from Worley Parson, Clinsulf DO from Linde. Catalytic Reduction and Absorption Process (amine based TGT) – This utilizes a two step process of first catalytic reduction of the entire sulfur to H 2S followed by the absorption of the H 2S thus produced with an amine typically in MDEA or a variant of it. The H 2S is finally liberated from the amine and recycled back to the feed. This process has the capacity to capture the maximum amount of sulfur from the feedgas.
Available Processes: SCOT from Shell, RAR from KTI, BSR/MDEA from Worley Parson, HCR from Siritec Nigi, Clintox from Linde. The relative cost and sulfur recovery achieved in the various processes of the tail gas treatment is shown the table here. This will provide the preliminary guidelines in selecting the tail gas treatment method to strike a balance between the extent of sulfur recovery and the overall economics. But most refineries at present are forced to opt for the Catalytic Reduction and Absorption process to meet the required 24 • October 2017
sulfur recovery (>99.5%) due to the amount of sulfur handled by them. Very old refineries initially installed the sulfur recovery plants without the tail gas treatment facilities, thus it was having the Claus section only, and the entire tail gases were being incinerated. This was achievable mainly because the sulfur emission specifications were more lenient and this allowed more SOX to pass to the atmosphere. For such units, the best way to improve the sulfur recovery and meet the emission specs is to install an appropriate tail gas treatment unit; ideally an amine based TGTU. These TGT units are flexible to operate and may operate with even very low acid gas turn down flows. Hence for revamp units of such scenarios, it is also possible to have common tail gas treatment units for multiple Claus plants, which has less impact on additional plot space required. Alternate methodologies for revamp units include changing the type of amine used for H2S absorption, or even increasing the concentration of MDEA or the amine used in the unit. This though has only a marginal impact in increasing the overall recovery of sulfur from the Sulfur Plant.
Sulfur plant management in a Petroleum Refinery is an important subject and is gradually gaining importance; and a few simple yet key decisions when taken early in the life cycle of the project goes a long way towards a smoother execution of the project and better operability of the refinery. (The conclusions presented in this article are solely those of the author/s, and cannot be ascribed to Fluor Corporation and/or any of its subsidiaries.) Author’s Details
Debopam Chaudhuri Process Design Engineer Fluor Daniel India Pvt Ltd Email: debopam.chaudhuri@fluor.com
Conclusions For all Refiners, while the project set up is being done the attention provided to the proper design of an SRU is not always adequate. This is for the obvious
Srinivasa Oruganti Department Manager - Process Fluor Daniel India Pvt Ltd Email: srinivasa.oruganti@fluor.com Chemical Engineering World
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CEW Features
Hexane as a byproduct of Isomerization Unit using a Top Dividing Wall Column The article focusses on the disruptive thinking which made it possible to co-produce hexane along with Isomerate by using the world’s first top Dividing Wall Column
I
somerization process is gaining importance in the present refining context due to limitations on gasoline pool benzene, aromatics and olefin content. The isomerization process saturates benzene and upgrades the octane of light naphtha fractions. Isomerate product contains very low sulfur and benzene, making it an ideal blending component for the refinery gasoline pool. This process complements the catalytic reforming process, in upgrading the octane of refinery naphtha streams. Post commissioning of a continuous catalytic regeneration reformer at Bharat Petroleum Corporation Limited (BPCL) Mumbai Refinery, the existing semi regeneration catalytic reformer unit would become redundant. In view of this anticipated redundancy, a process study had been carried out along with the setting up of the continuous catalytic regeneration reformer. Conversion of the catalytic reformer unit to an isomerization unit would not only enable the refinery to increase its Bharat Stage (BS) IV motor spirit production from 40 to 100 per cent of the pool, it would also build the capability of producing some quantity of more stringent quality, BS VI motor spirit. Considering this, a global notice inviting tender for the conversion of catalytic reformer unit to isomerization unit was floated. The scope for this revamp was prepared in-house without any Project Management Consultant (PMC). Hexane of world class specification was included, as a byproduct from isomerization unit, as a part of this tender. The possibility of production of hexane from an Isomerization unit was explained to the interested bidders 28 • October 2017
as hexane is traditionally produced by solvent extraction method. Economic evaluation, by comparing the net present value, of the proposals received, was also carried out in-house. In March 2017, Isomerization unit, licensed by M/s GTC Technology, LLC was commissioned at Mumbai Refinery.
units like hydrocracker and reformer. Middle cut from the naphtha splitter can augment motor spirit production / reformer feed while the bottom cut can be routed to motor spirit pool / high speed diesel pool / reformer.
The challenge of installing a divided wall column in the isomerization unit was taken up, although it had never been used to produce stringent quality hexane ever before, as BPCL is a trend setter in the Industry. We also recognized the phenomenal outcome of our disruptive thinking to co-produce hexane from an isomerization unit, which was being installed to take India on the road of total BS IV motor spirit sufficiency.
The isomerization process improves the research and motor octane number of light naphtha, predominantly C5/C6, so that it can be blended into motor spirit pool. The light naphtha fraction of the refinery is typically high in normal paraffin content resulting in low octane number, around 68. Isomerization process converts an equilibrium proportion of these low octane normal paraffins into their higher octane branched isomer.
Isomerization Complex
The isomerization reaction is carried over a fixed bed non-chlorinated mixed-metal oxide catalyst in a hydrogen environment. The unit operates at moderate operating conditions (130 – 180oC / 27 kg/cm2g), low hydrogen partial pressure and high space velocity. These operating conditions promote the isomerization reaction and minimize hydrocracking.
The isomerization unit has a capacity of 0.62 million metric tonnes per annum. The salient feature of the unit design is co-production of petrochemical feedstock like Special Boiling Point (SBP) product and Hexane along with motor spirit blend component, isomerate.
Isomerization Process
The revamped unit comprises of a naphtha hydrodesulphurization unit to remove impurities from wide cut (IBP140oC) naphtha and naphtha splitter 1 top cut (IBP – 60oC) to meet the stringent quality of motor spirit blend component, isomerate and specialty products, SBP and Hexane. The desulphurized naphtha is split in naphtha splitter 2 into three cuts. Top cut is routed to the isomerization unit along with other light naphtha cuts from refinery
Figure 1: Isomerization of Paraffins Chemical Engineering World
CHEMICAL & PHARMA INDUSTRY
CEW Features This 27% decrease in reboiler duty due to use of divided wall column along with change from medium pressure steam reboiler to fired heater reboiler resulted in a saving of ` 63.1 crores per annum translating into 9.5 cents per barrel of crude processed in the refinery. Hexane production Mumbai
Refinery
used
to
produce
hexane from its solvent extraction unit, which is the traditional process for producing hexane. The hexane so produced had a benzene content of 130
Figure 2: Typical Isomerization Process Scheme
– 240 ppm wt.
Figure 2 above, shows the schematic of a typical Isomerization unit with a De Iso Hexanizer to split the stable isomerate. In our case, the De Iso Hexanizer is used to co-produce hexane along with motor spirit blend component, isomerate.
In addition, a divided wall column reduces plot area requirement - four column in series vs single column installation.
Hexane, so produced, is treated in a polishing unit.
Design
The divided wall column is categorized into three types based on the location of
specification, is being co-produced from the isomerization unit commissioned at Mumbai Refinery: Actual
Actual
May 2017
June 2017
Divided Wall Column
Density @ 20oC
0.6600 - 0.6870
0.6770
0.6753
96
99
99
The De Iso Hexanizer column installed in the isomerization unit, at Mumbai Refinery, is a divided wall column.
Distilled between % volume 63/70oC Sulphur
mg / kg
< 0.5
< 0.5
< 0.5
Benzene
mg / kg
< 3.0
< 3.0
< 3.0
Although the concept of a divided wall column has been around for decades and has been applied to a wide variety of processes but it is the first time that a divided wall column has been installed in an isomerization unit and that also for co-production of very stringent quality hexane along with isomerate. BPCL chose to implement a divided wall column, for this service, in line with its aptitude of ‘the first mover status in the Industry’. The high energy saving potential as compared to a multi column system gave the final push in this decision. This energy saving potential is achieved as the column design avoids the back mixing of a concentrated lighter stream into the heavier bottom stream, after separation. 30 • October 2017
MT/m3
Since March 2017, hexane of world class
the wall inside the column: the top, the middle and the bottom. Out of around 150 divided wall columns being operated world vide, the divided wall column commissioned
at
Bharat
Petroleum
Corporation Limited Mumbai Refinery in 2017 is the first grass root divided wall column in India and the world’s first top Divided Wall Column. Energy reduction due to use of a divided wall column in the isomerization unit for co-production of hexane and isomerate is as tabulated:
Incorporation of high purity hexane production into the design of the isomerization unit, paved the way for dismantling of a 1989 installed, solvent extraction unit thereby making plot area available for upcoming projects in the refinery. It has also reduced the variable operating cost for production of hexane ( 6700 per metric tonne of hexane produced from the solvent extraction unit). Variable operating cost of hexane polishing unit, in the isomerization unit, is around-204 per metric tonne of hexane produced.
Four Column system Divided Wall Column Reboiler Utility consumption
MMKcal/Hr 23.5
Utility consumption reduction %
17.1 27.4 Chemical Engineering World
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CEW Features Benefits Installation of a divided wall column and coproduction of superior quality hexane from the isomerization unit is accruing savings of ` 95.7 crores per annum i.e. 14.4 cents per barrel of crude processed in the refinery.
Prabhune of BPCL for their unwavering support & guidance and GTC Technology for their understanding of our process requirements and unit design to meet the same.
Epilogue
Figure 3: Top Divided Wall Column at Mumbai Refinery
By implementation of this project, BPCL Mumbai Refinery has successfully changed their product slate of producing ‘food grade’ hexane to ‘pharmaceutical grade’ hexane. This has helped BPCL in increasing its market share.
This success story, which began with BPCL Mumbai Refinery’s foresight to pursue the path not trodden resulted in making India the first in the history of refining with the production of very stringent quality hexane as a byproduct along with the main product, motor spirit blend component (isomerate) from an isomerization unit. This isomerization unit also has the world’s first top Divided Wall Column. Acknowledgements We would like to thank P. Padmanabhan, C. J. Iyer, P. V. Ravitej and A. C.
Authors’ Details Kondapalli Shreya Chaudhary Chemical Engineer Bharat Petroleum Corporation Limited Mumbai Refinery, India
Prateek A. Shanware Chemical Engineer Bharat Petroleum Corporation Limited Mumbai Refinery, India
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CEW Features
Wireless Network: The Next Generation Communication Methods of Field Instruments The Industry 4.0 and IIOT had defined a digital domain to the advantage of the Industry & New area of business prospects are picking up. The prime considerations that are ushered in are digital codification of equipment and devices and communication through wireless for information exchanges. Thus wireless communication had become a necessity now and not a preference. This paper will address the requirement of digital wireless communication, its technical aspects and its challenges with reference to Wireless Networking of smart process sensing devices.
T
he digital wireless communication had a much wider purview covering human & material identification, their movement, acquiring condition monitoring information of plant and equipment and other plant information including its logistics data. We will however address here the wireless communication as pertinent in the process industry. Wireless technology is more often considered for monitoring applications than for Control applications, especially in remote / inaccessible places in process areas where it is difficult to lay the cables. They are also used hey are also used in trial applications in Pilot plants as also models in R&D which are temporary in nature.
contrast, signals in Medium-range wireless communication can travel up to 100 meters or so, while signals in Wide-area wireless communication can travel from several kilometers to several thousand kilometers.
The Objective of this paper is to discuss the Wireless technology in Process Plants, the considerations for implementing a Wireless Sensor Network (WSN), including its Architecture, advantages & limitations and the Data security and interoperability between different protocols and devices.
• • •
Wireless Technology in Process Plants: Wireless is a term used to describe telecommunications in which electromagnetic waves (rather than wired connection) carry the signals over part or whole of the communication network. Wireless communication involves codification or modulation of the signal on a carrier frequency, transmitting the packaged information over a longer distance without the use of wires or cables. The distance over which communication may be established can vary from a few meters to thousands of kilometers. Depending on the distance of communication, the type of wireless communication can be selected. In Shortrange wireless communication, signals travel from a few centimeters to several meters. In 34 • October 2017
The field mesh or WSN is used for transmitting a few kilobytes (kB) of data over a short range up to a few hundred meters. This field wireless network comprises sensors and actuators, field mobile devices and these types of networks will be discussed in this paper.
Frequency Bands The frequency of communication is one of the most important factors which need to be considered when implementing a wireless sensor network. The 2.4 gigahertz (GHz) communication frequency is the most widely used band for industrial applications for the following reasons: World wide availability for unlicensed use. High data rate (250 Kbps). Lower power requirement.
Wireless Solutions for the Process Industry The Industrial Wireless technologies can be classified into three main categories based on their range / area of coverage. They are Global canopy, a Site backbone and a Field mesh. The Global canopy is also known as long range wireless communications which is used for long distance data communication. It comprises private networks joining two sites / locations which are hundreds of kilometers apart or Public network like Internet or satellite communication for long distance data transmission. A site backbone is a communication method in which data is transmitted over a few miles from node to node. Although the distances covered are shorter than with a global canopy, a site backbone network can still be used to transmit data over relatively long distances.
The modern wireless technology utilizes IEEE 802.15.4 compatible DSSS (Direct Sequence Spread Spectrum) radios and operates in the 2.4GHz ISM radio band. The IEEE 802.15.4 also supports multiple bands. Two standards using the IEEE 802.15.4 radio technology are IEC62591 (Wireless HART) and ANSI/ISA100.11a-2011 (ISA100.11a/ IEC62734), which are the most important standards accepted by the industry. In wireless networks, typical network topologies are Star, Mesh or Hybrid network (a combination of star and mesh). All field devices in Wireless HART support full Mesh topology, as they have routing capability. On the other hand, the I/O devices in the ISA100.11a network can be defined as nodes with or without routing capability. It thus supports both star, mesh and hybrid topology. Factors to be Considered When Implementing A Wireless Sensor Network (WSN): (a)Understanding Measurement Requirements While designing the system, the basic considerations are the parameters that require monitoring, measuring or controlling with the WSN system, the Sensors used to acquire this data and how the sensors communicate with the Data Acquisition System. Power is an important factor for WSN systems. . The sensors in WSN application are powered by batteries, considering they Chemical Engineering World
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CEW Features could be located in remote / inaccessible areas. Hence external power availability is not always feasible. The internal battery provides upto 50mA at 12V which powers the sensors. Lower sampling rates (100 Hz or below) are considered to conserve the battery power and extend its life. Hence the parameters considered for monitoring and its response time are important factors. Considering the latency of the Process parameters, like pressure, temperature, level, flow etc, the sample rate adequately meets the requirement. (b) Selecting a Wireless Protocol The Wireless standards can be selected based on the power requirements, throughput and range. Cellular and WAN standards such as GPRS, WiMAX and EDGE provide significant throughput and range. However, they consume more amount of power. The Bluetooth protocol requires very little power, but does not provide adequate range. For WSN systems communication distance requirements are of the order of 100 to 200 mts. However, Standards such as IEEE 802.11 and IEEE 802.15.4 consume a reasonable amount of power & can provide adequate throughput and range for wireless measurement systems. Table1 brings out the distinct differences between IEEE 802.11 & IEEE 802.15.4 devices. The IEEE 802.11 devices have the advantage of high bandwidth which is associated with increased power consumption. On the contrary, IEEE 802.15.4 devices such as ZigBee, 6LoWPAN, Wireless HART and ISA 100.11a, have the advantage of range & power.
Sl. No.
Parameters
Typical IEEE Typical IEEE 802.11 (n) Devices 802.15.4 Devices
1.0
Typical Lifetime
2.0
Bit Rate (Maximum)
3.0
Range (Without ~100 m Repeaters)
~300 m
4.0
Band Width
2 MHz
Battery 1-2 days
2-3 years
300 Mbit/s
250 Kbit/s
5 MHz
Table 1: Typical Battery lifetime, throughput and Range for IEEE 802.11
is preferred when concern for battery power preservation is the prime consideration while the other topologies are considered, when the limitation of power supply does not exist. The simplest network topology is the star having one node at the center which both sends and receives data directly from all of other nodes in the network. Thus, the center node handles both sending and receiving operations. The other nodes have the only distinct function of transmitting information to the node at the center. This result in energy saving as the end nodes beyond data transmitting to the center node does not have any other function. Further any end node failure does not stop functioning of the other part of the network as long as the center node is operating. In the mesh topology each of the nodes can both send
and receive data & hence can each exchange data with the other nodes network. Thus the mesh topology ensures more reliability as in case of any node failure the other nodes establishes new route of communication ensuring that the balance part of the network is functional. With a combination of star and mesh topology all other network topologies may be configured. Architecture of WSN WSNâ&#x20AC;&#x2122;s are networks for real time applications comprising a number of nodes. The function of these nodes is to sense the process parameters such as Pressure, level, temperature, humidity etc. After sensing, these nodes, the data is stored in their memory and passed to the Control system for further processing. Any device to connect itself to another device needs a protocol stack. The
( c) Software and Data Access The other important factor is the deployment of the appropriate software responsible for acquisition, data handling and analysis, transmission to local close & far away nodes & presentation in appropriate Format. Functional decentralization of intelligence and controlling capabilities for the remote nodes enhances system performance & optimization. (d) Wireless Network Topologies The various Topologies for WSN are Star, Tree, Mesh and Cluster. The star topology 36 â&#x20AC;˘ October 2017
Figure 1: Typical Wireless Network Topology Chemical Engineering World
CEW Features protocol stack of WSN comprises of 5 layers. • Physical Layer In the Physical layer, transmission, reception and modulation functions are implemented. • Data Link Layer In the Data link layer, noise elimination, avoiding collisions and a well defined interface with the higher layers are implemented. • Network Layer In the Network layer functions like addressing, connecting and forwarding the data sent by the above layers are addressed. • Transportation layer Transport layer ensures and organizes the data flow in the network. • Application layer Application layer assists in building various applications based on the sensing data. In addition, a central system manager is associated with routing, communication & scheduling of the network in totality. The above 5 layers are aided by three modules as mentioned below: • Power management module: As the nodes are battery power dependant, this module organises optimal utilization of the power. • Mobility management module: This module manages the movement of the nodes along with their neighbors. • Task management module: This module balances and schedules the sensing tasks in a specific region of the network. Advantages of WSN • Implementation cost is cheaper than wired network • In some situations where wired connections are exposed to extreme conditions, a wireless replacement can actually be more reliable. In other situations, a redundant wireless connection can serve as a backup for wiring. • It eliminates cabling. • Introduction of new devices as node can be accommodated at any time. • Easy conversion of an existing plant having Wired Smart Transmitters with 4-20mA over HART to Wireless network using Adapters. (Note: External power is needed for Adapters while the communication is Wireless) 40 • October 2017
Limitations • Unless adequate protection is taken, the system is susceptible to hacking. Performance may be affected by presence of blocking elements like building walls, interference from devices like Microwave oven etc.
width is 22 MHz and each channel is separated by 5 MHz. IEEE 802.15.4 also supports 14 channels in 2.4GHz frequency range, with 2 MHz separation, thus having reduced bandwidth than the Wi-Fi channels at the same frequency.
(e) Data Security and Interoperability between different Protocol Devices In the wireless frequency band 2.4 GHz, there are many users with technologies like Wi-Fi, Wireless HART, ZigBee, UWB and others and hence if proper security measures are not adopted, there are chances of interference and data corruption.
Conclusion
The methodology to be adopted to ensure no interference & data corruption occur: • Encryption: Proper encryption of messages. In ISA100.11a data communicator follows a 128-bit Advanced Encryption Standard (AES) . • Authentication: - Authentication of members participating in communication whether it be transmitting or receiving. Only members authenticated by the system or security controller are allowed to participate in sending & receiving data. • Integrity: To retain integrity of communication, each network node uses a Media Access Control address (MAC address) which is a distinct property assigned to network interfaces for communications to confirm data integrity and transport security. MAC addresses are used as a network addres for most IEEE 802 network technologies, including Ethernet and WiFi. • Key Management: All the network nodes must have a join key that may be assigned to be the password recognised by devices to grant entry into the network.This is adopted in the ISA100.11a protocol. By adopting this methodology, the security of the network may be increased & and unauthorized participants may be restricted from joining the network. • (f) Requirement to establish secured communication in a platform of multiple simultaneous wireless users: To ensure security, reliability and data integrity, measures for co-existent operation of other users in RF environment must be ensured. In IEEE 802.11, there is provision for 11 channels in the 2.4GHz frequency range. The channel
To sum up, it may be concluded that IEEE 802.15.4 had become the choice of all the users and manufacturers of Wireless instruments and networks. IEEE 802.15.4 supports IEC62591 (Wireless HART) and ANSI/ISA100.11a - 2011 (ISA100.11a / IEC62734). The primary choice had been decided on the battery life which is very important for a wireless device which has no other source of power, while the speed, range and bandwidth meet the process requirement adequately. Further the features and protections adopted to maintain the signal integrity has been time proven and so user shall have no hesitation to switch to wireless network. With advent of new technology of solar cell with light sensitive nanoparticles, soon we will have facilities of powering the smart wireless instruments by integral body mounted solar cells by which we can extend the life of the batteries. Hence in the near future the process networking through wireless will become the only choice. REFERENCES: 1. National Instruments – White Paper 2. Five factors to consider when implementing a Wireless Sensor Technology – NI.com 3. White Paper - ISA100 – Application, Technology & Systems.
Authors’ Details
Sugata Bandyopadhyay Consultant (Instrumentation & Control) at TATA Consulting Engineers Ltd.
C. Sailaja General Manager (Instrumentation & Control) TATA Consulting Engineers Ltd. Chemical Engineering World
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12/10/2014 1:41:53 PM
CEW Features
Thermal Energy Storage with Phase Change Materials The materials which go through the process of phase change and having the unique property of large latent heat of fusion; melting and solidifying at almost constant temperature are accepted as phase change materials (PCMs). Phase change materials are the efficient sources of storing the thermal energy. PCMs are well recognized as “Latent Heat Storage Materials”.
D
uring the phase transitions PCMs charge and discharge the isothermal energy and are having the large latent heat capacity nearly 5 to 14 times higher than the ordinary thermal storage materials such as masonry and rock. At first National Aeronautics and Space Administration (NASA) introduced this technique of PCM. The NASA’s space research program in the late 1970s and early 1980s included the abundant research and development on some new materials to protect astronauts and the delicate instruments from the extreme temperature fluctuations in space. Hence, a new technique of PCM was introduced to the world. Methods of Energy Storage The process of capturing the energy generated at once for its use at the later stage comes under the energy storage. Energy can be stored in multiple forms including electrical, mechanical and thermal energy. The technique of energy storage is important in preserving the available energy for improving its utilization. Energy storage sources/methods can be classified as: • Short term behaviour • Long term behaviour In most of the applications short term energy storage (of few hours) is required, while some other applications demands for the long term energy storage (of few months). For e.g. solar energy is available only during the day. So for its application storage of thermal energy is mandatory such that the stored heat may be used at the later stage.
42 • October 2017
temperature range. This method of The following index contains the types of energy storage: storing the energy is superior to SHS • Mechanical energy storage includes method because of its high storage the pumped hydropower storage and density and isothermal nature during flywheel energy storage. the phase change . In Latent heat storage (LHS) method, storing of energy is based on the changing of a • Electrical and electrochemical energy phase i.e. by melting/vaporizing/solidifying /liquefying. So this method of storing the storage includes the capacitor, flow Latent Heat Storage Materials energy is made by heat absorbing or releasing during the phase change process for batteries and rechargeable batteries. e.g. from solid to liquid or vice versa. heat storage usually deal in the In Latent the midst of the systems above methods latent • Thermal energy storage (TES) contains materials with a considerable capacity of heat of fusion. PCMs change their phase from heat thermal energy storage is a fascinating the sensible heat and latent heat solid to liquid absorbing a considerable of thermal energy for latercan use be in a way. amount The phase change process storage: particular temperature range. This made method inof the storing the energy is superior to SHS following ways: solid-solid, method because of its high storagesolid-gas, density and solid-liquid, isothermal nature during the phase liquid-gas and • In Sensible heat storage (SHS) change [4]. method, storing of energy is done vice versa. In the solid-solid transitions Latent Storage by Heat elevating theMaterials temperature of a heat storage is made during the material form solid or liquid i.e. by the process of transformation from one crystalline [5]. The phase In the midst of the above methods latent heat thermaltoenergy storage is a fascinating way transitions another. These solid-solid heating change processorcancooling. be made The in thedrawback following ways: solid-solid, solid-gas, solid-liquid, liquid-gas and show small changes in volume & also of SHS system is the large vice versa. In the solid-solid transitionsvolume heat storage is made during the material transformation from associated with small latent heat than requirement for These the solid-solid small transitions one crystalline form toeven another. show small changes in volume & also solid liquid transitions. These have the temperature change. associated with small latent heat than solid liquid transitions. These have the advantages of greater advantages of greater design flexibility • Inflexibility Latent heat storage method, design and offer the (LHS) advantage of less rigorous container requirements [6]. However, these and offer the advantage of less rigorous storing is based on the transitions are of veryenergy slow. Higher latent heat of phase promising transitions i.e. liquid-gas and solid-gas container However, changing a phase i.e. by melting/ transitions sufferoffrom a disadvantage of showing very largerequirements. changes in volume duringthese phase transitions are very slow. Higher vaporizing/solidifying /liquefying. So transitions. These are also associated with container requirement problems which completely latent rule out heat[2, 7]of promisingtransformations transitions i.e. this method of thermal storingenergy the energy . Nophase doubt solid-liquid have their potential utility in storageissystems and are solid-gas transitions suffer comparatively latent heat than liquid-gas; butliquid-gas these transitions having advantage of involving made bysmaller heat absorbing or releasing from ahave disadvantage showing very only very less volume change. Hence, solid-liquid turned out to beofvery effective for use during the phase change process transitions large changes in volume during phase in thermal energy storage (TES) systems. PCMs themselves cannot be used as heat transfer medium for e.g. from solid to liquid or vice because of their low thermal conductivity. Hence, there is a need of a separate medium transitions. These are heat alsotransfer associated versa. Latent heat storage systems [2]. Thus whichusually must be deal hired with PCM in order to transfer the energy from the PCM to the substrate in the materials with with container requirement problems any latent heat storage system (PCM) should possess the following characteristics: a considerable capacity of heat of which completely rule out their potential in thermal energy storage systems. change phase be inutility fusion. MeltingPCMs temperature of thetheir PCM should the desired operating temperature range. No doubt solid-liquid transformations solid to heat liquid absorbing from An appropriate exchange surface.a considerable PCM should beamount compatibleofwiththermal container. have comparatively smaller latent heat energy for later use in a particular than liquid-gas; but these transitions are
MELTING (HEAT GOES INTO THE SOLID AS IT MELTS)
LIQUID
SOLID SOLIDIFICATION (HEAT LEAVES THE LIQUID AS IT SOLIDIFIES)
Figure 1 Chemical Engineering World
Selection Criteria For their application as PCM these must display the assured advantageous thermodynamic, kinetic and CEWproperties. Features chemical So any PCM should be chosen on the basis of the following selection criteria: having advantage of involving only very
• Latent heat of fusion per unit volume
subdivided into two classes: salt hydrates
[8] Thermodynamic less volume change.properties Hence, solid-liquid and metals. should be high transitions have turned out to be very • High density, specific heat & thermal Melting temperature in the desired operating temperature Refer Figure 2.range effective for use in thermal energy storage conductivity Latent heat of fusion per unit volume should be high (TES) systems. PCMs themselves cannot • Small volume changes on phase • Organic phase change materials cover alteration High density, heat & thermal conductivity aowide range ofo melting points between be used as heattransfer medium becausespecific 0 ° and 200 C. However, because • Congruent melting of their low thermal conductivity. Hence,changes Small volume on phase alteration of the high content of carbon and there is a need of a separate heat transfer hydrogen; these are not very stable at Congruent melting medium which must be hired with PCM in Kinetic properties
• Nucleation rate should be intensified
high temperatures. Also the thermal
order to transfer the energy from the PCM Kinetic properties conductivity of organic PCMs is very to the substrate. Thus any latent heat • Crystal growth rate should be high low. so thatbe large heat can be recovered intensified storage system(PCM)Nucleation should possessrate the should • Paraffins: are usually applied to the from the storage system during the following characteristics: Crystal growth ratereverse should be high so that large heat can be having recovered from paraffin waxes the general process of phase change chemical formula C nH 2n+2, where the storage system during the reverse process of phase change • Melting temperature of the PCM should be
19 <n <41. Crystallization of these long straight chains discharges the enormous amount of latent heat and with the increase in the number of carbon content in the chain there Non-corrosiveness, non-poisonous and non-combustible Please refer Figure 1. melting point also increase . Economic properties • Non-paraffins: PCMs are associated • Availability Economic properties Selection Criteria with highly varied properties. Non• Low cost paraffin PCMs are having inimitable For their application as PCM these Availability properties unlike the paraffins must display the assured advantageous Classification of Phase Change having very similar properties and Low and costchemical Materials thermodynamic, kinetic covers a wide range of materials properties. So any PCM should be chosen on for phase change storage. Abhat In general, phase change materials can the basis of the following selection criteria: et al. can & Buddhi & Sawhney haveas: be categorized as: organic and inorganic Classification of Phase Change Materials In general, phase change materials be categorized examined a number of esters, fatty PCMs. Organic PCMs can be further Thermodynamic properties organic and inorganic PCMs. Organic PCMs can be further divided into two classes: paraffins and nonacids, fatty alcohols and glycol as • Melting temperature in the desired divided into two classes: paraffins and paraffins. Inorganic PCMs can be subdivided into twoInorganic classes: salt and metals. PCMs. the Non-paraffin non-paraffins. PCMs canhydrates be operating temperature range Chemical properties in the desired operating temperature range. • Absolutely reversible freeze/melt cycle Chemical properties • An appropriate heat exchange surface. • Non-corrosiveness, nonPCM should be compatible with container. Absolutely reversible freeze/melt cycle poisonous and non-combustible
Phase change materials
Organic
Paraffins
Inorganic
Non-paraffins
Salt hydrates
Metals
Figure 2 44 • October 2017
Chemical Engineering World
the outside environment and preventing the large volume changes during the phase alteration. The methods of microencapsulation are separated into three types:
CEW Features
Spray drying
Physical and Mechanical Process
Fluidized bed Solvent evaporation
Chemical Process
Interfacial condensation Insitu polymerization
Coacervation and phase separation
Physical and chemical process
Polymer expansion by rapid expansion of superfacial fluids
Figure 3
• Inorganic phase change materials are having melting enthalpies per unit mass similar to those of organic PCMs, but having larger enthalpies per unit volume because of their intensified densities. • Salt hydrates are considered as the mixture of inorganic salt and water with the formation of a crystalline solid with the general formula AB.nH 2O. Their phase change is literally a dehydration of the hydration of the salt & resembles the process of melting/freezing thermodynamically. a) Salt hydrates breakup into the lower hydrate and water AB.nH 2O →AB.mH 2O + (m-n).H 2O b) Salt hydrates breakup into its anhydrous form AB.nH 2O →AB + n.H 2O The most common problem using these inorganic PCMs (salt hydrates) is their incongruent melting behaviour. As n moles of hydration water are not enough to dissolve the lower hydrates or anhydrous salts, as a result solution becomes supersaturated at the melting temperature. These salts settle down at the bottom of the container because of their high densities making these salts unavailable for recombination with water again during 46 • October 2017
the reverse process of freezing. Another main disadvantage during working with salt hydrates as PCMs is super cooling of the liquid. Nucleation rate is generally very low at the temperature of fusion. That’s why the solution needed to be super cooled to achieve a reasonable rate of nucleation. Hence, energy is being released at much lower temperature instead of being released at their fusion temperature. • Metals: are the broad categories of inorganic PCMs. Most significant properties of these materials are as follows: • Lower quantity of heat of fusion per unit weight • High amount of heat of fusion per unit volume • High value of thermal conductivity • Low value of specific heat Measurements Techniques of the Latent Heat of Fusion and Melting Temperatures The techniques generally used for calculating the temperature of melting and latent heat of fusion of PCMs are: a) Differential thermal analysis (DTA) b) Differential scanning calorimeter (DSC)
In these techniques specimen and reference material are heated at a constant rate say x°C/min. The value of temperature difference between them is noted which is being directly proportional to the difference in the heat flowing between two materials and the result is recorded as a DSC curve. The preferred reference material is alumina (Al2O3) which melts at near about 1150°C. By measuring the area underneath the DSC curve (peak) latent heat of fusion can be calculated and by drawing a tangent at the point of greatest slope on the face portion of the peak, melting temperature can be estimated. Both these techniques can be used with different inflowing atmospheres i.e. air, nitrogen and even argon. Encapsulation materials
of
phase
change
Organic PCMs have disadvantages in low degree of thermal conductivity, large volume change during phase change and their flammable character. When dealing with inorganic PCMs; show the high value of latent heat per unit volume, high thermal conductivity and non flammable character also, but they suffer from disadvantages of corrosiveness to most metals and also suffer from decomposition and super cooling which surely affect their phase change properties. So to rise Chemical Engineering World
CEW Features Phase Change Material
Melting Temperature ( oC)
Crystallization Temperature( oC)
Heat Capacity (J/g)
Hexadecane
18.5
16.2
237
Hepadecane
22.5
21.5
213
Octadecane
28.2
25.4
244
Nonadecane
32.1
26.4
222
Eicosane
36.1
30.6
247
Table 1: Phase Change Material
above all these problems a new technique of employing the microencapsulated phase change materials in thermal energy storage has been introduced. Microencapsulation is described as the process of covering the small micron sized particles or droplets by coating/ embedded in a homogeneous matrix to give small capsules offering many advantages such as an increase in the heat transfer area, minimizing the PCMs interaction with the outside environment and preventing the large volume changes during the phase alteration. The methods of microencapsulation are separated into three types (Refer Figure 3): Applications of Microencapsulated Phase Change Materials Since Microencapsulated phase change materials were introduced; it had been used in textile and building applications: Textile Applications: Phase change technology in textiles means blending the microcapsules of PCM into the textile structures. Thermal performance of the textile is improved with the effect of the PCM treatment. During the phase transition from solid to liquid PCMs acquire the energy and during the reverse process of freezing energy is being discharged by them. In 1987 the triangle research and development corporation (Raleigh, USA) proved the feasibility of blended PCMs within textile fibers. For the application of PCMs in textiles the temperature of phase change materials should be in the comfort zone of human i.e. in a range from 15 oC to 35 oC. PCMs to be used in textiles should have a significant value of heat of fusion and 48 • October 2017
specific heat per unit volume and weight; a high level of thermal conductivity; chemical stability and non corrosiveness. PCMs should have a reproducible crystallization without decomposition and should not affect the human’s health. It should present a small super cooling degree and a high degree of crystal growth. Mostly used PCMs in textiles are the paraffin waxes with distinct phase change temperatures depending on the number of carbon atoms. Please refer Table 1: Phase Change Material. Hence, encapsulation of PCMs is mandatory before using in textiles in order to prevent the paraffin dissolution while it changes to the liquid state. Building Applications: The capability to store thermal energy is the important factor for the effective use of solar energy in buildings. The problem affiliated with light weight building materials is their low thermal mass which tend to create the high temperature oscillations; resulting in the high heating and cooling demand. Due to growth in the demand of thermal comfort of buildings the energy consumption is correspondingly increasing. PCMs are adjudged as the credible solution for minimizing the energy consumption of buildings. For raising the building passivity and to stabilize the indoor climate, PCMs are beneficial. The blending of PCMs in building walls is a way to intensify the storage capacity of the building envelope (walls, floors & ceiling). PCMs are executed in plasters, Gypsum wall boards and/or textured finishes. During the day time with high
ambient temperature; PCMs blended in the building envelope melts storing the large amount of thermal energy. Thus, during the process of phase change heat gain into the buildings is reduced and hence lesser energy is required to keep the building cool. During the night time PCMs changes the phase back from liquid to solid discharging the excess heat into the buildings. This process is profitable during the winter time as the released heat is beneficial in warming the buildings. Thus, phase change materials are the substances offering the storage of thermal energy by undergoing the process of phase change. There are plethora of techniques by virtue of phase change materials can be fabricated. Applications of phase change materials are not limited to the specific areas of textiles and buildings, but are having the vast number of other applications too.
Authors’ Details Kapil Gulati Research Scholar, Chemistry Department, Kurukshetra University Sohan lal Assistant Professor, Chemistry Department, Kurukshetra University Sanjiv Arora Professor and Chairman Chemistry Department, Kurukshetra University Chemical Engineering World
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CEW Features
Developing Trends & Technologies in Petrochemicals and Plastics In the downstream sector, catalysts and processing technologies need to endlessly evolve to enable processing and purification of the most difficult crudes, and to transform them into the desired fuels and petrochemical intermediates. Further along the value chain, in all the sectors, technology solutions are needed to improve energy efficiencies, allow the amalgamation of non-conventional fuels and moderate the climate-change impacts. As the energy demands attended with the growth of petrochemical and polymer industries continue to increase, there is an urgent requirement to apply the advancement of technology and innovative researches in the upstream operations such as exploration, production and downstream operations such as refining, petrochemical, polymer and general chemical industries operations for flagging the path of sustainable developments. Hence the development of promising technologies for exploration, production and refining of crude oil, on one side, and production of petrochemicals, state-of the–art polymers and various other products, on the other side, have made it unavoidable to pursue higher level of innovative researches amongst the experts and academicians in the and the like. Alongside of these operations, remain the up-keeping and maintenance of storage tanks, furnaces, transportation and utility systems and equipment thereby reducing loss of energy, corrosion and stress-induced cracks to avoid spillage of valuable products.
I
nnovation and R&D is imagined to become more complex, thereby challenging more investments. Therefore, organisations may opt to continue sharing experiences and commitment to similar objectives and should influence opportunities for regional integration.
decade as different for the petrochemical and plastic industry from other previous decades as it relates to the prominence of these raw materials? Will technologies permit an emergence of a viable platform for the industry’s profitability beyond a brief trend of activity that passes into oblivion?
The competitive environment of petrochemical industry is global in nature. In addition, the cost of production of petrochemicals is highly reliant on on feedstock cost. The regions with abundant low cost feedstock have obvious advantage over the regions where the accessibility of feedstock is limited or closely linked to crude oil pricing levels. The development of these conveniences are challenging due to high capital concentration. The petrochemical landscape has become even more compound with new technology trends that make the strategic master planning of these facilities even more stimulating.
As described in Figure 1, the entire chain in the Plastic industry can be categorized into: • Upstream sector: Manufacturing of polymers, • Downstream sector: Conversion of polymers into plastic articles.
This paper focuses on the technology trends that are shaping the petrochemical and plastic industry and contribute to the competitiveness of the businesses.The petrochemical and plastic industries are both driven by fundamental raw material and product supply-demand aspects, and enabled by technologies that open the road to these drivers. What makes the next 52 • October 2017
The upstream polymer manufacturers have commissioned globally competitive size plants with imported state-of-art technology from the world leaders. The upstream petrochemical industries have also seen amalgamation to remain globally competitive. The downstream plastic processing industry is highly fragmented and consists of micro, small and medium units. There are over 30,000 registered plastic processing units of which about 75% are in the small-scale sector. The small-scale sector, however, accounts for only about 25% of polymer consumption. The industry also consumes recycled plastic, which constitutes about 30% of total consumption.
Emerging trends and way forward: The short assessment sees the rapid technological responses to the Shale Gas Revolution, the China Coal Renaissance or the Biochemical Emergence, to coin a few tags, as evidence that the innovative expertise of the industry is alive and well. Is this really so or is the technology response just a patchwork mix of old incompetent technologies dressed up to appear pertinent to the short-term drivers? For example, prominent technologies offered as process solutions to the olefins product mix change caused by lighter steam cracker feedstocks include metathesis (developed and commercialized in the 1980s), propane dehydrogenation (commercialized in the early 1990s), butane-to-butadiene (commercialized in the 1960s), methanol-to-olefins (developed in the 1980s and 1990s), gas-to-liquids (developed in the 1970s and commercialized in the early 1980s), and LPG-to-aromatics (developed in the 1980s and commercialized in the late 1990s).The Indian Plastic processing industry has seen a move from low output/low technology machines to high output, high technology machines. There has been some major technological progression of global standards leading to achievements. Focus to develop a state-of-the-art R&D is disappearing down with more focus on growing the capacity utilization. Domestic Chemical Engineering World
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Figure 1: : Indian Plastic Industry structure
machinery is manufactured as per the existing technology to improve productivity and energy efficiency, in order to enable the processors to strive globally. Key machineries are imported from Europe, the U.S. and Japan which invite an 18% IGST causing huge losses. India’s technical requirements are critical in areas like high production and automatic blow molding machines, multilayer blow molding, stretch/blow molding machines, specific projects relating high capital expenditure like PVC calendaring; multilayer film plants for barrier films, multilayer cast lines, BOPP and non-woven depend solely on imported technology/machinery. The application of nanotechnology to plastics is the opportunity to affect the performance of a specific resin and a profile of additives at the molecular level. This type of detailed engineering has produced materials with properties such as significantly enhanced heat, dent and scratch resistance. There can also be an upsurge in dimensional constancy, electrical conductivity, stiffness, and flame retardancy – any number of promising characteristics. Being able to control the material performance at such a fundamental level and input a nearly infinite variety of substances as additives, gives the engineer and product designer substantially more latitude in product design and performance. Materials that are being applied to nanocomposites include nanoclays, carbon nanotubes, nanotalcs, other minerals and 54 • October 2017
associated materials. At this level, the vital characteristics of the resin can have a exclusive interplay with the properties of each additive. This opens up the field of material science to a whole new tactic but also brings a much higher level of complexity. This will drive the need for a wide selection of software modeling, prototyping and testing to enable a more measured and rapidly deployed material growth process.Some of the instant applications for nanocomposites include automotive and aerospace components; military hardware; electronics; medical devices; timed release of biocides and dyes; barrier layers within food packaging; semiconductor/polymer device for improved photovoltaic solar cells; foam applications for seat cushions, disposable diapers; packaging materials – the list seem endless. Nanocomposites will be a key player in the on-going materials revolution that will produce many new product applications. Advancement in technologies: • Gravimetric technology furthered the use of weigh scale blending, gravimetric dosing, and integrated control in any production facility. • “Liquidmetal” technology has evolved to molding technologies advanced by the plastics industry for forming amorphous metals. • High performance polyamides grades viz., PA6, PA66, PPA, PA612, PA12, amorphous grades and bio-based grades, which are used for metal replacement, high temperature,
The level of production and consumption of plastics is low in India at present and it provides a big opportunity for development of the sector. However, there are challenges like lack of sufficient feedstock, for the industry. The industry should look at newer sources of energy like shale gas, bio fuels and even hydrocarbon streams which were not exploited earlier, for the manufacture of value-added petrochemicals. Adopting the latest technology would also turn the negative image dominating in certain forms of plastics and turn it into a constructive one. The speedy changes in new material technology may outdate existing products by offering improved performance or reduced cost. In addition, the progressing ability of off-shore sources to provide lesser cost substitutes to more refined parts and equipment fabrication will unceasingly cut into domestic production. It is important to stay up-to-date of new product and process developments and be positioned to make tactical changes and investments. Larger companies may need to augment their R&D function and gain access to additional R&D resources such as a university with a polymer program or other technology partner..
Authors’ Details Pranjal Kumar Phukan Senior Manager (C&P) Brahmaputra Cracker and Polymer Limited. Chemical Engineering World
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CEW Products Medium Pressure Push-in Fittings MP is a push-in fitting conceived for medium pressure grease applications up to max 80 bar. MP completes, with its technical features the existing products offer for central lubrication applications and highlights further the distinguishing markets of the whole C MATIC production: quick connections, performance and reliance guarantee. For details contact: Luthra Pneumsys 38 Madhu Vrinda Dhuri Indl Estate Waliv Pata, Vasai (E), Dist: Thane, Maharashtra 401 208 E-mail: Pooja.pneumsys@gmail.com or Circle Readers’ Service Card 01
Programmable DC Power Supply Programmable electronic power supply is a high performance single/double output programmable DC power source. It is easy to control from the front panel or via the serial port by the computer. It has low noise, excellent regulation and built-in voltmeter/ammeter. For details contact: Vasavi Electronics 95, Road No: 6A, Jyothi Colony Secunderabad, Andhra Pradesh 500 015 Tel: 040-27744445 E-mail: vasavi@vasavi.com
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Triple Quadrupole Mass Spectrometer Agilent Technologies Inc offers triple quadrupole liquid chromatography mass spectrometers (triple quad LC/MS). The Ultivo triple quad is a transformative approach to LC/MS that integrates several hardware and software innovations designed to deliver even more improved business results for customers. Ultivo is optimized to address the food and environmental routine testing segments employing triple quad LC/MS systems for quantitative analyses. In addition to its trendsetting size, Ultivo provides reproducible, reliable assays that result in exceptional performance in complex matrices. Greater ion transmission efficiency leads to optimized sensitivity; and improved, intelligent diagnostics use intuitive readbacks that can quickly identify issues, ensuring optimum uptime. Furthermore, Ultivo’s new VacShield vacuum provides vent-less ion injector exchange capabilities that reduce wear and tear and facilitate rapid front-end maintenance. Ultivo’s seamless integration with the Agilent MassHunter Software suite provides high-performance instrument monitoring, data acquisition, analysis, and reporting for currently regulated and emerging environmental contaminants and pollutants in our water supplies. For details contact: Agilent Technologies India Pvt Ltd Agilent Technologies International Pvt Ltd CP-11 Sector 8 Technology Park, IMT Manesar Haryana 122 051 Tel: 0124-4863000 E-mail: cag_india@agilent.com CircleReaders’ Readers’Service ServiceCard Card0323 oror Circle
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Products CEW Industrial Wet & Dry Vacuum Cleaner Indovac Pumps & Engg Co offers industrial vacuum cleaner for every useful applications. A complete set of accessories makes it usable for all kind of practical operation without trained personnel. These cleaners are suitable for dry and wet application and patented triple filters avoids any particle entering inside. Available in tiny and bulk 25 to 200 litres, suction 200 to 400 mbar, and in single/three phase motors. For details contact: Indovac Pumps & Engg Co 21 Anand Raj Indl Estate Sonapur Lane, B/h Asian Paints Off L B S Marg, Bhandup (W) Mumbai 400 078 Tel: 022-25664937, 65062751 Telefax: 91-022-25664917 E-mail: indovac@yahoo.co.in or Circle Readers’ Service Card 04
Revolutionary Zone 3D Software Platform FARO offers the FARO Zone 3D software. This revolutionary platform, through its advanced smart tools, is the first of its kind to enable investigators to move fluidly between 2D and 3D environments and enhance the quality of incident reconstruction analysis or presentations for public safety professionals. FARO Zone 3D dramatically elevates the visual impact of presentations, including courtroom exhibits, by enabling accurate 2D and 3D scene diagrams, 3D scene walkthroughs and full scene reconstruction animations. FARO Zone 3D also enhances the ability of public safety professionals to plan for and respond more effectively to emergencies by creating accurate representations of real-world locations within local communities.Key leading-edge functionality of FARO Zone 3D includes: advanced smart tools to drive a more confident result and enhanced flexibility to drive a faster result. FARO Zone 3D is currently available for ordering - www.faro.com/Zone3D/in Trial versions of FARO Zone 3D can be downloaded from www.faro. com/faro-3d-app-center/stand-alone-apps/faro-zone-3d. For details contact: FARO Business Technologies India Pvt Ltd E-12, B-1 Extension, Mohan Co-op Indl Estate Mathura Road, New Delhi 110 044 Tel: 011-46465664, 46465644 E-mail: india@faro.com or Circle Readers’ Service Card 05
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CEW Products Gas Chromatograph
Precision Balances
The Thermo Scientific TRACE 1110 GC is a new multichannel, high performance, robust gas chromatograph offering up to four injectors and four detectors allowing users to efficiently switch between different applications on the same GC. TRACE 1110 is a world class GC, offering advanced accessories. This winning quality GC is capable of easily handling routine and challenging applications in the most cost-effective way.
Citizen’s new and improved precision series incorporates unique and unequalled hlgh end technology built to match the highest international standards. The result is tenfold increase in weighing performance, which maintains their proven, simple and easy to use operator interface. Attractive quality of this new design is demonstrated by the CE mark of conformity along with the Citizen ISO 9001:2008 Certification.
For details contact: Thermo Fisher Scientific India Pvt Ltd 102, 104, Delphi C-Wing Hiranandani Business Park Powai, Mumbai 400 076 Tel: 022-67429494 Fax: 91-022-67429495 E-mail: sagar.chavan@thermofisher.com or Circle Readers’ Service Card 06
For details contact: Citizen Scale (I) Pvt Ltd Citizen House, Unit No: E-2 Plot No: 11, WICEL Opp: SEEPZ Gate No: 1 Andheri (E), Mumbai 400 093 Tel: 022-42437700 Fax: 91-022-42437800 E-mail: sales@citizenscales.com or Circle Readers’ Service Card 07
Platinum Cured Silicone Hose Imawrap is platinum cured silicone hose reinforced with SS-316L helical wire and 2-3 layers of polyester fabric wrapping. Imawrap is having multiple layers of high quality polyester fabric to enhance burst pressure rating. The product is suitable for high pressurized steam transfer application in pharma and biotech industries. Imawrap conforms to US FDA 21 CFR 117.2600 Food Grade Standard, USP Class VI and ISO 10993-1. It is certified by ROHS and Animal Origin Certification (free of animal derived material), free of restricted heavy metals. It is free of Phthalate/ Bisphenol/Volatile Plasticizer. It has US FDA DMF accreditation #26201. Complete validation package available upon request. Imawrap has high pressure rating ensures safe material transfer handling process. It is designed for high vacuum rating applications. It has excellent flexibility and kink resistance. It imparts no taste and odour. It is lot traceable. Its temperature range is -80 0°C to 180 0°C. It is available with SS-316 L Tri-Clover end. It is sterilizable by Autoclave, Ethylene Oxide Gas & Gamma Radiation. For details contact: Ami Polymer Pvt Ltd 319 Mahesh Indl Estate, Opp: Silver Park Mira-Bhayander Road, Mira Road (E) Thane, Maharashtra 401 104 Tel: 022-28555107, 28555631, 28555914 E-mail: mktg@amipolymer.com or Circle Readers’ Service Card 08
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Products CEW Triplex Series Pumps Mouvex offers the integration of Finder Triplex Series pumps into its growing portfolio of transfer solutions for the energy and industrial markets. Triplex Series pumps are highly reliable reciprocating plunger pumps specifically designed for a wide variety of critical applications found in oil and gas (onshore and offshore), nuclear and general industrial industries. These pumps are also compliant with API 674 to provide the best in reliability and safety. Triplex Series pumps are available in seven models – TD18, NF50, NH77, NJ116, NL171, TN 260 and TP420 – with power rating ranging from 13 to 310 kW (18 to 420 HP). Typical applications include water jetting, methanol injection, glycol recirculation, descaling, boiler feeding, and others. For details contact: Dover India Pvt Ltd – PSG 40 Poonamallee By-pass Saneerkuppam, Chennai 600 056 Tel: 044-26271020, 26271023 E-mail: sales.psgindia@psgdover.com or Circle Readers’ Service Card 09
NRV Valves & Check Valves Excel Metal & Engg Industries offers wide range of instrumentation fitting and valves for use in diverse range of industries and are capable to provide their customers with best possible solutions to meet their various requirements. The production process followed is of higher standards with its modern production and quality assurance facilities where due attention is paid at every level with maximum resource utilization. Excel Metal & Engg Industries offers NRV valves and check valves; in SS in 1/8 to 1 in size; pressure rating up to 6,000 psi (413 bar) at 100oF (380C); temperature rating: -10oF (-230C) to 375oF (1910C); cracking pressure: 1/3 to 25 psig (0.02 to 1.7 barg). For details contact: Excel Metal & Engg Industries 177/181 J T Bldg, 3rd Kumbharwada Lane Mumbai 400 004 Tel: 022-23892476, 66394004 Fax: 91-022-23884109 E-mail: info@excelmetal.net / excelmetal@mtnl.net.in or Circle Readers’ Service Card 10
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CEW Products Spray Coolers
Liquid Ring Vacuum Pumps
Spray cooling technology is a process to convert melts into solidstate by spraying into spray chamber. Cooling media are usually dehumidified cold air. The cooling media are admitted into the spray chamber. The spray mist comes in intimate contact with the cooling media and gets converted into solid state.
The proven compression principle allows them to be used in all the sectors of the industry. Critical applications such as evacuating saturated gases and vapours are easily carried out using their Dolphin liquid ring vacuum pumps.
AVM offers customised spray cooling systems with variety of configurations. For details contact: New AVM Systech Pvt Ltd AVM House, 3B+3 Part, 1/3 Akurdi Indl Estate Opp: Ador Welding Ltd, D-1 Block, MIDC Chinchwad Pune, Maharashtra 411 019 Tel: 020-27459986, 27459987 Fax: 91-020-27459988 E-mail: avmtechnologies@vsnl.net
For details contact: Busch Vacuum India Pvt Ltd 103, Sector 5, IMT Manesar Gurgaon, Haryana 122 050 Tel: 0124-4050091 Fax: 91-0124-2292103 E-mail: sales@buschindia.com
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Multi-Axis Robotic Controller Aerotech’s HEX RC is a 6-axis motion controller ideal for controlling robotic systems like hexapods. The HEX RC is 4U rack-mountable and compatible with the Automation 3200 (A3200) motion platform. A high-performance processor provides the intense computing power needed to run up to 32 axes, perform complex, synchronized motion trajectories, manipulate I/O and collect data at high speeds. The HEX RC features 6-axes of drives capable of controlling any combination of brush, brushless or stepper motors. It digitally performs both current loop and servo loop closures to ensure the highest level of positioning accuracy and performance. The HEX RC connects and controls up to 26 additional axes of servo, stepper or piezo-driven stages using the A3200 distributed control architecture. The HEX RC is designed with an ASCII command interface over TCP/IP for control in applications such as beamlines. Alternatively, it can act as a master controller to control other A3200 external drives via the FireWire interface.The HEX RC accepts amplified-sine or digital encoders. Optional integrated encoder multipliers, up to X4096, ensure high-resolution positioning. An optional 6-axis jog pendant permits easy, manual control of the positioning system. In safety critical applications, an emergency stop option with redundant safety relays can be added. Aerotech’s A3200 focuses on ease of use for the programmer, shortens development time compared with other tools, and provides the flexibility to use the tools or controller most familiar to programmers. A complete Integrated Development Environment and a comprehensive .NET motion library provide classes for motion, I/O, status, and diagnostic information. You can program in Visual Studio and use the .NET library or use the Motion Composer (IDE) to develop code with AeroBasic commands or G code. A LabVIEW VI library is available for NI users, while a complete C library is available for those using Visual Basic, C++, or C. For details contact: Aerotech, Inc 101 Zeta Drive Pittsburgh, PA 15238-2811 U.S.A. Tel: +1 (412) 967 6854 E-mail: smclane@aerotech.com / jbala@aerotech.com or Circle Readers’ Service Card 13
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Products CEW Vacuum System Vacuum system finds application in many fields, including pharma, chemical, plastic, food and pasta production, leather chemicals and centralized vacuum systems. Vacuum systems are variable and optimized by the selection for the application and working parameters. It is possible to decrease power, saving in the range 30-40 per cent. The condensor helps in reducing the process time of drying, distillation, etc, by effectively condensing the condensable vapours. The condensor has been standardised with 1.5-m 2², 3-m 2² and 6-m ² cooling surface area. The material of construction can be given in mild steel/ SS-304/SS-316 for shell and copper/Cu. Nickel/SS-304/SS-316 for the cooling coil. 2
For details contact: Toshniwal Instruments (Madras) Pvt Ltd 267 Kilpauk Garden Road Chennai 600 010 Tel: 044-26448983, 26448558 E-mail: sales@toshniwal.net or Circle Readers’ Service Card 14
Mobile Pumping Stations Grundfos India offers an intelligent mobile water pumping station. The unit comprises of two pumps, each capable of discharging 200,000 liters per hour. The mobile pumping station aims at reducing losses post disasters and can also be used for water supply in agriculture, horticulture, gardens and parks. With its double shaft seal system, which ensures trouble-free operations, the dewatering pumps along with a 50 kVA generator, control panel and a cantilever crane in a weatherproof enclosure, are mounted on a movable trolley that can be hauled by a truck or tractor. With a portable and compact design, these mobile pumping stations are light-weight and operate on just one cable, thus saving the need for additional sensor cables. These high-capacity pumps are suitable to use across harsh environments for dewatering of flooded areas in construction sites, draining of storm water, shipyards, waterlogged facilities/basements, drainage pits, power stations, low-lying catchment areas, fishponds, etc. The pumps are also specifically designed for pumping dirty water with a high content of abrasives like sand. For details contact: Grundfos Pumps India Pvt Ltd 118 Rajiv Gandhi Salai, Thoraipakkam Chennai 600 097 Tel: 044-45966800, Fax: 91-044-45966969 E-mail: salesindia@grundfos.com or Circle Readers’ Service Card 15
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CEW Products Rotary Screw/Paddle Dryers/Roasters/Coolers The heating/cooling media is circulated through jacket as well as centre shaft and hollow screw/ paddles. The material gets dried/ roasted/cooled while traveling from feed-end to discharge-end by conduction heat transfer. Heating media can be steam/hot oil. Cooling media can be chilled water, glycol, etc. For details contact: New AVM Systech Pvt Ltd AVM House, 3B+3 Part, 1/3, Akurdi Indl Estate Opp: Ador Welding Ltd D-1 Block, MIDC, Chinchwad Pune, Maharashtra 411 019 Tel: 020-27459986, 27459987 Fax: 91-020-27459988 E-mail: avmtechnologies@vsnl.net
High Pressure Needle Valves Excel Metal & Engg Industries offers wide range of instrumentation fitting and valves for use in diverse range of industries and are capable to provide their customers with best possible solutions to meet their various requirements. The production process followed is of higher standards with its modern production and quality assurance facilities where due attention is paid at every level with maximum resource utilization. Excel Metal & Engg Industries offers high pressure needle valves in SS 1/8 to 2 in size, pressure rating up to 10,000 psi (689 bar) at 100oF (38o°C); temperature rating:-65oF to 600oF (-54o°C to 315o°C); PTFE packing on stem for leak tight sealant long life cycle. For details contact: Excel Metal & Engg Industries 177/181 J T Bldg, 3 rd Kumbharwada Lane, Mumbai 400 004 Tel: 022-23892476, 66394004 Fax: 91-022-23884109 E-mail: info@excelmetal.net / excelmetal@mtnl.net.in
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Vacuum Pump for Vacuum Packaging Vacuum packing is a technique of storing and preserving food. The foods are stored in an air-tight pack or bottle to put off the growth of micro-organisms. The vacuum environment provides the safe atmosphere without oxygen, protecting the food from spoiling by limiting the growth of fungi or aerobic bacteria. Vacuum packaging can extend the life up to 3-5 times. It increases the shelf life. After evacuating the air in the pack, still some amount of oxygen will remain. Air contains 21 per cent of oxygen at atmospheric pressure 1,013 mbar. The objective of packaging is to reduce the oxygen content by lowering the pressure. For example, if pressure is reduced to 10-mbar, the oxygen per cent will be 0.21. If it is non-food item, the vacuum packing protects it from oxidization, corrosion and moisture damage, eg, packing of matches, socks, medicines, etc; moist foods wont dry out; and seal dehydrated foods and dried herbs prolongs storage.The pump has to evacuate air in presence of water-vapour for food items like meat, fish, which are moist and also the pump should be able to withstand the cyclic load due to packing and also evacuation prior to flushing operation for modified atmospheric packaging (MAP), like N2 filling. The vacuum oil used should be food grade oil and Toshniwal multivane semi-dry vacuum pump is the pump designed for packaging industry. Suitable for continuous operation, quieter, better vacuum in short cycle time, good water vapour handling capacity, etc. For details contact: Toshniwal Instruments (Madras) Pvt Ltd 267 Kilpauk Garden Road Chennai 600 010 Tel: 044-26445626, 26448983 E-mail: sales@toshniwal.net or Circle Readers’ Service Card 18
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Products CEW Oil Lubricated Vacuum Pumps Toshniwal supplies oil lubricated vacuum pumps. These oil lubricated vacuum pumps of the TMS Series are single stage, oil-lubricated rotary vane vacuum pumps with oil re-circulation system. The lubricant system is rated for continuous operation of high intake pressures so that the pump may be used in a versatile manner in most rough vacuum applications. The pumps are used for suction of air also in presence of water vapour and for continuous industrial use. TMS Series pumps are made from high quality materials, has economical features which matches together to achieve: high pumping speed over the range of absolute pressure 1,000-0.5 mbar; high water vapour tolerance and low noise level; no pollution; air-cooled: built-in anti-suck-back system. The pumping capacities available are:17 m3/hr, 35 m3/hr, 65 m3/hr, 100 m3/hr and 150 m3/hr For details contact: Toshniwal Instruments (Madras) Pvt Ltd 267 Kilpauk Garden Road, Chennai 600 010 Tel: 044-26448983, 26448558 Fax: 91-044-26441820 E-mail: sales@toshniwal.net or Circle Readers’ Service Card 19
Hydro MPC Pumps with IE5 Motor Grundfos India offers its new range of Hydro MPC pumps with the IE5 Motor. The Grundfos Hydro MPC booster systems are of high standards and combining this with the IE5 motor, which is integrated with a frequency converter, connects the accumulated pump experience of Grundfos into the dedicated control software. This combination of pump and customizable software optimizes your system’s performance for any load point, delivering an unsurpassed reduction of energy consumption. Grundfos IE5 Motor, which helps in energy conservation of up to 7 per cent and a reduction in the payback time of these controlled pumps. The Hydro MPC pumps with IE5 Motors will be available with systems that are pre-configured from the factory with variety of pump sizes to increase water boosting. For details contact: Grundfos Pumps India Pvt Ltd 118 Rajiv Gandhi Salai, Thoraipakkam Chennai 600 097 Tel: 044-45966800, 45966896 Fax: 91-044-45966969 E-mail: mahathi@grundfos.com / salesindia@grundfos.com or Circle Readers’ Service Card 20
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4 th International Conference & Exhibition on “Pipeline Integrit y Management” Date : 10-11 November 2017 Venue : Holiday Inn Hotel, Mumbai Event : The integrity of pipelines is a basic concern for pipeline operators, and therefore, the ability to detect anomalies due to corrosion, erosion, milling and mechanical damage shall be of significant interest to the operators. Pipeline Integrity Management Program not only can extend the life of the existing pipelines, also helps to prevent any future damage if follows during design and construction of the new pipelines, maintain adequate safeguards for assets, human life and the environment. This event- 4th ICEPIM will provide an ideal platform for experts and technocrats to share ideas to improve safety & control measures to effectively minimize corrosion and other damages. For details contact: Tel: 011-4654 5757 Email: consultmatcorr@gmail.com CHEMTECH South World Expo 2017 Date
: 13-15 December, 2017
Venue : HITEX Exhibition Center, Hyderabad Event : In Hyderabad, the government’s industrial policy is very liberal and high priority is given to its development especially since it plays a vital role in sustainable economic growth. These conditions have made Hyderabad a prime destination for chemical services, making it an alluring destination for many companies worldwide. CHEMTECH Hyderabad Expo 2017 will provide the much needed integrated platform to facilitate the growth of the industry in the region. The three day global process industry meet will offer enormous opportunities to the service providers to display the latest state-of-the-art technologies products and services and their strengths to the wide base of the user industry in the Southern region. Concurrent thematic seminars will have deliberations on the topical issues and enable the professionals to engage and network to explore business potential. For details contact: Tel: +91-22-40373636 Email: conferences@jasubhai.com
Waste Technology India Expo Dates : 18-20 January 2018 Venue : Bombay Convention & Exhibition Centre, Mumbai Event : Waste Technology India Expo is a 3 day event in Mumbai. The waste management and recycling exhibition will have solutions for managing and recycling of different kinds of waste, both solid and liquid, generated in industries, cities, homes, etc, to ensure clean surroundings. This event showcases product from air and water management, environment and waste management industries. For details contact: Virtual Info System Pvt Ltd 231 Mastermind-1, Royal Palms Mayur Nagar, Aarey Milk Colony Goregaon (E), Mumbai 72 • October 2017
7th World Congress on Petrochemistry and Chemical Engineering Dates : 13 – 14 November 2017 Venue : tlanta, Georgia, USA Event : 7th World Congress on Petrochemistry and Chemical Engineering, will be organized around the theme “A global hub for exchanging the advanced technologies in Petrochemistry”. Petrochemistry 2017 is comprised of keynote and speakers sessions on latest cutting edge research designed to offer comprehensive global discussions that address current issues in Petrochemistry 2017. For details contact: Tel: 91-40-71279013 Email: petrochemistry@petroleumconferences.com SOMChE 2017 Date
: 6 – 7, December 2017
Venue : Monash University Malaysia Campus, Malaysia Event : Universities have an important role to play in carrying out research to improve knowledge and understanding that can enhance the well-being of all. Fundamental research is vital in the advancement of scientific understanding. For Engineers we like to believe that our research can make a direct impact on society. Even at the more fundamental level we aim to make a difference. Beyond this, helping to come up with new ideas to help to solve the problems of industry is very rewarding. This could be new methods and applications to improve efficiency or to help solve problems related to health, safety, the environment and sustainability. It is key to all this that researchers have a good understanding of the problems that are facing society in general and industry in particular. The aim of this conference, therefore, is to try and bring together participants from both Universities and Industry, so that ideas and issues can be shared and partnerships formed to enhance future research.. For details contact: Professor Michael Cloke / Priya Ravindran Tel: +60 3 22831381 Email: mcloke@icheme.org, pravindran@icheme.org Yapex Building Exhibition 2017 Date
: 15 November 2017 - 18 November 2017
Venue : Antalya Expo Center, Antalya, Turkey Event : Yapex Building Exhibition 2017 is an International Trade Fair for Building Materials, Construction Technology and Building Renovation. Yapex Building Exhibition 2017 to be held on 15-18 Nov 2017 at Antalya Expo Center, Antalya, Turkey. It is an excellent occasion to meet the expanding building market of Turkey, to present the latest products to international professional visitors and to establish new contacts with industrialists and businessmen. For details contact: Mr. Faith Onkar Tel: 90-242-3164600 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 Coal India is planning a `10,000-crore joint venture along with GAIL India, Rashtriya Chemicals & Fertilizers (RCF) and The Fertilizer Corporation of India (FCIL) to set up a urea and ammonium nitrate chemicals complex that will run on gasified coal. Coal India has appointed Projects and Development India (PDIL) to conduct a feasibility study on the project. The plan is to use around 6 million tonnes of coal from coalfields at Talcher in Odisha and manufacture about 3 lakh tonnes of urea annually and around 300-400 tonnes of ammonium nitrate per day. Ammonium nitrate is the principal ingredient for making explosives used as blasting material at coal mines. The country is facing a crunch in the supply of ammonium nitrate and explosive suppliers often jack up prices, resulting in higher input costs for the company. Songwon Industrial Co Ltd of South Korea has launched its new pilot plant in Panoli, Gujarat, thereby strengthening the organisation’s overall specialty chemicals development capability. Built on Songwon’s Indian site with all the necessary main unit operations, the new plant is equipped with the most up-to-date technologies and materials for producing a wide range of chemicals for a broad spectrum of applications - from one kilo up to several hundred kilo samples. To reinforce the organisation’s position in existing areas of business and enhance its ability to enter new areas, the new pilot plant will be supported by the Songwon’s strong local R&D team in Panoli, as well as its central technology innovation center located in Maeam, Korea. AkzoNobel and Atul Ltd have agreed to jointly set up a manufacturing plant for monochloroacetic acid (MCA) at Atul’s facility in Gujarat. Each partner will hold a 50 per cent stake in the venture. The partnership will build on Atul’s status as a leading global supplier of the herbicide 2,4D (which uses MCA as a key raw material), and AkzoNobel’s leading global position in MCA market, with plants in the Netherlands, China, Japan and the US. The investment is subject to regulatory approvals and signing of final agreements. The partnership will use chlorine and hydrogen manufactured by Atul to produce the monochloroacetic acid, taking advantage of both Atul’s existing infrastructure and the leading eco-friendly hydrogenation technology supplied by AkzoNobel. From an initial annual capacity of 32 kilo-tonnes (KT) at start-up, the plant has been designed for future expansion to 60 KT. The plant will produce enough MCA to meet the captive requirement of Atul; AkzoNobel will market the rest of it, primarily in India. Monochloroacetic acid is an essential building block in the chemical industry and is used in a wide variety of chemicals. Camlin Fine Sciences Ltd, which offers shelf-life solutions (anti-oxidants and intermediates), performance chemicals and aroma chemicals, has received environmental clearance from the State Level Environment Impact Assessment Authority of Gujarat for setting up a manufacturing facility for hydroquinone (HQ) and catechol and their down-stream products at Dahej SEZ. The Dahej plant will expand capacities and provide CFS with a base to manufacture hydroquinone and catechol in India. The plant will also help Camlin Fine Sciences to add capacity for manufacturing of vanillin, for which catechol is a key raw material. Chemical Engineering World
The company expects to commission the Dahej plant in FY18. The plant will have capacity to produce 9,000 metric tonne per annum (MTPA) and 6,000 MTPA of HQ and catechol, respectively. SRF is planning to invest ` 3,500 crore over the next four years, 70 per cent of which would go into its fast-growing chemicals business, to cater to rising global demand. SRF, which exports 90 per cent of its chemicals and counts Syngenta, BASFBSE 0.08 per cent, BayerBSE -0.04 per cent CropScience and other global biggies as its clients, has over the years steered its focus away from technical textiles to chemicals, where it has witnessed a rapid revenue growth and fat operating margin. LyondellBasell, one of the world’s largest plastics, chemical and refining companies, completed the previously announced acquisition of the polypropylene (PP) compounding assets of Zylog Plastalloys Pvt Ltd. The company entered into a definitive agreement to acquire Zylog’s PP compounding assets in November 2015. LyondellBasell has supplied the Indian market through imports and tolling arrangements since 2009. In October 2015, LyondellBasell acquired SJS Plastiblends Pvt Ltd’s PP compounding business which is located in Aurangabad, Maharashtra. With the acquisition of Zylog’s manufacturing operations in Sinnar, Maharashtra, and Chennai, Tamil Nadu, LyondellBasell is now the third largest producer of PP compounds in India with an annual capacity of 44,000 metric tonnes. In addition to the already existing product lines offered at these sites, LyondellBasell will produce its Hostacom glass fibre-reinforced, mineral filled and unfilled coloured grades as well as Hifax high impact thermoplastic olefins. These compounds are used to manufacture automotive parts, home appliances and other products. Bodal Chemicals of Ahmedabad has received environmental clearance (EC) from the Ministry of Environment, Forests & Climate Change for the expansion of dyes and dyes intermediates manufacturing facility located at Vadodara, Gujarat. The company is expanding its dyes and intermediates manufacturing capacity from 2,200 metric tonne per month (MTPM) to 6,000 MTPM, and set up a co-generation power plant (5-MW) in Gujarat. Bodal Chemicals, one of the leading manufacturers of dyes and dyes intermediates in the country, has the capacity to manufacture over 25 varieties of dye intermediates and around 150 variants in dyestuff which are mainly used as raw material in textile, leather, paper and other dye consuming industries. Out of the total production, the company exports about 40 per cent to more than 35 countries across the world. Perstorp of Swedish a specialty chemicals firm is planning to set up a manufacturing facility for pentaerythritol (penta) in Maharashtra. To evaluate the opportunity to invest in a new world scale production plant for penta in India, the company has signed an MoU with Maharashtra Industrial Development Corporation (MIDC). Pentaerythritol, a white crystalline polyhydric alcohol containing four primary hydroxyl groups, is used as building blocks in alkyd resins for coatings, radiation curing monomers, polyurethanes, rosin esters, synthetic lubricants and explosives. Perstorp currently manufactures producing penta in three different production plants in Germany, the US and Sweden. The related market for coatings in India is growing fast in the country. Building a world October 2017 • 73
CEW Book Shelf Chemical Process Equipment: Selection and Design Authors : James R Couper, W Roy Penney, James R Fair, Stanley M Walas Price : USD 47.25 Page : 755 (Hardcover) Publisher: Butterworth-Heinemann About the Book: Chemical Process Equipment is a guide to the selection and design of a wide range of chemical process equipment. Emphasis is placed on specific information concerning the process design and performance of equipment. To this end, attention is given to examples of successful applications, and a generous number of line sketches showing the functioning of equipment is included with many graphs and tables giving their actual performance. For coherence, brief reviews of perininent theory, including numerical examples to illustrate the more involved procedures, are provided in key chapters.
Chemical Process Equipment Design Authors : Richard A Turton, Joseph A Shaeiwitz Price : USD 54.98 Page : 416 (Paperback) Publisher : Prentice Hall About the Book: Trends such as shale-gas resource development call for a deeper understanding of chemical engineering equipment and design. Chemical Process Equipment Design complements leading texts by providing concise, focused coverage of these topics, filling a major gap in undergraduate chemical engineering education. Richard Turton and Joseph A. Shaeiwitz present relevant design equations, show how to analyze operation of existing equipment, and offer a practical methodology for designing new equipment and for solving common problems. Theoretical derivations are avoided in favor of working equations, practical computational strategies, and approximately eighty realistic worked examples. The authors identify which equation applies to each situation, and show exactly how to use it to design equipment.
Process Technology Equipment Authors : CAPT(Center for the Advancement of Process Tech)l Price : USD 54.98 Page : 464 (Hardcover) Publisher : Pearson About the Book: Process Technology Equipment is designed to teach readers about equipment used in the process industries. This book includes a variety of topics including, valves, tanks, pumps, turbines, motors, heat exchangers, cooling towers, furnaces, boilers, separation equipment, reactors, filters, dryers and solids handling equipment. Each chapter contains objectives, key terms, a summary, review questions and activities to enhance the learning experience. Readers will find this book to be a valuable resource throughout their process technology career. The Center for the Advancement of Process Technology (CAPT) currently offers several instructor manuals and student workbooks for their books. Currently these must be PURCHASED by the instructor or institution. 74 â&#x20AC;˘ October 2017
Process Technology Equipment and Systems Author : Charles E Thomas Price : USD 54.98 Page : 496 (Paperback) Publisher : Cengage Learning About the Book: PROCESS TECHNOLOGY EQUIPMENT AND SYSTEMS, 3E is the ideal book to provide process technology learners with state-of-the-art graphics and photos, alongside updated information that keeps pace with industry developments. This book carries on the tradition of excellence established by the first two editions which have successfully launched thousands of process technicians into the chemical processing industry. PROCESS TECHNOLOGY EQUIPMENT AND SYSTEMS, 3E is both student and industry-oriented and contains excellent line art to better illustrate key points and processes. Key topics include valves, vessels, and piping, pumps and compressors, motors and turbines, heat exchangers, cooling towers, boilers and furnaces, reactors and distillation, extraction and separation systems, and process instrumentation.
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Inside Cover I
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27
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21
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Premium Transmission Ltd
29
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11
7
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5
21
Prima Equipment
53
8
Hi-tech Applicator
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22
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43
9
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23
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23
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35
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33
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55
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14
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CEW Interview INTERVIEW
“Increased globalization, sustained market opportunities and the emergence of Indian leaders are combining to create an exciting period for specialty chemicals” “Global companies are looking for opportunities to invest in India for specialty chemicals. They are doing alliances/collaboration with firms to jointly manufacture speciality chemicals in the country. Exports are growing rapidly as India is becoming an important manufacturing hub,” says M S Vijayan-Joint Managing Director, Resil Chemicals Pvt. Ltd. Excerpts from his email interaction with Chemical Engineering World. Please apprise us of company’s performance over the years? Over the years the company has successfully achieved various milestones. Some of our major milestones are:• 1994 – First manufacturing unit set up in Bangalore • 1999 – Silicone and Organic Polymer Integration • 2001 – ISO certification and second manufacturing plant setup • 2003 - DSIR certification for research labs, strategic collaborations with Celessence UK, Daikin Japan and Thomson Research Associates Canada • 2006 - Collaboration with Dow Corning, Creation of Vista Car Care range • SAP integration, branch set up in Bangladesh 76 • October 2017
• 2010 - Third manufacturing unit set up, branch set up in Thailand, entry into nanotechnology and advanced materials • 2014 - Launch of Klenza Alcohol-Free hand Sanitizer • 2016 - Won the prestigious CII IPR AWARD for the top design driven industry of the year among small and medium enterprises (SME’s) 2016. • 2017- Strategic partnership with Acticell GMbH May we have your views on Polymers and Specialty Chemical market in India and overseas? India’s polymers market is projected to grow at a CAGR of 11.61%, in value terms by 2026 where as specialty chemicals industry is valued at about USD 25 billion,
constituting about 3 percent of the global specialty chemicals market. This sector has great potential and is about to grow 6-7 percent in 2023 with market size in the range of USD 80-100 billion. The growth for specialty chemicals is driven by both domestic consumption and exports since they have numerous applications across consumer and infrastructure segments. There is consolidation going on in the industry and India is not immune to it. As opportunities and ambitions expanding, industry is witnessing heightened levels of M&A interest by players across the spectrum. The increased globalization of the sector, sustained market opportunities and the emergence of Indian leaders are combining to create an exciting period for specialty chemicals. Global companies are looking for opportunities to invest in India Chemical Engineering World
Interview CEW for specialty chemicals. They are doing alliances/collaboration with firms to jointly manufacture speciality chemicals in the country. Exports are growing rapidly as India is becoming an important manufacturing hub. Tightening environmental norms in developed countries and the slowdown in China are contributing to the growth of exports. The Make in India” campaign is also expected to add thrust to the emergence of India as a manufacturing hub for the chemicals industry in the medium term.
Our business has been structured in order to cater to the customer needs, so we have industry focused business divisions and not product focused – Textiles Specialty chemicals, Performance Chemicals (where we sell specialty silicones for personal care, agro, rubber, paper, pharmaceuticals etc; emerging technologies which deal with technologies related to silver, titania and mosquito control and Vista car care, a leading brand of automotive maintenance and cleaning solutions. Our largest division and our core business is the Textile Specialty Chemicals division.
What are the major challenges for the industry? The industry today is facing numerous challenges but going forward our main challenge would be a more stringent and dynamic regulatory environment for specialty chemicals. While Resil is compliant with the current global standards, the regulatory and product registration requirements are dynamic and fast changing. Each market has a separate set of regulations that require compliance; while the compliance requirements are broadly similar, we see a trend of increasing “cost of compliance” due to the added legal and procedural costs for each regulation and registration. One of the major challenges is to focus on taking the industry to the Green zone of eco-friendly products and processes, address the pollution issues and ensure zero discharge in water and air. Other three systemic challenges the sector is confronted with are fragmentation and lack of scale, commoditization and regulations. How quality control is important in industry? Efficient quality control and accurate planning are key factors in achieving of quality for the products or services offered by companies in chemical industry. It is critical to know exactly what chemicals, and of which grades are moving through the plant at any given time. Variations in the grade of chemicals being used and supplied may have a significant impact on overall plant performance. It could also damage the plant, resulting in serious wastage of resources and capital. How you have been strategizing your business activities to face the competition within the country, especially from the international companies, who are expanding their business horizon in India? Chemical Engineering World
Resil operates in a very niche category and our products are customized as per customer specifications. We are differentiated from international competitors by offering tailormade products for customers and offer a complete range of technical service solutions. How do you evolve the research and development within the company? Resil has a dedicated in-house design team working around the clock at our in-house R&D centre. Our R&D has the state-of-the-art facilities to engage the team in innovative R&D activities such as development of new product/ technologies, design and engineering, improvements in process/ product/ design, developing new methods of analysis and testing, research for increased efficiency in use of resources such as capital equipment, material and energy, pollution control, effluent treatment and recycling of waste products or any other areas of research. For product design and development, we have a designated design team with industry-spanning expertise applying the best possible technology to the product concept. The outsourcing of design helps a lot in exploring out the different aspects. Importing the technology/design patterns from the international market including inspirations and innovations that can be manifested in a new product design, a new production process, a new marketing approach, or a new way of conducting training is Resil’s forte. Innovations created by taking inspirations from international and other market gives an competitive advantage by perceiving an entirely new market opportunity or by serving a market segment that others have ignored. It often involves ideas that are not even “new”—
ideas that have been around and have huge potential, but are never vigorously pursued. Please tell us about Resil’s revolutionary N9 Pure Silver and its significance and application in Industry? N9 Pure SilverTM, along with its variants N9 PlastixTM, is a family of silver-based antibacterial and hygiene solutions. It is based on a revolutionary Silver-based technology that, on contact, neutralizes odour-causing bacteria, keeping the treated product fresher for longer. It is a finish that can be applied onto fabrics or garments. This breakthrough technology delivers outstanding odour control performance, combined with impeccable environmental credentials and safety profile. Textile materials do not have any inherent antimicrobial properties. The natural properties of textile fibers provide room for the growth of microorganisms due to sweat. Humid and warm environments further aggravate the problem. Staining and the loss of performance of textile substrates is a result of microbial attack. The antimicrobial present in N9 Pure SilverTM finish is applied to textiles with the intention to protect the wearer from malodour and the textile substrate from degradation. The potential presented by N9 Pure Silver is immense. From articles of daily use, such as clothing, and bed linen, to food packaging and hair care the opportunities are vast; making it an ideal solution for several industries. N9 Pure Silver™ also finds very interesting consumer applications on textiles as well as other non-textile substrates such as plastic packaging materials which can be made more hygienic. Cosmetics can be preserved and their antimicrobial properties can be enhanced. Shoes and leather articles can be made odour free and safe to touch using N9 Pure Silver™. Disinfectant cleaners, personal care products, sanitizers can be enhanced with the disinfectant properties associated with N9 Pure Silver™. Healthcare and hospitality industries greatly benefit from such applications as they improve safety levels for people using their facilities. Medical instruments can be made cleaner between cleanings. October 2017 • 77
CEW Interview The Department of Science and Technology (DST) Government of India has chosen Resil as an Industrial partner for textile finishing under the Nano Mission programme in Collaboration with eminent research institutes. Please tell us about more on this and How Resil is going to tap this opportunity? We are a strong believer in the Make in India initiative and believe India will be a strong manufacturing hub. When we got the opportunity a few years ago to work with the DST, we jumped at it. Through this collaboration, we have come out with many world class products, like our award-winning N9 Pure Silver ™. Thanks to this, now all our existing businesses have strong opportunity pipelines. Recently, Resil has joined forces with Austrian chemical research company Acticell. Can you take us through the benefits, the synergies and the rationale behind that deal? Resil Chemicals has partnered with Acticell GmbH to eliminate what they consider a hazardous process of using potassium permanganate spray in the denim industry. Most denim manufacturers rely on hazardous and environmentally damaging chemical processes like Potassium Permanganate treatments to create effects on denim. Potassium permanganate, considered as toxic and hazardous substance, is sprayed onto the denim fabric with a hand spray gun, exposing the factory employees to the danger of exposure to micro particles of Potassium permanganate. ACTIGO ™, is a laser activated bleaching technology, powered by Green screen listed; patented Acticell® technology. It helps in improving laser productivity thereby providing a cost neutral solution to switch over from Potassium permanganate sprays. Additionally, the new process saves water and energy in denim finishing and eliminates labor-intensive hand sand and not to mention improving the safety of factory employees.This treatment is currently being used by major denim companies in North America and we also seek to offer these solutions for South Asia. Resil has a very strong focus on growth through global partnership. What are the basic criteria for partnership and how do you ensure the success? 78 • October 2017
The basic criteria for ideal partnership to ensure success are: • To have a strong belief in Innovation and technology • Willingness to collaborate • Willing to have a long term association. All these factors are the important key factors, in the absence of which we do not collaborate. Innovation through collaboration takes time and lots of efforts between the collaborating organizations. May we have your views on GST in chemical industry? Impact of GST on the Indian industrial sector looks positive, especially for the chemicals industry. Chemicals businesses in India have long suffered the wrath of added taxations on their production capacity as well as their consumption demands. The major benefit of implementing the GST legislation will be simplification of the tax code and the improved logistics. Already we have seen our goods move at a much faster pace to our customer. How do you plan to leverage on Make in India campaign? We are a strong believer in the Make in India initiative and believe India will be a strong manufacturing hub soon globally. Our basic plan is to have more factories in India rather than setting up base abroad. This will not only help out in cost advantage but also in building our own ecosystem with the home base here with the top-of-the-line development facilities to tap the country’s engineering base. Setting up of more R&D centres and factories in India will also help us to work closely with Department of Science and Technology (DST) Government programs to develop more indigenous technology. Taking Make in India to the next level. How do you propose to become Asia’s leading innovative formulators in specialty chemical sector by 2020? Resil has already become the leading innovative formulators in speciality chemical sector. We have successfully been able to make customized products for individual customers and niche applications and for industries, ranging from textiles to pharmaceuticals and agriculture. We currently exports to more than 10 countries
and do full-fledged sales operation in Bangladesh and has made inroads into Sri Lanka, Turkey, Philippines, UK and Thailand diversified into emerging technologybased products such as hand sanitizers, disinfectants and car care items We are now looking at growing worldwide with our innovative products. In the specialty chemical industry, collaboration is the key. At Resil, our has always been a collaborative approach to work with top international silicone manufacturers and chemical majors to ensure we make differentiated products. The recent partnering with Acticell GmbH to eliminate the hazardous process of using potassium permanganate spray in the denim industry will help us to offer these solutions to South Asia as this treatment is being used by major denim companies in North America. What are the other opportune areas for Resil in India? Currently at Resil chemicals there are enough opportunities lined up in pipe line and we are focusing on that only. We are focusing on positioning our self in the right sector using the right set of technologies to grow worldwide with our innovative products. How do you intend to steer the growth of Resil chemicals in the years to come? What are your future projects and plans? What are the new markets you planning to enter? At present we are planning to setup one more manufacturing unit, over the span of next two years. We will be also expanding our existing R&D centre to develop more of indigenous technology and futuristic concepts for sustainable pretreatment processes and also to work closely with Department of Science and Technology (DST) Government programs to. We are looking towards to expand the Resil horizon to Bangladesh and rest of the ASEAN counties, since the textile industry in these counties have an important global significance. Connecting with the key decision makers and industry leaders in textiles from these countries will not only help in sharing ideas about trends in textile processing but will also lead to foster better industry cooperation.ials
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