VOL. 48 NO. 9 September 2013 US $ 10 ` 200
CHEMICAL ENGINEERING WORLD SEPTEMBER 2013
FOUR DECADES OF GLOBAL LEADERSHIP Processing in Concentrated Phase
VOL. 48 ISSUE 9 Mumbai ` 150 Martin Fischer President - Global Sales LIST AG
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VOL. 48 NO. 9 September 2013 US $ 10 ` 200
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NEWS ► Industry News / 08 Technology News / 16
NEWS FEATURES ► Cutting Edge Solutions for Polymers & Solar Industries / 20
FEATURES ► PCPIRs: A Distant Dream for India? / 24
Place of Publication: Jasubhai Media Pvt Ltd
SALES
Vol. 48 | No.9| SEPTEMBER 2013 | Mumbai | ` 200
– Vijay Sarathy, Pratik Kadakia - Roland Berger Strategy Consultants Reduce Cost of Ownership with Dry Vacuum Pumps / 30 – Dr Don Collins, Alagar Sivabalan - Edwards Ltd Application of UG-140 for Overpressure Protection
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36
– Sushant G Labhasetwar - Daelim Industrial Corporation Corrosion - A Life Cycle Challenge / 44 – M Valliappan - We CAN Control Corrosion in India Network
MARKET INSIGHTS ► Raising the Bar in Sustainable Lubrication / 48
PRODUCTS ► / 50
Special Coverage LIST AG 94-103
EVENTS ► / 54 PROJECT UPDATE ► / 56 BACK OF BOOK ► Ad Index / 91 Book Shelf / 62 Interviews / 64 & 68 Expanding the Product Basket
– Prasad K Panicker, Executive Director, Kochi Refinery, BPCL Balancing ‘Risks vs Rewards’ Equation – Samik Mukherjee, Country Head & Managing Director, Technip India
SOUTH SPECIAL ► Glasfab Scientifics / 72 APIIC: Leveraging on ‘Andhra Advantage‘ / 74 Outokumpu: 80 Years of Duplex Experience / 78 Raj Process: Evolving with Continuous Evaluation / 84 Steel Aiids: Future Perfect Technologies / 90 Nagman Instruments & Electronics Pvt Ltd / 92 Rasaii Flow Lines Pvt Ltd / 93
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CEW Industry News India at Low Risk Potential for Shale
Ujaas Energy Plans Capacity Expansion
Chennai, India: The two major resources have been stressed due to exploration of Shale gas which was repeatedly warned by experts since shale gas was becoming overenthusiastic issue in India. The reports published in The Energy Research Institute had precisely underlined the dangers of utilising groundwater that was used for hydraulic fracturing to release gas from shale. Generally, 3 to 4 million gallons of water was utilised for the purpose and required treatment.
Ahmedabad, India: Ujaas Energy Ltd on Friday said it wants to achieve 100 MW in solar power production capacity by next March. Viklap Mundra, Joint Managing Director, said that the company’s solar parks in Madhya Pradesh will develop two facilities of 15 MW each for investors which initially had capacity of nearly 27 MW by the end of September. Additionally, the company will also add on its own 12 MW of solar power capacity.
A few months ago, the Director-Exploration of ONGC, N K Verma, mentioned that shale gas prospects in India should not be “hypedup” and unlike the US, India has its “own set of problems.” “We can definitely start with moderate amount of 80-90trillion cubic feet of gas since we can work on alternative natural gas resources such as coal bed methane that has larger potential. India’s CBM potential is estimated at 450 tcf,” he added.
The project will be required ` 8.50 crore for generating 1MW of solar power that comprises of cost of land transformers and transmission lines.Ujaas Energy (formerly M&B Switchgears) is the first company to install a solar power plant under the Renewable Energy Certificate (REC) mechanism last March. It is now venturing into two segments — Ujaas Mysite and Ujaas Home — to provide solar energy solutions for commercial and domestic requirements.
ONGC Arm to Sell Stake in Dahej Project Mumbai, India: ONGC Petro-additions Ltd (OPaL) has started talks with Saudi Aramco for global partner. Sudhir Vasudeva, Chairman and Managing Director, ONGC, and Chairman, OPaL said that the company had held its first round of introductory and exploratory discussions with Aramco. “No timeline has been fixed as yet,” said a source. ONGC is the primary promoter of OPaL, the other partners being GAIL (India) and Gujarat State Petroleum Corporation (GSPC). ONGC holds 26 per cent stake in the venture whereas formed to set up a petrochemical complex at the Dahej special economic zone in Gujarat. GSPC holds 5 per cent stake and GAIL holds 15.5 per cent. The promoters have to tie up equity for the remaining 53.5 per cent.Originally GAIL had decided to pick only 19 per cent in the project but after it has revised, they have restricted 17 per cent eventually reducing its holding to 15.5 per cent.
Hero Group Enters Renewable Energy New Delhi, India:The USD 5.6 billion Hero Group declared its entry into the renewable energy sector with the launch of Hero Future Energies, a new business unit. By 2016-17, Hero Future, an Independent Power Producer (IIP) has planned to develop 1 gigawatt of renewable energy. The organisation will function across several verticals of renewable energy comprising solar, hydro and wind. Rahul Munjal, Managing Director, Hero Future Energies, said: “In the wake of significant power shortages currently being witnessed in our country, we are making a strategic move into the renewable energy sector.” The organisation has already commissioned a flourishing wind pilot project of 37.5 MW in Rajasthan. Hero Future Energies currently has a project pipeline which comprises 400 MW of wind projects and 50 MW solar projects across Madhya Pradesh, Maharashtra, Karnataka and Andhra Pradesh. It was recently awarded a 10 MW solar power project in Karnataka under the State’s Solar Power Programme.
Sushil Maroo is Essar Energy’s Chief Mumbai: India: Sushil Maroo has been appointed as Essar Energy’s new Chief Executive Officer and Director wherein for mer CEO Naresh Nayyar has been selected as a member of Essar Corporate Centre, an advisory c o m m i t t e e . E s s a r s a i d i t s b o a r d ’s nominations and governance committee had their plans in place for the Sushil Maroo , CEO& Director, succession of directors and other senior Essar Energy executive positions. The committee had been looking for a new Chief Executive Officer as Nayyar had indicated his desire to step back from day-to-day operations. Prashant Ruia, Chair man, said,“Maroo has a strong track record of business operations and providing strategic and financial advice. We are pleased that he has agreed to work as a part of organisation.” 8 • September 2013
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Unrest Delays Opening of Dhunseri’s Egypt Facility Kolkata, India:The unrest in Egypt has delayed commissioning of Dhunseri Petrochem & Tea’s 4.3-lakh-tonne PET (polyethylene terephthalate) resin facility at Ain El Sokhna, near Cairo. Due to this, the project cost has already increased by USD 12 million to nearly USD 170 million from USD 159 million. The project which was scheduled in the first quarter of 2013 will now be streamed in December. “The civil unrest in Egypt and the resulting delays in supply of equipment (from India) led to cost escalation. A c c o r d i n g t o D h a n u k a , h i s s o n M r i g a n k , t h e c o m p a n y ’s Vice-Chair man and Managing Director, will be looking after the day-to-day operations of the Egyptian unit. With both the Egypt and Haldia facilities on stream, Dhunseri is eyeing a near 3.2 times jump in turnover to ` 8,000 crore by 2015-16. “Currently, we are consolidating our position,” said Dhanuka. Chemical Engineering World
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CEW Industry News HPCL to Start Rajasthan Refinery Mumbai, India: Hindustan Petroleum Cor poration Ltd will break ground for the ` 37,000-crore Rajasthan refinery-cumpetrochemical project (RRP) by this month end. The project is set to change the nature of the company’s refining business, said S Roy Choudhury, Chairman, HPCL. In the company’s Annual General Meeting, S Roy Choudhary stated that the project will be fast tracked since, the land in Barmer district is already in the Rajasthan government’s possession. He said the refinery would give a Gross Refining Margin (GRM) of USD 12 to USD 14 per barrel of crude oil. The Rajasthan Government holds 34 per cent stakes in the Project, whereas the other 76 per cent are owned by HPCL. Choudhury said that the refinery design is very innovative and it would process about 4.5 mt of crude oil from Cairn India’s Mangala field. The rest of the crude oil would be sourced from the international market, he said.
ONGC Out of Race for HPL Stake Kolkata, India: The Haldia Petrochemicals Ltd disinvestment process is witnessing n ew t w i s t s a f t e r M u ke s h A m b a n i l e d Reliance industries and state owned GAIL has opposed a joint bidding for ONGC and Indian Oil which has pushed ONGC to pull out themselves from the race to capture the West Bengal government’s share in easter India’s largest petrochemical company. Mukesh Ambani, Chairman & The 40 per cent stakes belonging to the MD, Reliance Industries Ltd state are for sale in HPL through West Bengal Industrial Development Corporation after the ONGC and RIL pulled out themselves. GAIL also joined RIL in its protest against joint bidding.RIL, IOC, GAIL and Cairn India remain in the fray to acquire the state government’s stake in HPL. Government has intended to get the price bids by the end of September. In the meanwhile, WBIDC has agreed to change the clause in the purchase- share agreement which restricted the bidders f r o m s e l l i n g m a j o r i t y o f t h e i r a c q u i r e d s t a ke s i n t h e H P L five years earlier.
Dhunseri Petrochem Puts IT-SEZ on Hold
ONGC, She ll for NOCL’s Sta k e Ra c e
Mumbai, India: On the back of the US shale gas business, Reliance Industries Ltd (RIL), Mukesh Ambani led oil and gas major, is now exploring opportunities in refinery & petrochemicals, fertilisers, power generation and coal mining in the western country. Reliance has already worked out investments of USD 1.5 billion annually for the next three years in the shale business there. It has invested USD 6 billion in shale operations till the first quarter of this fiscal and produced a cumulative 183.1 billion cubic feet of gas equivalent — comprising natural gas liquid, condensate and shale gas. The company posted an 84 per cent rise in revenue from its shale gas venture in the US on rising production during the first quarter.
Mumbai, India: Shell Indian along with State run ONGC is in talk with Nagarjuna Oil Corporation for a strategic stake in Nagarjuna’s Cuddalore Refinery. Sources from investment bankers aware of the deal have mentioned, that IOL is also involved in the conflict whereas HPC and BPCL have also pulled themselves from the race. A senior official from ONGC stated that a few strategic investors are carrying out the due diligence which should be completed by October comprising the stakes to be diluted.
RIL has three joint ventures, with Chevron, Pioneer Natural Resource and Carrizo Oil & Gas, and a midstream joint venture with Pioneer for its shale business in the US.
RIL Eyes US Petrochemicals Sector Kolkata, India: According to C.K. Dhanuka, Executive Chairman, Dhunseri Petrochem, the company has put the construction of its ` 7.5-lakh-sq-feet IT SEZ on hold, for want of takers. The organisation has spent around ` 40 crore in executing construction work at the IT-SEZ facility. “We have put on hold the project (capacity expansion) and are waiting for the right time to resume work. Once markets look up, we hope to continue with it,” Dhanuka said. The ` 2,500 crore-company operates in tea and petrochemicals as their major verticals. Dhunseri was expecting its IT-SEZ facility to produce rental income. According to Dhanuka, the first phase of the construction has been completed whereas the primary work for secondary phase has been already finished.“The work will begin depending on the market scenario,” he said 10 • September 2013
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One of the Tamil Nadu’s largest private sector project- Cuddalore project is worth ` 25,000 crore wherein Nagarajuna has already spent ` 6000 crore and the rest funds by investors are on hunt by the company. To finish the execution of the refinery project, Nagarjuna group partnered with Tata Petrodyne and Tamil Nadu Government. The project aims to make Tamil Nadu self-sufficient in petroleum fuels. Located 180 km south of Chennai on the Bay of Bengal, the project will refine six million metric tonnes of crude petroleum a year in the first phase and will primarily meet the growing energy needs of the southern states of India.
Kirloskar Brothers bags CII National Award Hyderabad, India: The innovative Energy Saving Product Award for Lowest Life Cycle Cost pumps and Excellent Efficient Unit Award has been won by Kirloskar Brothers Limited at the 14 th National Award for Excellence in Energy Management 2013 by The Confederation of Indian Industry (CII).Dr Naushad Forbes, Chair man Energy Efficiency Summit 2013, Dr Ajay Mathur, Director General Bureau of Energy Efficiency and L S Ganapati, Chairman – CII National Energy Award for excellence in Energy Management 2013 presented the award to KBL teams at a recent ceremony held in Hyderabad. Chemical Engineering World
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CEW Industry News HPCL Refinery in Maharshtra may Delay
Welspun to Invest in Assam
Mumbai, India: Hindustan Petroleum Corporation Ltd plans to set up refinery in Maharashtra at a cost of ` 30,000 crore has moved into the cold storage d u e t o u n cle a r re p o r t s on Wes ter n Ghats. Subir Roy Choudhary, Chairman and Managing Director, HPCL, precisely mentioned that the organisation was going ahead with the Rajasthan Refinery S u b i r R o y C h o u d h a r y, but has kept the plans on hold for Chairman & MD, HPCL Maharashtra Refiner y. “We want to invest in new projects and grow. The Rajasthan Government has given us good incentives and we are going ahead with the refiner y,” Roy Choudhur y said at a press conference in Mumbai.
Guwahati, India: Mumbai based Welspun Group’s subsidiary Welspun Energy Limited has expressed their interest to invest in Assam’s renewable power sector. “Most of the states from Southern and Western parts of India have been covered by us. It is our eagerness to enter the North-Eastern part where we have not yet ventured. It is an important region for us and we are looking at how we can put our footing in the area, particularly in Assam which is the most progressive state in the North-Eastern belt,” said Kishor Nair, president of WEL at a conference on renewable energy organised by the Associated Chambers of Commerce and Industry of India.
The Madhav Gadgil-led Western Ghats ecology expert panel had termed the entire hill range an ecologically sensitive area and suggested “no new dams based on large-scale storage should be permitted in ecologically sensitive zone-1 and no new polluting industries, including coal-based power plants, be allowed in the zones”.
“The state government needs to think in terms of investor friendly policies so that investment comes,” added Nair. He confirmed that the payment security is one of the major concerns and thus they are not directly investing but pulling out funds from lenders and bankers.
Chemexcil Felicitates Nadir Godrej Mumbai, India: The grand moment walked in when Nadir Godrej was awarded by the Life Time achievement award in the honor of his contribution to the Indian chemical Industry.
.In 2011, Roy Choudhury had said the refinery would be ready in four years, once it secured an environmental clearance. Engineers India Ltd has already prepared a detailed feasibility report for the new refinery.
CPCL Looks for Commodity Hedging Via IOC Chennai, India: The private refineries are reducing their output to protect themselves from consequences Rupee depreciation against Dollar thus the public sectors are suffering the heat due to unfavorable formula chalked out by the Government. The Chennai-based refiner stated that the unpredicted depreciation of the Rupee and precariousness in the foreign exchange market resulted in an exchange fluctuation loss of ` 341 crore in 2012-13. R S Butola, chairman, Indian Oil Corporation, accepted that for the downstream and refining companies suh as CPCL have lost their profits due to high volatility in the crude oil market. Nevertheless, the CPCL will have to protect itself from getting impacted with the falling Rupee against Dollar since the refining business is dominated by Dollar. B a s u s t a t e d t h a t t h e c o m p a n y i s l o o k i n g fo r c o m m o d i t y hedging through its parent IOC since the estimated o f f s e t o f ex c h a n g e g a i n / l o s s o n p r o d u c t s a l e i s c o u n t e d to be around 70 per cent of the exchange gain/loss on crude oil. 12 • September 2013
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Anand Sharma presents the award to Godrej
The Function was hosted by Basic Chemicals, Pharmaceuticals & Cosmetics Export Promotion Council popularly known as CHEMEXCIL.
A n a n d S h a r m a , t h e M i n i s t e r o f C o m m e r c e a n d I n d u s t r y, Government of India bestowed the awards to outstanding exporters who have excelled in their export performance during the financial year 2009-10 & 2010-11. Expressing his happiness on receiving the award, Nadir Godrej, Managing Director - Godrej Industries said, “This honor, while giving us the necessar y impetus to achieve greater heights, demonstrates the confidence of our consumers and shareholders. It further strengthens our resolve to continue contributing to the industry. We are constantly in pursuit of new technologies and ideas based on market and vendor feedback to make us ready in future. He further added that the global turmoil in 2008 -09 and subsequent crisis in the Euro zone impacted on exports of Godrej industries but after certain incentives declared by government, exports did rise and boosted the growth. An increase of nearly 72 per cent is a testimony to the effort of the team and the high level of quality consciousness of the company”. It is currently a Star Export House and is now eligible for the Star Trading House status. Chemical Engineering World
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CEW Industry News SABIC, IITB-Monash Extend Partnership
Ernesto Occhiello, Executive Vice President, SABIC
New Delhi, India: The world’s leading research academics, the Indian Australian IITB- Monash has signed a multi-year strategic partnership with SABIC Research a n d Te c h n o l o g y P r i v a t e L i m i t e d i n Bengaluru. This deal has opened gates for collaboration of multiple research projects which will allow both the organisation to grow mutually into innovative solutions that will help in meeting the global demands.
Commenting on the par tnership, Ernesto Occhiello, SABIC’s Executive Vice President – Technology & Innovation, said “SABIC understands that innovation is critical to achieving the goals of our sustainability strategy and to help societies around the world achieve the same. SABIC’s global par tnerships in technology and innovation are central to the company’s growth plans and this latest agreement with IITB-Monash represents an important step forward in our global commitment for advancing technologies and responding to the needs of society across a range of technology sectors”. Commenting on the cultural similarities between the two organisations, Frank Kuijpers, SABIC General Manager for T & I highlights “At SABIC, we empower our people and reward them for innovative and pioneering work undertaken collaboratively with our customers and research partners. IITB-Monash has a similar “can do” culture to SABIC and we look forward to embarking on this new journey with them”.
Modest Growth for Grundfos in First Half Year New Delhi, India: The graph for the Grundfos Group’s first six months of 2013 clearly states 3 per cent growth and a turnover of 1.47 billion euro. ”At best, the pump market is stagnating, and when seen in that light, our modest growth is very reasonable. The first half-year is always weaker than the second half-year in Grundfos, and it is our hope that the figures for growth, turnover and earnings will develop positively for the entire year. So far, market developments have not been favourable to us. The halfyear result is only just satisfactory”, says Group President and CEO Carsten Bjerg. China has witnessed highest growth figures with 12 per cent and the Eastern European countries with five per cent, whereas other Asian countries lag a little behind the plans and Western Europe is stagnating. ”Our global sales organisation is making a great effort by being close to the customers. At the same time, we continuously monitor our level of cost, adapt the business and keep a watch on expenses. Everything is under control, and we expect the 2013 result for the year to show satisfactory growth for the Group. We are pleased that our financial strength remains more than intact with an equity ratio of 66.2 per cent as against 64.7 per cent after the first half-year last year”, says Carsten Bjerg. 14 • September 2013
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Bayer CropScience Pact with Deccan Fine Chemicals New Delhi,India: Agro Chemical firm Bayer Crop Science declared that they have signed an agreement with the Deccan Fine chemicals to sell their Gujarat based unit for approximately ` 127 crore. Bayer CropScience confirmed that its Board gave nod for the proposal to sell the chemical manufacturing unit located in Gujarat. In India, Bayer CropScience operates in three business sectorscrop protection, bioscience and environmental science. It offers wide range of products and extensive service backup for modern, sustainable agriculture as well as for non-agricultural applications. Bayer CropScience is one of the world’s leading innovative crop science companies in the areas of seeds, crop protection and nonagricultural pest control.
L&T Hydrocarbon Bags Major Orders Mumbai, India: The leading L&T Hydrocarbon recently bagged new projects worth ` 807 crore for the supply of cracking furnace modules and supply of equipment, EPC execution of cryogenic ethylene package, civil, structural, mechanical, electrical & instrumentation for petrochemical complexes of oil companies in India. Fabrication and assembly work for all the modules and equipment will be done at L&T’s modular fabrication facility at Hazira near Surat, Gujarat. The company offers complete design to build engineers and construction solutions for the oil & gas sector. In-house expertise, extensive experience and collaborations with strategic business partners enable it to deliver end-to-end solutions for every phase of a project – from front-end design engineering through fabrication, project management, procurement, construction and installation up to commissioning.
US Signs Chemical Decree Washington DC, USA: The US President Barack Obama has signed an executive order to improve the safety and security of chemical plants and minimise the risks of har mful chemicals to workers and communities. “However, incidents such as the devastating explosion at a fertiliser plant in West Texas, are tragic reminders that the handling and storage of chemicals are serious risks which must be addressed,” Obama added. “While the cause of the Texas explosion is under investigation, we can take some common sense steps now to improve safety and security and build on federal agencies’ ongoing work to reduce the risks associated with hazardous chemicals.”
Barack Obama, President, the USA
The order also asked to indentify the best pracices to reduce safety and secur ity r isks in the production and storage of harmful chemicals. Chemical Engineering World
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02-10-2013 21:43:17
CEW Technology News Honeywell Introduces Advanced Technologies
NEERI Develops Technology to Clean Polluted Industrial Water
Benguluru,India: Honeywell introduced various new technologies that will transform the control rooms in the future including an advanced dashboard which will help the industrial plants to manage control cyber system security better. Other new control-room technologies highlighted at the event include the Experion ® Collaboration Station with expanded capability, the recently announced Premium Platform for Experion Vir tualisation Solutions, and the newest version of Honeywell’s OneWireless Network. Along with it, the company previewed a futuristic relieve for its Experion Process Knowledge System (PKS) O r i o n p l a t fo r m a s i t r e d u c e s o p e ra t o r fa t i g u e w i t h a n improved, ergonomic design featur ing a larger display and new alarm lighting. Honeywell expects to launch the Experion Orion Console – which was designed based on input from operators – with the platform’s next release in 2014 to provide better mobility for operators while improving situational awareness. Jason Usro Cheif Technology Officer, Honeywell Process Solutions
Jason Urso, Chief Technology Officer, Honeywell Process Solutions said “In many ways, the control room of the future won’t be limited to the control room at all, and that concept is perfectly illustrated through technologies like OneWireless, because it extends the control room to the field, At the same time, because we expect increasing connectivity, we’ll see a greater need for cyber security management systems like the Cyber Security Dashboard, and collaboration solutions like Experion Collaboration Station. These solutions complement each other to improve overall plant safety, reliability, efficiency, and sustainability.”
Jakson launches Solar-Powered Generators, Water Purifiers New Delhi, India: Jakson Power Solutions launched solar-powered generators and solar-based water purifiers based on the plug-and-play concept. The portable generators are available in the range of 0.5 kW25 kW and the battery back-up can provide power for six hours without sunlight. The battery can also be charged through conventional sources. The company has come out with low-capacity and high-capacity generators. The former products were suitable for low electricity demand uses such as for 1-2 kW in offices, shops or homes.Products in the second type are 12-25 kW range and can be used in off-grid locations such as defence applications, telecom, remote locations, rural electrification, disaster management and oil and gas projects. The company is targeting additional revenue of ` 200 crore from the new product line by 2015-16. 16 • September 2013
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Nagpur, India: The National Environmental Engineering Research Institute has recently developed an excellent technology to destroy a variety of pollutants which will be helpful in clean up of polluted water. Nandesari Industries Association in collaboration with NEERI has developed an ‘Electro Oxidation Technology’, which was implemented by NIA for the treatment chemical waste water treatment. An electro oxidation plant, comprising 26 reactors has recently been installed at NIA for treatment of 50 lakh litres of highly polluted chemical industry effluents every day. According to sources from Neeri, The plant was inaugurated by Gujarat Pollution Control Board Chairman K U Mistry.
Aqua Most Reveals Chemical-Free Water Treatment Holland, Netherland: AquaMost Inc, whose board of directors includes Fort Worth-based Holland Services CEO Robert Gaudin, has unveiled a new product providing the oil and gas industry chemical-free water treatment. The system, already deployed in Texas, Colorado and Utah locations, represents the latest water-treatment tool for exploration and production companies. Earlier this year, AquaMost said the device outperformed chemical biocide treatment methods, killing more types of bacteria for less money and without requiring the purchase, storage, handling and insurance of chemicals.“The SX reactor system allows operators to both lower cost and increase performance while maximizing operator safety through reducing chemical use,” said AquaMost CEO Todd Asmuth. “This is a chemical-free biocide that can handle different water types and flow rates with little or no operator interaction,” he fur ther added.According to AquaMost, the device can handle fresh, brackish and saltwater, as well as source, flowback and produced water. Chemical Engineering World
30-09-2013 20:45:37
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September 2013 • 17
02-10-2013 21:44:24
CEW Technology News Robust Temperature Sensors for the Injection Molding Process Schaffhausen, Switzerland:To fulfil the increasing requirements in the injection moulding process, PRIAMUS, the market leader in the area of cavity temperature sensors has come up with an idea. The existing offerings has been extended with a new line of “Heavy Duty“ cavity temperature sensors which now can be used at mould temperatures up to 32 0 C. This proved and tested systems can therefore also be applied for demanding processes without difficulty. “Heavy Duty” sensors dispose of robust connecting cables which were designed for the use in a rough and industrial environment and can be ordered with a hardened sensor front for the use with abrasive media. As another new development, PRIAMUS introduces a melt temperature which has been especially designed for the temperature measurement of plastic melts under high pressure where it is provided with a special seal. The sensor is delivered with a hardened sensor front as standard, in order to withstand high filled melts.
Emerson’s CHARMs Automation Technology, Logs 1 Billion Austin, Texas: Emerson Process Management’s next-generation DeltaV digital automation system, featuring electronic marshalling w i t h C H A R M s te ch n o lo g y, h a s p rovid e d a n engine for the business’ strong growth for the past two years. With CHARMs (characterisation modules) technology, the DeltaV system not only offers unprecedented flexibility and cost savings, but also transforms and streamlines automation practices. Instead of implementing the costly and complicated traditional approach of a pre-engineered physical wiring scheme, CHARMs technology provides a flexible approach that reduces the complexity of connecting automation systems with thousands of devices in a typical process operation. “DeltaV’s CHARMs technology has overturned 35 years of industry thinking and promised to forever change how automation projects are designed and implemented,” said Steve Sonnenberg, president of Emerson Process Management. “Our customers are proving this true - our business has seen a tremendous increase in demand for each of the past two years, and we anticipate continuing this robust performance this year.” “We saw a 40 per cent drop in installation costs over traditional approaches,” said Bryan Beyer, operations manager, Southern States Chemical, the East Coast’s largest sulfuric acid supplier. “The simplicity of CHARMs technology also means fewer failure points, which translates into more reliability and greater up-time for our plant.” Southern States Chemical was the first North American facility to install CHARMs technology. The technology has also proven popular among innovative engineering and procurement contractors like WorleyParsons, which engineers, designs and builds plants and platforms and works with Emerson to provide the automation systems. 18 • September 2013
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Scientists Confirmed Existence of New Element Berlin, Sweden: Scientists in Sweden say they have confirmed the existence of a new chemical element, but its name may need some work. Researchers at Lund University said Tuesday their find backs up claims by teams in Russia and the United States a decade ago that had remained unverified until now. The Swedish scientists say they conducted experiments which allowed them to detect the ‘fingerprint’ of the short-lived but super-heavy element that’s been dubbed ununpentium. The name, which refers to the element’s 115 th place in the periodic table, is only provisional. The element will likely get a new name if the discovery is formally approved by experts from the International Union of Pure and Applied Physics and Chemistry. Well-known chemical elements include carbon, silicon and iron.
Ticona Wins JEC Americas 2013 Innovation Award Dallas, Texas:Composite Fluid Transfer LLC has won a prestigious JEC Innovation Award for its new composite pressure pipe that features Celstran continuous fiber reinforced ther moplastic composites (CFR-TP) from Ticona, the engineering polymers business of Celanese Corporation. Composite Fluid Transfer, Ticona and Valéron Strength Films, which supplies a protective outer wrap, will receive the “Pipes & Water Management” category award during the awards ceremony at the JEC Americas 2013 – Composites Show & Conference in Boston. The award recognises the innovative Fiberflex-11 pipe with multiple options for robust connections that Composite Fluid Transfer of Kilgore, Texas, designed for general water transport infrastructure applications. At 4.26 per foot, the Fiberflex-11 pipe is lighter than comparable diameter and pressure rated composite and plastic pipe. A 30-foot section weighs only 128 pounds vs the same length of 12-inch HDPE SDR 9 pipe that weighs 655 pounds, making it 80 per cent lighter.
Tessenderlo Dissociate from UK Activities Brussels, Belgium: Belgian chemical firm Tessenderlo Group has divested its UK activities to private equity firm H2 Equity Partners.The sale includes three production sites, a warehousing site and 124 sales branches, employing 978 people. Tessenderlo said the sale, which completes the divestment of all its profiles businesses, is part of its plans to focus more on specialty products and services in the areas of food, agriculture, water management and valorising bio-residuals. Eurocell has a PVC recycling facility and supplies PVC building materials such as window and door profiles sold to fabricators in the UK. Eurocell, which generated revenue of about Euro 140 million in 2012, also distributes roofline as well as other building products, with 124 sales branches covering the UK.Tessenderlo employs about 6,200 people and generated consolidated revenue of Euro 2.1bn in 2012. Chemical Engineering World
30-09-2013 20:45:38
Steam Tube Bundle Rotary Dryer
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02-10-2013 21:45:27
CEW News Features
Cutting Edge Solutions for Polymers & Solar Industries In Nov 2012, Pluss Polymers had an equity infusion from Tata Capital Innovations Fund. With this new association, the organisation envisions putting itself on the world innovation map with consistent and pragmatic innovations. The company’s mission is to provide solutions to create a definitive change in the polymers and thermal energy storage industry.
E
stablished in 1994, Pluss Polymers is a polymers research and manufacturing company involved in the field of speciality polymeric additives and phase change materials for thermal energy storage. Pluss has been a constant trendsetter in its field, being the first in the country to commercially manufacture functionalised polymers for improving compatibilisation and processing of polymer composites. Pluss also bears the distinction of pioneering Phase Change Materials for a wide variety of applications in the country and is among the distinguished few in the world heading this revolution. The company has been on a growth path for the last few years. It seen a growth of 30-35 per cent in the last three years. Company has expanded its geographical presence in USA, Turkey and Thailand. The range of products has increased manifolds. Pluss Polymers is also starting a new manufacturing unit in Bawal and have a second one planned in 2014-15. To sustain the growth, the company is also investing in human resource and the number of employees has touched 100 last month.
Samit Jain Managing Director Pluss Polymers
The company has been on a growth path for the last few years. It seen a growth of 30-35 per cent in the last three years. 20 • September 2013
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On the sidelines of India Cold Chain Show 2013 in Mumbai, Harshal Y Desai caught up with Samit Jain, Managing Director, Pluss Polymers, to know about company’s products and services, its technologies and innovations, and more importantly – significance of speciality polymers and Phase Change Materials. Edited excerpts... Significance of Speciality Polymers Speciality polymers are produced by chemical grafting of reactive monomers like
maleic anhydride, glycidyl methacrylate and other similar materials on polyolefin. They possess superior properties than the simple polyolefin in terms of polarity, adhesion to different substrates, compatibility with reinforcements and fillers and so on. Speciality polymers are used as coupling agents, compatibilisers, wetting/dispersing agents, impact modifiers, flow modifiers, scrap upgraders and chain extenders for polymer compounds. Pluss markets these speciality polymers under the brand names OPTIM ® , OPTIPET™ and NOVIS™. These enhance properties of polymer compounds thus enabling their increased adoption in white goods, automotives, wire and cables, wood plastics composites and plastics film industries besides several others. With the increasing number of global automotive and white goods players setting up manufacturing unit in India, the need of speciality polymers to get improved properties will increase. All these speciality polymers are currently imported with only Pluss manufacturing it in India. However, these imports are not sustainable considering the demand and supply constraints. Companies will definitely look for a local source and Pluss is already gearing up for it. We are increasing our capacity for speciality polymers from 800 tonnes/ annum to 1800 tonnes/annum by Nov 2013. We believe the increase in demand will also bring in more local and international players. The competition will increase to benefit all. Chemical Engineering World
30-09-2013 20:53:07
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CEW News Features Pluss’s technology and products contribution in area of plastic recycling On April 4, 2013 Supreme Court of India said “We are sitting on a plastic time bomb”. According to Central Pollution Control Board, India generates approximately 56 lakh tonnes of plastics waste annually and only 60 per cent of this waste is recycled. As 40 per cent of plastics waste is not recycled, this waste is a source of continuing pollution as plastics is not bio-degradable. More than 50 per cent of the plastic waste generated is from the packaging, automobile and white goods industry. The most common plastics are polyesters (the common plastic for mineral water and cold drinks), polypropylene (mostly used in automobiles), polyethylene (the infamous carry bags) and nylon (automobile under the hood parts). Recycling of these plastics has its own issues. The presence of other materials like aluminum and metals in the plastic waste makes it difficult to recycle. The properties of plastics deteriorate after recycling and therefore cannot be used in the same application. Moreover, compatibilisation is difficult because of the presence of combination of polymers in the plastic waste. These problems of recycling mixed wastes have been the basis of research at Pluss Polymers. The company has launched Optipet, an additive which helps in conversion of unusable waste materials to high value products. Optipet designed especially to improve the properties of waste PET has been a result of indigenous R&D at Pluss. We have been actively engaged in finding solutions to environmental problems posed by polymers – Pluss was the first Indian company to also design special additives for upgrading nylon waste to the equivalent virgin grades used in the industry. PLUSS has the knowledge base and provides consultancy to manufacturers for recycling packaging waste which consists of paper, aluminium, and layers of plastics (tetrapak packaging). Proposed ‘Plastic Parks’ and thier Impact on Pluss’s Grwoth Strategy Pluss is looking at setting up new manufacturing units 3 years down the 22 • September 2013
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line. For these new units, we will explore the opportunity of taking land in the upcoming plastic parks. The focus of the company is a lot more exports. Plastics parks because of its close proximity to the port will help us become price competitive in exports. Moreover, the combined maintenance facility in the plastic parks will reduce the burden of providing all ancillary facilities within the factory, such as ETP plants etc. Another benefit that we foresee is that with the setup of plastics parks, our customers, who choose to shift there, will become price competitive which would result in their growth and in turn ours. It would also mean that so many more companies will come up and therefore the overall industry will grow, including us. Phase Change Materials and its Application Pluss is among the very few in the world manufacturing Phase Change Materials and the only company in India do so. PCMs are special thermal energy storage materials being extensively used as a reliable source of energy to maintain required temperatures in various industries. They use chemical bonds to store and release heat. The thermal energy transfer occurs when a material changes from a solid to a liquid or from a liquid to a solid. This is called a change in state or “phase.” PCMs can be used in a wide range of application wherever there is a need to store thermal energy to reduce energy cost, ensure temperature control when power is unavailable or improve overall efficiency of the system. For countries like India, where there is a power shortage, PCMs can help save on diesel costs. Energy cold/hot can be stored when electricity is available and utilised during power outages. PCM is still in the nascent stage in the country. There has been some traditional solutions like glycol and gel pack for storing thermal energy for the cold chain and pharmaceutical sectors. PCM’s are replacements for such products and also finds varied applications in many sectors. There has been a lack of awareness regarding the advantages one gets by
using PCM instead of the traditional solutions. However, industry response has been positive until now. They are surprised by the performance of PCM’s and many companies are testing it as of now. PCM’s are bound to take over the market in the next 2-3 years. Advantages for Solar Industry One of the biggest challenges has been storing solar energy for use after sunset. If the end application is to use the energy for heat, it makes absolutely no sense to convert solar energy into electricity and store in a battery as DC. Then convert it back to AC and run a heater to produce heat. You loose on the efficiency with so many conversions. Instead, PCMs allow you to store heat in the form of heat.All you need is a right temperature PCM – say between 60 to 100 0 or even higher, store the heat and use it to heat your rooms at night or heat your water or for your process – say extend the solar drying from day time to night time and improve productivity for the farmers. Hence, PCMs, if applied well, can be a boon for the solar industry. Tessol tie-up TESSOL is a Technology-based startup. Pluss has tied up with Tessol to provide HVAC solutions using PCM’s. The systems on offer under this partnership are ideally suited for commercial offices and shopping complexes operational for 10 - 12 hours during the day essentially. These energy storage systems enable the building to generate and store cool energy at night and use when there is a shortage during the day. They will help state electricity boards meet the huge demand – supply gap. The combination of R&D expertise in materials; polymers offered by PLUSS and the application development team of TESSOL will collectively allow us to roll out products besides the conventional ice storage systems that the country has seen so far. We are enabling storing of the cool energy that is freely available at night for desert regions and warm energy freely available during the day in cold regions of the country. Chemical Engineering World
30-09-2013 20:53:08
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02-10-2013 21:46:55
CEW Features
PCPIRs: A Distant Dream for India? To ensure PCPIRs achieve their objectives, we need to clearly identify the critical success factors from global best practices and apply them to India, write Vijay Sarathy and Pratik Kadakia. In this article, they further elucidate how India should move forward keeping the challenges at bay.
I
ndia currently accounts for about 2-3 per cent of the global chemical industry. In light of the country’s booming population (one in seven global citizens is an Indian); this sector clearly needs to play a larger role. To encourage investment in India’s chemical industry, PCPIRs (Petroleum, Chemicals and Petrochemicals Investment Regions) were conceived a few years ago. Although some progress has been made and the concept has evolved since then, it remains to be seen whether PCPIRs will achieve their objectives. To make sure they do so, we need to clearly identify the critical success factors from global best practices and apply them to India.
Vijay Sarathy Partner Roland Berger Strategy Consultants, North America
Pratik Kadakia Principal Roland Berger Strategy Consultants, India
24 • September 2013
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One of the objectives of PCPIRs in their original design was to establish chemical industry parks. In Western Europe, these parks were formed as a response to increasing urbanisation, industrialisation and shortage of resources. They served many purposes: - Economic steering: attracting new businesses, providing integrated infrastructure in one location, creating new job opportunities for qualified employees and providing eligibility for government benefits - Clustering: concentrating dedicated infrastructure in a specific area (and thereby reducing the cost of that infrastructure for each business), focusing the businesses on a dedicated value chain and strengthening business initiatives through improved cooperation between companies
- Environmental protection: moving industry away from urban areas, thus reducing the environmental and social impact - Resource management: providing localised environmental controls that are specific to the needs of an industrial area and saving resources through efficient use of by-products and residuals Participating in such industrial parks offers many advantages for a chemical company. The necessary infrastructure is readily available (utilities, regulatory clearances and permits, etc.), the company is integrated along the value chain and can leverage synergies with other companies and businesses can share facilities and access to well-trained people. All of these benefits allow companies to focus on their core business and therefore operate successfully. Yet the road to reaping these benefits is not without stumbling blocks. The National Chemical Policy, initiated by the Planning Commission in 2010 and driven by the Ministry of Chemicals with active industry participation, identified the challenges facing PCPIRs today. These need to be addressed if PCPIRs are to achieve their intended objectives: - Feedstock access: Industry expected the lead/anchor tenants of PCPIRs to make feedstock available, and infrastructure and ancillary industries would then develop around them. However, the way it has evolved, the lead/anchor tenants achieve economic viability with investment plans that
One of the objectives of PCPIRs in their original design was to establish chemical industry parks. In Western Europe, these parks were formed as a response to increasing urbanisation, industrialisation and shortage of resources. Chemical Engineering World
01-10-2013 21:44:33
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02-10-2013 23:41:59
CEW Features
Figure 1: Benefits of Clusters, Source: Roland Berger Strategy Consultants
include downstream products such as polymers, elastomers, derivative products, etc. Therefore, with feedstock ethylene, propylene, etc. not being made available, other downstream investment in PCPIRs was not forthcoming - Infrastructure: Dedicated pipelines, rail and port access, roads, power and utilities along with clear land are essential. Some of the proposed PCPIRs have not taken off as envisaged since these elements have not been adequately provided - Regulatory clearance: Delays and procedural issues for environment clearances plus pollution-related clearance even for compliant companies have affected the plans and operations of many businesses, thus affecting investment and expansion The devaluation of the rupee may make a case for local manufacturing, as it further escalates the cost of import-intensive components and technology for the project. Sustained high interest rates, long project ramp-up periods and Free Trade Agreements (FTAs) with Association of South East Asian Nations (ASEAN) and other countries are making it more difficult to argue in favor of investing in India. All in all, given the time it takes to execute a project of the size of a world-scale cracker plus the downstream/ ancillary units in specialty chemicals, achieving the desired investment in the coming decade is unrealistic. So, Where do We Stand Today and What are the Options for Moving Forward? Of the five PCPIRs initially announced, the one at Dahej has become operational 26 • September 2013
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Figure 2: India’s estimated shale gas reserves, Source: Roland Berger Strategy Consultants
largely due to state-owned OPal going ahead with their investment. Dahej is located in the state of Gujarat, which already hosts more than half the Indian chemical industry. Three of the other PCPIRs are located on India’s eastern coast: Haldia, Paradip and Vishakhapatnam. Of these, Haldia was scrapped, and Paradip has not yet announced a naphtha-based cracker, given the shale gas cracker investment being made elsewhere in the world and the lack of available gas in India. Vishakhapatnam is still investigating the feasibility of setting up a world-scale cracker. As for the refinery and chemicals complex at Jamnagar, the expansion plans announced by Reliance Industries are already in an advanced stage of implementation. These plans include an off-gas cracker that will benefit from the company’s record refining capacity. Besides this and the cracker at Dahej, no other cracker or downstream investments are likely to be realised over the next decade. By that time, the market for petrochemicals and specialty chemicals is likely to more than double, mostly met through foreign investment in manufacturing abroad. Reliance Industries is rapidly becoming a success story for the development of the Indian chemical industry. Their
announced investment will most likely go ahead, at the moment it would simply be a question of when. The company has unparalleled refining capacity on a global scale and the resulting access to feedstock. It has been operating successfully at this location for over two decades, gaining much experience and generating goodwill in the process. Reliance also boasts competitive access to the undersupplied markets in west and north India, technological expertise in running and optimising its existing cracker, plus a pool of talented people who can execute the project in record time and on budget. We need more such business cases for the Indian chemical industry to truly flourish. Are PCPIRs a distant dream for India, given the potential and strong intent of the chemical industry to grow profitably? I suggest we rephrase the question: how can PCPIRs continue to remain relevant in the current context? There are a couple of lessons to be learned from global best practices, which can be adopted to boost India’s competitiveness in the chemical industry. Lesson one is shale gas. Shale gas has revolutionised the chemical industry in the US and made it competitive once again, offering cheap feedstock and energy, supported by developed infrastructure. India would do well to explore and
Are PCPIRs a distant dream for India, given the potential and strong intent of the chemical industry to grow profitably? I suggest we rephrase the question: how can PCPIRs continue to remain relevant in the current context? Chemical Engineering World
01-10-2013 21:44:33
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CEW Features
Figure 3: Case Study – BASF, Source: Roland Berger Strategy Consultants
exploit its own shale gas reserves, which are estimated to be quite significant.
A comprehensive knowledge-rich magazine that disseminates information on all segments of Chemical Process Industry
While shale gas can serve as much needed feedstock and source of cheap energy for the chemical industry, certain critical factors are needed to successfully exploit its potential. These include availability of land and water to extract the gas from the shale deposits, pipelines to transport it safely and effectively to the most competitive sites for processing, as well as the power and infrastructure to manufacture and transport this even farther. India is still a long way from this point, and needs to develop a plan that reflects the experience of challenges faced in executing the PCPIR policy. Besides extending to shale gas, the PCPIR programmes should also look at existing chemical investment/clusters. It can shape them into eco-industrial parks by providing incentives for developing the relevant ecosystem around these plants. Many such opportunities exist in India. A single site can expand to become a multi-company complex through joint ventures and alliances if the businesses are offered the right incentives to invest and promote investment. We can learn from BASF’s in Spain, which started out the 112-hectare site has people, and generating an tonnes today.
example at their Tarragona site as a single site in 1969. Today, 8 companies employing 1,000 annual output of 750,000 metric
Shale gas and existing clusters would serve as a two-pronged approach to push investment. The approach would also establish a chemical ecosystem with the goal of moving toward an eco-industrial park that is sensitive to the environment and promotes additional investment. This goal is consistent with that of PCPIRs. PCPIRs will remain relevant in India’s quest to boost the competitiveness of its chemical industry. However, the scope of the programmes may need to be redefined in response to the trends that have impacted the industry globally.
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02-10-2013 22:31:27
CEW Features
Reduce Cost of Ownership with DRY VACUUM PUMPS The use of dry vacuum pumps in the chemical process industries brings many benefits, not least a significant reduction in installation and operating costs. This article reviews the technology and gives examples from some recent dry pump installation experiences.
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acuum technologies used in the chemical process industries include wet and dry mechanical pumps. Wet technologies require lubrication fluids, such as oil or water. Oil-sealed pumps require regular maintenance. External oil cleaning devices or regular oil changes may increase the reliability of these pumps, but when pumping solvents, corrosive vapours or dusts there can also excessive wear on internal parts. This can reduce performance often translating into increased production costs. There is also the issue of proper disposal of contaminated oil. In addition to the cost of treatment and disposal, this waste poses a significant threat of pollution to the environment, particularly when contaminated with solvents. Steam ejectors, whilst usually reliable and robust, can require very large quantities of steam and cooling water, which often create a condensate that is contaminated with process vapour, requiring costly disposal. Liquid ring pumps (LRPs), although simple and reliable, can require large amounts of cooling water. This water can become contaminated with process materials and require appropriate disposal. Proper disposal of wastewater or oil in these systems can be difficult and costly. The key advantage of all dry pumps is that they do not use water or oil for sealing or lubrication of the vacuum stages. They have a lower environmental impact with no contamination of the process stream or cooling water, and little or no effluent generation. Even though dry pumps are made from ductile cast iron there is no corrosion when operating in the vapour phase. (See figure 1) This is because the
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Figure 1: Temperature Graphics
pressure and temperature profile inside the pump is maintained above the dew point of the process media, ensuring reliable operation, even when pumping highly aggressive chemicals. Dry pumps require little maintenance, and are often more reliable than oil-sealed pumps, therefore dry vacuum is used to pump some of the most aggressive and problematic gases in a broad range of chemical processes. Cost of Ownership The capital cost of a dry vacuum pump is often higher than that of an equivalent wet pump, but there tends to be very little difference when the total installation cost is considered. The installation cost of the latest “fit and forget� dry pumps can be significantly less than for other process vacuum technologies, including other dry pumps. When running costs are taken into account, the dry system often shows a considerably lower cost of ownership.
The latest dry pumps with integral pressure control will generally have a lower installation cost than other options. Dry pumps offer the best thermal efficiency of any process vacuum-producing system. Not only does the dry system use significantly less energy when it is running but, unlike a steam ejector, it can be switched off between cycles so that it uses no energy at all when it is not required. Inverters can also be used to minimise the power usage when in standby mode. Reduced power consumption results in lower carbon footprint and environmental impact. The dry vacuum pump can cost up to 90 per cent less to run than its steam ejector equivalent. Similarly, compared to a liquid ring pump system, the running cost of a dry pump can be significantly cheaper. Even when the higher capital cost of a dry pump system is taken into account, the lower
The dry vacuum pump can cost up to 90 per cent less to run than its steam ejector equivalent. Similarly, compared to a liquid ring pump system, the running cost of a dry pump can be significantly cheaper Chemical Engineering World
01-10-2013 21:17:44
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CEW Features Cost of Ownership of Wet And Dry Vacuum Pump Systems
Units or Value
Steam Ejector System
Dry Vacuum Pump Model CXS250 Cat 2 w/o FA
cost of ownership of the dry system means that it often pays for itself very quickly.
Vacuum specification Operating Pressure (mbara)
10
Pumping speed (m /hr)
250
Operating hours
h yr -1
3
8000
8000
Steam - Flow rate
kg h -1
- Unit cost
Rs.kg
110 1.8
1.8
Rs.yr -1
1,584,000
0
Interstage condenser of EJ & dry pump
m 3 h -1
2.414
0.24
Chiller unit
m 3 h -1
-
-
Total Recirculated water flow rate
m h
Steam cost
-1
Cooling water Reciruclated water
2.414
0.24
Rs.m -3
4
4
Rs.yr -1
77,248
7,680
- Flow rate
m 3 h- 1
0
- Unit cost
Rs.m -3
25
25
Rs.yr -1
0
0
- Flow rate
m 3 h -1
2.415
- Unit cost
Rs.m -3
115
115
Rs.yr -1
2,221,800 2,299,048
0 7,680
- Unit cost Recirculated Water cost
3
-1
Make-up DM water
Make-up DM water, If any Contaminated (effluent) water treatment
Treatment cost Total water cost / year
Rs.y
r-1
Nitrogen - Flow rate (Seal purge, gas ballast & cooling gas)
m 3 h -1
- Unit cost
Rs.m N 2 Purge cost
-3
Rs.yr -1
12.00 4.00
4.00
0
384,000
Power - Liquid ring pump(s), condensate pump
kW
- Brine pump +circulation pump,DP’s&OSRVP’s
kW
Total Power
kW
0
4.2
Rs.kW h-1
6.6
6.6
Rs.y
- Unit cost
4.2
0
221,760
Total Utility Cost/yr
Rs.y r-1
3,883,048
613,440
Maintenance Cost/yr,averaged 5 years
Rs.y r-1
20,000
60,000
Yearly Operating Cost
Rs.y
r-1
3,903,048
673,440
Yearly Operating Cost
Rs.y r-1
3,903,048
673,440
Operating Cost/month
Rs.mth -1
325,254
56,120
Savings per year compared to Stean Ejector
Rs.yr-1
3,229,608
Savings per month compared to Steam Ejector
Rs.mth-1
269,134
Power cost
r-1
Total installed cost Capital Cost
Rs
250,000
2,600,000
Installation Cost
Rs
120,000
60,000
Total Capital, Delivery & Inst. Cost
Rs
370,000
2,660,000
Total 1st year installed and annual operating cost
Rs.
4,273,048
3,333,440
Table 1: Cost of Ownship of a Dry Pump System vs. Steam Ejector System Note 1: Green cell data are estimated operating hours - confirmed by customer Note 2: Yellow cell data is the assumed steam ejector utility consumption - confirmed by customer. Note 3: orange cell data estimated utility rates - confirmed by customer. Note 4: Pink cell data estimated maintenance & installation - confirmed by customer. Note 5: Blue cell data is the estimated cost of steam ejector system- confirmed by customer. Note 6: Currency of units is in `.
32 • September 2013
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Case Studies Highlighting Cost Reductions The following case studies highlight some examples of companies who have reduced their costs by using dry vacuum pumping solutions. Precision Control A manufacturer of chemical intermediates for the pharmaceutical industry based in Hyderabad, (India) had been relying on traditional steam ejectors, which can be unreliable.The comapny began a trial using a dry pump with discrete, tapered variable pitch screws on an acetone recovery process that requires precisely controlled vacuum. The pump is now in regular operation, and the company reports enhanced end-product quality. The vacuum is being applied accurately and consistently, and batches are no longer interrupted. Of particular interest is that they have confirmed they will see a return on investment in less than three months. The reliability of the dry vacuum system allows for a more efficient process, and the substantial improvement in end-product quality means an increase in market value, further reducing the cost of ownership. Prevent Condensing o f Ag g r e s s iv e Chemicals A major global agrochemicals manufacturer based in Gujarat (India) needed to pump aggressive chemicals including phosphorus oxy chloride, thionyl chloride and hydrogen chloride. Faced with these very aggressive chemicals, the existing liquid ring pumps would have needed to be protected with an expensive up-stream scrubber with high operating costs and potential pollution issues. A reverse claw dry vacuum pump was installed and configured to operate relatively hot so that the pumped vapours could not condense internally during compression. After two years of operation the pump was still in pristine condition. In another corrosive application, pumping phenol, thanks to the staged and controlled compression and temperature profile within the pump, the supplier was able to offer operation above the saturation temperature, even when pumping a high boiling point material like phenol. Chemical Engineering World
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CEW Features
Figure 2: Cost of Steam Ejector System vs Edwards Dry Vacuum Pump - 5 Year Operating Period
Reusable Uncontaminated Speciality Chemicals Another agrochemical manufacturer based in Andhra Pradesh (India) wanted to reduce their energy consumption while pumping speciality chemicals. Dry vacuum pumps replaced their multi-stage steam ejectors and in a 12-month trial project they calculated significant savings as a result of reduced energy consumption. The customer also found that they were able to recover almost all of the valuable uncontaminated speciality chemicals at the exhaust for reuse in the process. The results were so impressive that the customer ordered a further 12 systems, and has now replaced all its steam ejector systems with dry vacuum pumps. (See figure 2) Energy and Water Savings A specialised fine-chemicals company that produces brominated organic compounds for the pharmaceutical, agrochemical and photographic industries was looking to replace the liquid-ring pump (LRP) and steam ejectors on its distillation system. Bromine and brominated compounds are aggressive chemicals that pose a high risk of corrosion to a pumping system and the production of wastewater was another issue. A large volume of wastewater used to be produced by both the LRP and steam ejectors at the plant, which was costly to treat. As well as standing up to the corrosive application, the ideal system also had to produce no polluted effluent. Further, a very tightly controlled vacuum environment was required, capable of providing a very high vacuum of less than 2 Torr. A reverse claw dry pump was installed and as a result, the company has achieved higher margins thanks to the increased control over their processes and lower pressures. There have also been considerable savings on energy and the cost of water from not
Dry vacuum pumps replaced their multi-stage steam ejectors and in a 12-month trial project they calculated significant savings as a result of reduced energy consumption. 34 • September 2013
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using steam ejectors and liquid-ring pumps. This system has been running successfully since 1996, followed by similar ones on the same site since then. Environmental Considerations Green credentials are becoming increasingly important for India’s chemical and pharmaceutical industries. The proper disposal of effluent and other pollutants can be an expensive proposition. Dry pumps, as well as having little or no effluent to dispose of, are energy efficient and the reduced power consumption results in lower carbon footprint and environmental impact. Conclusion Dry pumps are clean, reliable and provide low to high vacuum and require minimal maintenance. They can be used quite safely even when pumping flammable and corrosive vapours. Innovation in this sector continues, producing ever more ‘utilitarian’ high performing, highly controllable vacuum equipment that allows processors to reduce environmental impact and minimise running costs.
Author’s Details Dr Don Collins Market Development Manager - Chemical Sector Edwards Ltd
Alagar Sivabalan Senior Sales Manager – Chemical Sector Edwards India Pvt Ltd,
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Tel : +91 11 30810244, Email : info@malvernaimil.com Chemical Engineering World
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CEW Features
Application of UG-140 for Overpressure Protection It’s a common understanding that for a pressure vessel, pressure relief device is required to protect against overpressure scenario. In the event of credible overpressure scenario, the device is sized for the scenario. However, if there are no credible overpressure scenarios, a practice of providing a “token valve” sized arbitrarily is generally followed. This article addresses the question on whether the relief device is required when there are no credible scenario and how to meet the code requirements even without providing the pressure relief device.
P
ressure vessel is defined as the vessel designed above 15 psig pressure. When the vessel is designed per code ASME Section-VIII Division-1 (henceforth referred as code), the requirements of the code are followed for design, fabrication, and inspection & testing. ASME coded vessels are marked with ASME “U” stamp on nameplate. One of the basic requirements of the code is to provide overpressure protection for the vessel covered by ASME Section-VIII Division-1, UG-125 through UG-140. Overpressure protection for pressure vessel can be achieved by either or combination of following three options: 1. Relief Device: Requirements of relief device for pressure vessel are covered by UG-125 through UG138. When the findings of detailed evaluation of various overpressure scenarios per API Standard-521 state that there are credible cases for overpressure, pressure relief devices are provided and sized per applicable equations given in API Standard-521. 2. System Design (Inherently Safe Design): This option overcomes the requirement of a relief device to protect pressure vessel. The documentation and other specific requirements of this option are covered by UG-140(a). 3. Safety Instrumented or High Integrity Protection System (HIPS): This option can overcome the requirement of a relief device in specific cases. The documentation and other specific requirements of this option are covered by UG-140(b). 36 • September 2013
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The ASME UG-140 requirements and procedures are commonly known as “Code Case 2211”. In 2008, ASME incorporated “Code Case 2211” into the body of Section-VIII Division-1 as Section UG140. All overpressure protection systems addressed by second or third option or a combination of second and third require compliance of ASME UG-140 including all approvals, responsibilities, analysis and reviews including documentation and sign-offs. Detail Requirements of UG-140 (a) and (b) Per UG-140, pressure relief device is not required to protect a pressure vessel if the pressure is self-limiting and this pressure is less than equal to MAWP of the vessel at coincident temperature. The major requirements of UG-140 are Detail analysis of various overpressure scenarios; Multidisciplinary team review; Risk assessment in the event of credible scenarios; Manufacturer data report to state the system protected by design; and Documentations & signoffs. 1. Detail analysis of various credible scenarios: API Standard 521, Pressure-Relieving and Depressuring Systems, describes “Causes of Overpressure”. Other standards or recommended practices that are more appropriate to the specific application may also be considered. The typical overpressure scenarios that need to be analyzed are Loss of cooling water or cooling medium, Loss of power, Loss of steam, Loss of instrument air or electric supply failure, Individual control valve failure, Inadvertent valve operation, Blocked outlet, Individual equipment
failure, Loss of air cooling, Thermal expansion, Heat exchanger tube rupture, Fire case, Liquid overfill, Gas Blow by Reactive hazard All the scenarios shall be evaluated with detail explanation to identify whether the scenario is applicable and if it is applicable how the pressure reached in the scenario is less than MAWP of pressure vessel at co-incident temperature. All the relevant documents such as Piping and Instrumentation Diagrams (P&IDs), Process Flow Diagrams (PFDs), Equipment General Arrangement (GA) Drawings, Equipment Data Sheets, Plot Plan, Equipment Elevation Drawings, Paving and Drainage Plans, Process Control System Documentations, Instrument Data Sheets and Material Safety Data Sheets (MSDS) of chemicals involved etc. shall be used to evaluate credibility of overpressure scenarios. All the relevant documents shall be attached as a part of documentation. 2. Multidisciplinary team review: The documentations shall be reviewed and evaluated by multi-disciplinary team of people including Process Safety engineer, Process Technology Leader, Manufacturing Representatives, Process Engineers and Relief Design Subject Matter Experts (SME). 3. Risk assessment in case of credible overpressure scenario: For a pressure vessel, if a scenario is found to be credible for overpressure, then risk associated with the event shall be judged to decide whether or not the relief device shall be provided. The design shall comply with local regulations and owner’s risk tolerance criteria. This approach is scenario specific and if Chemical Engineering World
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CEW Features it can be justified that having a relief device does not benefit then one can go without having a relief device even when the case is credible for overpressure. To illustrate, examples can be as follows: • If fire scenario is applicable to a pressure vessel operating in gas service, pressure relief device is of no help in protecting the vessel as the vessel ruptures due to overheating before the pressure reaches the set pressure of relief device. • The pressure vessel is empty and fire case is applicable, relief device is of little help for the same reasons. • Pump Seal pots: Consider 5 gallon U stamped seal pot is provided for API pump and fire case is applicable. During a fire, the seal pot will likely fail, regardless of whether it has a PSV, and regardless of that PSV’s size. For vessel size being that small, a fire-sized PSV will quickly result in the seal pot being emptied of liquid. Once the liquid is gone the vessel will fail due to excessive heating (excessive wall temperature). Thus, a PSV can’t adequately prevent this vessel from failing during a sustained pool fire. One can go with UG-140 documentation for such cases. 4. Documentation and Sign off: All the involved parties shall sign off the document to conclude and certify that the vessel is protected by system design and in no credible event the pressure will exceed MAWP at coincident temperature. 5. Manufacturer’s data report to state the system protected by design: Annexure-W of ASME SectionVIII Division-1 provides details of Manufacturing Data reports. UG-140 requires that manufacturing data report shall mention that the vessel is protected by system design. Typically, vessel manufacture provides data report and this requirement is mentioned in the notes section of the report. To the data report, a U-1 or U-1A form is enclosed. Typically, U-1 or U-1A form should say “Overpressure protection is provided by others per UG-140 (a) or (b). OSHA inspector is likely to see this form to check for overpressure protection of the vessel when the ASME code stamped vessel is not provided with a pressure relief device. 38 • September 2013
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Figure1: Example of System Architecture for HIPS
High Integrity Pressure Protection System (HIPS) Industrial use of HIPS is to reduce the pressure relief device’s size for specific scenarios. It is not intended to drive the complete removal of pressure relief devices. However, in specific cases, use of HIPS can lead to elimination of relief device. The documentation and other specific requirements of this option are covered by UG-140(b). HIPS typically involve an arrangement of instruments, final control elements (e.g. valves, switches, etc.), and logic solvers configured in a manner designed to avoid overpressure incidents by removing the source of overpressure or by reducing the probability of an overpressure contingency to such a low level that it is no longer considered to be a credible case. With appropriate levels of redundancy, a HIPS can be designed to achieve a level of availability equal to or greater than a mechanical relief device. A detailed description of any safety critical instrumentation (HIPS-High
Integrity Protection System) used to limit the system pressure, including the identification of all truly independent redundancies and a reliability evaluation (qualitative and quantitative) of the overall safety system shall be provided as part of UG-140 documentation. HIPS finds its use in complex process applications. For example, the application of HIPS is for a reactor o perating at high temperature and pressure conditions where coolant is circulated to remove exothermicity of reaction and loss of coolant would lead to high temperature rise leading to runaway reaction or boil up of coolant. In such application, HIPS is used to cut off the feed once coolant flow is stopped. The table (on the next page) can be used as reference when making a choice between the options to be followed for overpressure protection of pressure vessel while meeting code requirements. Example of Pressure Protection of a Pressure Vessel Operating in Chlorine Service by System Design (UG-140 (a)) (See Figure 2 below)
Figure 2: D-101 Schematic
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CEW Features Equipment / System Protected
Pros and Cons of Relief Device, Safe Design and HIPS UG-140 (b)
D-101 (Chlorine gas knock out drum)
Relief Device
MAWP @ Coincident Temperature Pros 1. Commonly used System Information 2. Highly reliable 3. Designer feels confident with functionality 1.1 Protected Equipment : D-101 4.Standalone Mechanical device 1.2 Fluid HandleD : Chlorine 5.Can handle runaway reactions 1.3 Operating Pressure / Temperature : 6.5 Barg / 50°C 21.5 barg / FV @ 190 °C
Description of Overpressure Scenario 1. Loss of Cooling Water or Other Cooling Fluid: No cooling is supplied to D-101. Hence, the case is not applicable. 2. Loss of Power: There are no power operated equipment associated with D-101. Hence, the case is not applicable. 3. Steam Failure: No steam is associated with D-101. Hence, the case is not applicable. 4. Instrument Air / Electrical Supply Failure: In the event of instrument air failure, following valves shall close as failure position being Fail Closed. [Inlet of D-101 - 1. EBV-01: Closure of the valve shall lead to loss of chlorine gas flow to D-101. Hence, there shall be no overpressure. Outlet of D-101 1. FCV-01 / EBV-02: Closure of the valves shall not lead to overpressure as chlorine gas flow to D-101 shall be lost due to closure of EBV-01.] 5. Individual Control Valve Failure: Failure Opening of FCV-01: The valve is located on vent outlet of D-101. The case of failure opening of control valve shall result in no overpressure to D-101 as the valve shall provide open path to downstream system. 6. Inadvertent Valve Operation: Failure closure of FCV-01: Failure closure of the valve shall not result in overpressure as MAWP of D-101 is higher than the maximum pressure of chlorine gas at battery limit which is 9 barg. 7. Individual Equipment Failure: There are no mechanical equipment associated with D-101. Hence, the case is not applicable. 8. Loss of Air Cooling :No air cooling is provided for inlet and outlet streams of D-101. Hence, the case is not applicable. 9. Blocked Outlet: Refer to Case 6. No overpressure. 40 • September 2013
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Cons 1. Requires maintenance 2. Can plug in heavy service 3. Requires disposal system downstream for safe handling 4. When not used in combination of HIPS, may require bigger disposal system such as large flare headers and scrubbers 5. Not desirable in toxic services 6. Cannot provide protection against excessive temperature
Inherently safe design HIPS UG-140 (a) UG-140(b) Pros 1. Safest way of design 2. Eliminate relief device and associated disposal system 3. Preferred option for toxic services
Pros 1. Availability / Reliability 2. Eliminate relief device and associated disposal system 3. Suitable for toxic services 4. Can eliminate overpressure scenarios such as runaway reactions 5. Can provide protection against excessive temperature due to process upsets (*) 6. Useful when environment restrictions and safety constraints limit the venting
Cons 1. Higher design pressures 2. HIPS needs to be used in combination to handle runaway reactions and protection against excessive temperature 3. Designer needs to meet requirement of UG-140 by way of documentations, reviews and sign-offs
Cons 1. Maintenance, testing and inspection 2. Complex systems 3. Expensive systems
Table1: Comparison of Options for Overpressure Protection , (*) Fire case is not considered as a process upset scenario.
10. G as Blow Through:The case is not applicable. 11. E xternal Fire: Per Equipment GA drawing, the equipment is located above fire height of 7.6m. Hence, overpressure is not credible. 12. E xchanger Tube Rupture: D-101 is not connected to any heat exchanger. Hence, the case is not applicable. 13. L iquid Overfill: D-101 is operating in gas service. Hence, the case is not applicable. 14. T hermal Expansion: D-101 is operating in gas service. Hence, the case is not applicable. 15. V acuum: D-101 is designed for full vacuum. Hence, the case is not deemed to be credible. 16. Runaway Reactions (Reactive Hazards): No reactive hazard is associated with D-101. Hence, the case is not applicable. 17. A ny Other: Low pressure nitrogen can be hooked up to D-101 during maintenance
activities. However, maximum operating pressure of LP Nitrogen is 7 barg which is less than MAWP of D-101. Hence, overpressure is not credible. Safety Critical Instrumentation And Reliability Evaluation For D-101, no safety critical instrumentation is used for purpose of overpressure protection. Hence, this section is not applicable. As detailed evaluation of possible overpressure scenarios suggests that in no case the pressure can exceed MAWP of D-101, it can be concluded that pressure is selflimiting and D-101 is protected by system design. Hence, no relief device is required for overpressure protection. Conclusion In certain services, having Pressure relief devices adds to issues related to leaking and maintenance due to plugging. If it can be justified that the pressure vessel Chemical Engineering World
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CEW Features is designed to withstand all credible scenarios, UG-140 comes handy to meet the requirements of the code. In toxic services such as phosgene, it is desirable to protect the vessel by system design and/or by employing HIPS system. Pressure relief devices operating in phosgene service require proper disposal system and may create operational hazards. These devices also require critical procedures in place for inspection and maintenance. HIPS typically finds its application in critical process operations handling hazardous services. On the other hand, having a relief device on the vessel provides a kind of insurance for the vessel. Decision to have a relief device to protect the vessel depends upon number of factors as service it is operated with, type of overpressure scenario and experience of engineers working with the technology. As there are number of factors which influence the decision making to protect the vessel and the decision being scenario specific, its users responsibility to decide the option to be followed for overpressure protection keeping in mind that the code permits not to have a relief device by way of UG-140 provided the detail evaluation is performed and analysis is documented to ensure no hazardous situation would arise due to overpressure that may lead to loss of containment or risk to operating personnel. References 1. Pressure-relieving and Depressuring Systems, ANSI/API Standard 521, Fifth Edition, January 2007, Addendum May 2008. 2. ASME Boiler and Pressure Vessel Code VIII, Division 1, Rules for Construction of Pressure Vessels, Edition 2010
Definition of Terms 1. Design pressure: Pressure, together with the design temperature, used to determine the minimum permissible thickness or physical characteristic of each component, as determined by the design rules of the pressure-design code 2. MAWP: Maximum gauge pressure permissible at the top of a completed vessel in its normal operating position at the designated coincident temperature specified for that pressure 3. Overpressure: Pressure increase at the relief valve inlet above the set pressure, when the relief valve is relieving (Overpressure is expressed in pressure units or as a percentage of the set pressure.) 4. Relief device: Device used to relieve excess pressure and/or vacuum that has developed in a tank 5. Set pressure: The inlet gauge pressure at which pressure relief valve is set to open under service conditions
Author’s Details Sushant G Labhasetwar (P.E) Assistant Manager - Process Engineering Team Daelim Industrial Corporation, Seoul Korea Email: sushant@daelim.co.kr
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Contribute in CEW
Dear Readers, Chemical Engineering World (CEW), the Official Organ of CHEMTECH Founda�on, is India's premier technology magazine for the chemical process industry professionals. This highly reputed monthly publica�on provides novel insights on the dynamics of Indian and global process industries. CEW, a niche publica�on with proven track record, has been dissemina�ng authen�c informa�on on process industry innova�ons for more than four decades. You can contribute in the magazine with technical ar�cles, case studies, and product write-ups. The length of the ar�cle should not exceed 1500 words with maximum three illustra�ons, images, graphs, charts, etc. All the images should be high-resolu�on (300 DPI) and a�ached separately in JPEG or JPG format. Have a look at our editorial calendar on the website – www.cewindia.com. To know more about Chemtech Founda�on, Jasubhai Media and other publica�on and events, please visit our website – www.chemtech-online.com
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!
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CEW Features
Corrosion - A Life Cycle Challenge The article highlights the corrosion issue which is one of the major challenges for pump manufacturers and users. The gradual destruction of metals not only hampers the smooth functioning of any plant but also increase the cost of project to a great extent.
Pumps account for 30% of the power consumption in the country
P
ump plays an integral role in fluid transportation for industrial purpose. Indian pumps have contributed to the nation’s economy significantly. Prominent sectors amongst them are agriculture, onshore and offshore production of oil and natural gas, petroleum refining, petrochemicals, mining, ship-building and marine duties, power generation, public water supply and sanitation, domestic and household utilities, process industries producing fertilisers, insecticides, pesticides, drugs and pharmaceuticals, textiles, soaps and detergents, cosmetic and health care products, dairies, vegetable oil and processed and packed food products, breweries, paints, etc .1 Pumps account for 30 per cent of the power consumption in the country. Thus, efficient operation of pump system can yield substantial savings. Selection of pump-motor system would differ from one industry to another due to changes in application parameters, process parameters and liquid characteristics. 2 44 • September 2013
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Pump Selection, a Puzzle for Public and Material Selection and a Challenge for Pump Manufacturers. Pumps and valves are designed or chosen primarily for their mechanical performance i.e. containment of pressure, fluid sealing and, in the case of pumps, pumping capacity. For reasons of economy manufacturers offer their products in a limited range of materials. Each of these materials is suitable for a range of common fluids, and has the advantage of being available with relatively short delivery times. However, for corrosive and/or erosive fluids the user may require special designs (e.g. of seals) and/or special materials, which increase cost and delivery times. The balance of cost versus the likelihood of failure due to corrosion must be taken into account along with the
criticality of the component, i.e. what are the consequences of a failure. 3 When Pumps come to the minds of public for domestic application, the selection of pumps is always a puzzle for them. The moment the requirement is identified, the users merely check certifications like ISI mark, the only clue available for making a purchase decision. These ratings/ standards of manufacturing are the resultant effects of many strengths as well as weaknesses observed not only for the individual manufacturer, but also for the whole Industry. The technical knowledge required for proper selection of pump set and pipe sizing is clearly out of the reach of public, especially farmers, who are the final consumers.
Industries worldwide depend upon pumping systems for their daily operation. These systems account for nearly 20 per cent of the world’s industrial electrical energy demand and range from 25-50 per cent of the energy usage in certain industrial plant operations. Chemical Engineering World
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CEW Features the system over its lifetime. Additionally, plant facilities personnel are typically focused on maintaining existing pumping system reliability rather than optimising the systems for best energy efficiency. It is a common practice for pumping system design and procurement to be based primarily upon the initial purchase cost of the equipment. 5
Material Selection for Chemical, Oil and Gas, Refining, Power and other industrial purpose is driven by the fact that how adequate these industries are equipped to follow appropriate selection criteria and choose the fit-for-purpose materials associated with design, apply, research and develop processes. This is again a puzzle for the manufacturers with least access for national and international standards and procedures. There are 43 Standards in MED 20, Mechanical Engineering: Pumps developed by Indian Standards Institution (ISI). How do these standards solve the puzzle on proper pump selection and help the general users to choose the efficient pumps of their interest without compromising any of life cycle drivers? Agriculture sector consumes about 35 per cent of the total power generated. Most farmers use inefficient non ISI marked pump sets which consume more electricity and deliver less output. There is a potential of about 25 per cent to 35 per cent improvement in the efficiency of these pump sets by affecting minor/ major rectification and shifting to ISI marked pumps. The motors manufactured by unorganised units do not have ISI standards and is less efficient due to non-use of higher quality material resulting in iron loss and copper loss. The no load power factor is above 0.2 which is increasing the no load power consumption. There exists a mismatch in supply of pumps and motors by the 46 • September 2013
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unorganised sector as per operating load required by the client. There are many weaknesses associated with the development of pump manufacturing sector. Major contributors are: Absence of innovative approach to improve the existing processes and usage of lowgrade raw materials so as to produce cheaper products that are not efficient by unorganised sector. 4 There is a wide gap between the minimum efficiency required for ISI certification and the efficiencies achieved by reputed manufacturers, which are very near international efficiencies. So, there is a big scope for improving the efficiencies of pumps manufactured in the country (Source: Indian Pump Manufacturers’ Association). Many factors that contribute for improvements in efficiency are often bypassed when the focus is made on initial investment and quick sale of items without acquiring the experience on proven performance of materials used for construction. Industries worldwide depend upon pumping systems for their daily operation. These systems account for nearly 20 per cent of the world’s industrial electrical energy demand and range from 25-50 per cent of the energy usage in certain industrial plant operations. Purchase decisions for a pump and its related system components are typically based upon a low bid, rather than the cost to operate
Corrosion, the Neglected Concern The manufacture of pumps requires a wide spectrum of materials metals and non-metals which would not only satisfy the design and functional requirements of the particular component but should also have reasonable assurance on its application in the environment surrounding the entire pumping process. Corrosion characteristics play an important role in deciding the proper materials of construction. There is vast difference between the cost-intensive pumps imported for specialised applications from the manufacturers with access for the latest developments in materials and corrosion research and the low cost pumps manufactured locally without the involvement of appropriate material selection process. This difference is truly a life cycle challenge for the pump users as well as manufacturers in India. References: 1. Chemical Engineering World, March 2000 2. Energy for Sustainable Development, Volume III No. 1, May 1996 3. National Physical Laboratory, UK4. Coimbatore BDS 5. LBL 51042 Life Cycle Cost for industrial pumping)
Author’s Details M Valliappan We CAN Control Corrosion in India Network Email: visalvalli@hotmail.com
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CEW Market Insights
Raising the Bar in Sustainable Lubrication
T
he Indian lubricant market is the fifth largest market in the world in terms of consumption volume after the US, China, Russia and Japan. Growing personal disposal incomes, improvements in road infrastructure, increasing usage of automotive transportation, rural demand, growing industrial production and the support from government are some of the factors for the growth of Indian lubricants market, recent Ken Research reports. Shankar Karnik, Asia Pacific Mobil SHC Brand Manager, ExxonMobil Lubricants Private Limited, on the sidelines of an international conference during his visit to Mumbai, emphasised on sustainability as one of the key global trends in the lubricant market. On the growing front of Indian market, Shankar Karnik said India is a vibrant and emerging market. In the recent years, Indian lubricants market has experienced rapid growth and expansion of lubricant applications in the automotive and industrial sectors. Mobil Industrial Lubricants, a business of Exxon Mobil (Corporation) offers industrial lubricants that are used extensively in many industrial market sectors - including power generation, general manufacturing, metal working, food and beverage processing, pulp and paper, cement, construction, metals and mining. The Indian lubricant market is growing at a considerable
CAGR rate and is likely to exceed USD 7713 million by 2017, which will be driven primarily by the surge in the domestic automotive sector. Sustainability is the key word in the current market wherein the focus has been on saving the environment through various ways.In the current era of global warming; many organisations have adopted for green technology and thus have begun utilising products which emits less pollution. The introduction of such energy efficient products in the market is a beginning of saving environment. ExxonMobil is one of the companies who have aggressively stepped into protecting the environment by inducting excellent energy efficient lubricant solutions. Shankar Karnik on the current market trend mentioned, Sustainability as balancing the economic growth, social development and environmental protection, so that future generations do not suffer by actions taken today. We are committed to meet the world’s energy needs and address environmental and other citizenship challenges .It is not just our philosophy, but is a central to the way we do business. He further added that ExxonMobil recognises the central role of technology and thus is a leader in technology research and development. With heavy investment
The Indian lubricant market is growing at a considerable CAGR rate and is likely to exceed USD 7713 million by 2017, which will be driven primarily by the surge in the domestic automotive sector. 48 • September 2013
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Shankar Karnik Asia Pacific Mobil SHC Brand Manager ExxonMobil Pvt Ltd
in research and development over the past years and employed over 16,000 scientists as well as engineers, ExxonMobil is responsible for some of the industry’s most significant scientific and engineering breakthroughs. We are investigating technologies to support the critical role that energy will play in the decades to come and also technologies that will help supplement the core contribution. An area of technology that is often overlooked in the oil and gas industry is that of lubricants and lubrication. Lubricants are the life blood of the rotating equipment that finds, produces, processes and transports the energy supplies on which we rely. Selecting high performance, technologically advanced lubricants help oil and gas explorers and producers meet and exceed production targets more safely and more efficiently, while offering many sustainability related benefits. It is more important to spread the awareness for selecting appropriate lubricant by consumers for their desired equipments to safe guard and increase the productivity of the equipments. For example, a lubricant helps in maintaining the machine and safe guards the productivity of the equipments. Thus, any organisation needs to install the right kind of lubricant required by their equipment for higher productivity. It was the biggest challenge tackled by ExxonMobil during their initial days in Indian market as ExxonMobil entered the Indian market after the de- regulation wherein education and awareness was Chemical Engineering World
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Market Insights CEW scaled low in regards to lubricants and their uses. Karnik stressed that they had to work aggressively for developing awareness across industries about the importance of lubricants for equipments. Optimising lubricant selection can provide significant performance benefits in a multitude of applications: 1. Extends oil life 2. Increases oil drain intervals - helping to reduce used oil generation and extend intervals between routine maintenance; 3. Environment, Health, Safety – provides increased wear protection - helping to extend the reliability and life of critical equipment; and 4. Enhances energy efficiency - helping to reduce operating costs. Karnik expressed his concerns on the rising unorganised sector and considers them as the major counterfeits in the growing development. Thus, they have drafted effective communication with consumers and also implemented latest labelling techniques for brand verification aimed at reducing counterfeits. The communication barrier or broken communication has been the major problem for such counterfeits, laments Karnik. Thus, branding is playing important role in the market to introduce company’s significant quality products. Lubricant business model works cautiously on the social and environment front since they are aware of the vulnerability of waste disposal of oil. Shankar Karnik explained the importance of energy efficient lubricants in the meeting of Worlds Energy Needs wherein he stated that by using energy more effectively through new technologies and new practices, we can displace demand on a significant scale. Selecting right lubricants for their energy efficiency benefits the user in terms of operating costs. But it also supports the environmental goals of industry by helping reduce emissions growth. Mobil Industrial Lubricants help to drive productivity higher and safely, while offering sustainability related benefits and helping to ensure businesses remain competitive over the long term. To sum up, global demand for energy is expected to increase by almost 30 per cent by the year 2040. To meet the challenges presented by this demand increase, we will require more investment, more technology and more skill than ever before. Oil, coal, natural gas, nuclear and renewable supply sources will all be needed to meet the needs of the future. Lubricant technology and lubrication services can play an extremely important role by helping to increase productivity safely, while offering sustainability related benefits.
- Namrata Tanna Chemical Engineering World
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CEW Products SS Seamless & Welded Pipes, Tubes, U-Tubes & Large Dia Welded Pipes Suraj Ltd an ISO-9001, 14001, BS OHSAS 18001 certified company offers SS seamless and welded pipes, tubes and U-tubes, and large dia welded pipes in various sizes, grades and specifications as per customers’ requirements. Suraj has strong presence in global market. They find applications in refinery, petrochemical, food, pharma, fertilizer, oil and gas, breweries, sugar, shipbuilding, etc. Suraj also holds certificates for quality in accordance with AD2000 MERKBLATT W0 and Pressure Equipment Directives [PED] 97/23/EC from TUV Nord and offer material under all national and international third party inspection. Suraj also have their own lab to examine various tests such as hydro test, eddy current, PMI, IGC, UT, RT, spectroanalysis, mechanical properties and others as per the customers’ requirements. For details contact: Suraj Ltd Suraj House, Opp: Usmanpura Garden Ashram Road, Ahmedabad, Gujarat 380 014 Tel: 079-27540720 Fax: 91-079-27540722 E-mail: suraj@surajgroup.com or Circle Readers’ Service Card 1
Eccentric Helical Rotor Pumps UTPSL offers range of eccentric helical rotor pumps manufactured as per BORNEMANN Germany design acquired by virtue of previous JV par tnership. These pumps have stators and rotors manufactured in special design with longer pitch and low eccentricity. Such design offers a unique advantage of operation with low rubbing speed. Also, this means lower axial forces on bearings and joints. UTPSL single screw pumps are available in range of sizes and combination of MoC. These pumps come with special design sturdy cardon joints, which are sealed against liquid. Pumps are available in different sizes with capacity range up to 200 m 3/hr and pressures 6, 12 and 24 bars and special execution pumps up to 80 bars. UTPSLsingle screw pumps find application in different industries like fruit and pulp processing, construction, breweries, pharma, laboratories, ETP, chemical and petrochemicals, sugar, offshore and ship building, mining and others for handling different liquids like chemicals, sludge, molasses, food and dairy products, effluent, slurries, sand cement mixture and others For details contact: UT Pumps & Systems Pvt Ltd 14/7 Mathura Road, Faridabad, Haryana 121 003 Tel: 0129-4045831, 2274861, Fax: 91-0129-2258584 E-mail: sales@utpsl.in or Circle Readers’ Service Card 2
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Hot Water Unit The hot water generation system consists of hot water storage tank, hot water pump, shell and tube heat exchanger along with associated piping, electrical and instrumentation. The initial make up feed water shall be supplied at ambient temperature and the water temperature shall be raised to 75 °C and circulated in closed loop to the air-handling units. The return water from these air-handling units shall be at 65 °C. Typical system components will be hot water storage tank with dish end; U-tube heat exchanger; circulation/transfer pump; and all interconnecting valves, piping, electrical and instrumentation It finds application in bulk drug and pharmaceutical industries. For details contact: Shree Ganesh Process Equipments Pvt Ltd Plot No: F-82/83, MIDC, B/h ASB Co Addl Ambarnath, Dist: Thane Maharashtra 421 506 Tel: 0251-2620078, 2620742, 2621936, 2621932 Fax: 91-0251-2620079 E-mail: nhattarde@yahoo.co.in / sgec1304@yahoo.com or Circle Readers’ Service Card 3
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40
Road,
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CEW Products Precision Temperature Controller Model 5R7-388 RoHS controller is a bi-directional control for independent thermoelectric modules or in conjunction with auxiliary or supplemental resistive heaters for cooling and heating applications. The “H” bridge configuration of the solid state MOSFET output devices allows for the bi-directional flow of current through the thermoelectric modules. N-channel output devices are used for this control mode. This controller is PC programmable via an RS232 communication port for direct interface with a compatible PC. The easily accessible communications link permits a variety of operational mode configurations. Field selectable parameters or data acquisition in a half-duplex mode can be performed. For details contact: Oven Industries, Inc 5060 Ritter Rd, Bldg C, Suite 8, Mechanicsburg, PA 17055. U.S.A. Tel: (717) 766-0721, Fax: (717) 766-4786 E-mail: sales@ovenind.com / r.wescott@ovenind.com or Circle Readers’ Service Card 4
Axial Flow Fans
Infrared Gas Leak Detector (IR-5000)
Axial flow fans have defined hub ratio type 71 to 25 for given capacity, pressure and speed. Fans are available in 22 sizes from 225 to 2,500 mm in each type. Drive available for direct mounting/V-belt. Impeller blades rest at an angle to suit the system resistance. Fans run in parallel to suit capacity and in series for higher pressure. Impeller made of aerofoil profile from cast aluminium alloys. Bifurcated type fans are available for corrosive/hot gases. Fans available in capacity up to 300,000 m 2/hr and pressure up to 100 mm Wg.
IR point sensors use radiation passing through a volume of gas to detect leaks. Energy from the radiation is absorbed as it passes through the gas at certain wavelengths. The range of wavelengths that is absorbed depends on the properties of the specific gas. Carbon monoxide absorbs wavelengths of about 4.2-4.5 µm. This is approximately a factor of 10 larger than the wavelength of visible light, which ranges from .39 to .75 µm for most people. The energy in this wavelength is compared to a wavelength outside of the absorption range; the difference in energy between these two wavelengths is proportional to the concentration of gas present. This type of sensor is advantageous because it does not have to be placed in the gas itself in order to detect it. Infrared point sensors can be used to detect hydrocarbons, compounds composed of hydrogen and carbon atoms, and other infrared active gases such as water vapour and calcium fluoride. IR sensors is commonly found in wastewater treatment facilities, refineries, gas turbines, chemical plants, and other facilities where flammable gases are present and the possibility of an explosion exists. Engine emissions are another area where IR sensors is being researched for use.
For details contact: Vacunair Engg Co Pvt Ltd Nr Gujarat Bottling, Rakhial, Ahmedabad, Gujarat 380 023 Tel: 079-22910771, Fax: 91-079-22910770 E-mail: info@vacunair.com or Circle Readers’ Service Card 5
Indirect Air Heaters Aero Therm offer automatic oil/gas fired indirect air heater from 30,000 to 600,000-kcal/hr. Max operating temp will be 180 oC for standard models and can be offered higher temp up to 400oC in special construction. Air heater will be equipped with oil/ gas/burner. Direct fired hot air generator up to 600oC also available. For details contact: Aero Therm Systems Pvt Ltd No: 1517, Phase III, GIDC, Vatva, Ahmedabad,Gujarat 382 445 Tel: 079-25890158, Fax: 91-079-25834987 E-mail: contact@aerothermsystems.com or Circle Readers’ Service Card 6
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Ambetronics offers CMRI approved LCD detector with 4-20 mA output in flameproof and weatherproof versions. It is operating on 24 V DC having magnetic pen calibration facility and optional Isolated TWO SPDT relays and RS 485 communication port. For details contact: Ambetronics Engineers Pvt Ltd 17-B, Tarun Indl Estate, Mogra Pada New Nagardas Road, Andheri (E), Mumbai 400 069 Tel. 022-66995525, 28371143 or Circle Readers’ Service Card 7
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CEW Events
INDIA
INTERNATIONAL
ChemTECH World Expo 2015
Powtex Osaka 2013
Dates: 28-31 January 2015 Venue: Bombay Convention and Exhibition Centre, Goregaon, Mumbai Details: World meet of chemicals, petrochemicals, pharmaceuticals and process industry in India Organiser: Jasubhai Media Pvt Ltd Contact: +91 22 4037 3636 Email: sales@jasubhai.com Website: www.chemtech-online.com
Dates: 9-11 October 2013 Venue: INTEX OSAKA (International Exhibition Center, Osaka) Details: The 10 th Powder Technology Exhibition Osaka Organiser: The Association of Powder Process Industry & Engineering, JAPAN (APPIE) Contact: +81 3 5297 8855 Email: info2013@powtex.com Website: www.powtex.com
World PetroCoal Congress
SCM Chem USA
Dates: 15-17 February 2014 Venue: Convention Centre-NDCC, New Delhi, Details: World PetroCoal Congress discusses about the sustainable usage of the nonrenewable resources like coal, petroleum and natural gases. Organiser: Energy and Environment Foundation Contact: +91 11 24538318; +91 11 22758149 Email: punit.nagi@ee-foundation.org Website: www.worldpetrocoal.com
Dates: 4-6 November 2013 Venue: Wigwam Resort and Spa, Phoenix, Arizona, USA Details: SCM Chem USA gives an insight into the emerging business opportunities of the chemical sector Organiser: Worldwide Business Research Contact: +1 888 482 6012; +1 646 200 7461 Email: info@wbresearch.com Website: www.wbresearch.com
India Chem Gujarat
Clean Coal Forum Indonesia 2013
Dates: 24-26 October 2013 Venue: Mahatma Mandir, Gandhinagar, Gujarat Details: A prominent event on chemical industry Organiser: FICCI Contact: +91 11 2373 8760 Email: manoj.mehta@ficci.com Website: www.indiachemgujarat.com
Dates: 4-5 December 2013 Venue: Jakarta, Indonesia Details: Asia’s premier coal event Organiser: China Decision Makers Consultancy (CDMC) Contact: +86 21 6840 7633 Email: ccfi@cdmc.org.cn Website: www.cdmc.org.cn
Industrial Green Chemistry World
Chemexpo Africa
Dates: 6-8 December 2013 Venue: : Renaissance Mumbai Convention Centre Hotel, Mumbai Details: One of the largest Industrial meet on green chemistry & engineering Organiser: Newreka Green Synth Technologies Pvt Ltd Contact: +91 22 2879 1835; +91 222879 1275 Email: krishna.dave@newreka.co.in Website: www.newreka.co.in
Dates: 6-7 November 2013 Venue: Sandton Convention Centre, Johannesburg, SA Details: The large scale chemical related product and service sectors will be offered an outstanding international coverage in Chemexpo Africa Organiser: Quartz Chemicals Ltd Contact: +91 99 204 74017; +27 12 640 4600 Email: kerryleemccarthy@quartzltd.com Website: www.chemspecevents.com
Petrotech
WaterChem China + TECH
Dates: 12-15 January 2014 Venue: Greater Noida, India Details: Petrotech features among the most comprehensive oil, petroleum and natural gas sector trade fairs in India. Organiser: PETROTECH-2014 Secretariat (ONGC) Contact: +91 11 2331 2607; +91 112330 1169/ 1170 Email: exhibition@petrotech.in; secretariat@petrotech.in Website: www.petrotech.in 54 • September 2013
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Dates: 12-14 November 2013 Venue: Shanghai World Expo Theme Pavilion, Shanghai, China Details: A key event for entering china chemical market Organiser: China National Chemical Information Centre Contact: +86 10 6441 7706; +86 10 6441 6187 Email: likediwmj@163.com Website: www.chinaexhibition.com Chemical Engineering World
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Sometimes long lasting materials are the only choice. We provide stainless steel and high performance alloys to meet the safety needs of today’s demanding infrastructure industry. And we are working closely with our partners as they create tomorrow’s clean infrastructure solutions. We know it takes more than off-the-shelf thinking to enable a world that lasts forever.
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CEW Project Update
New Contracts/Expansions/Revamps The following list is a brief insight into the latest new projects by various companies in India. • CHEMICALS Resil Chemicals Private Limited is planning a specialty chemicals manufacturing project in Malur, district Kolar, Karnataka. As of July 2013, land has been partially acquired. The project is in conceptual stage. Other details are yet to be finalized. Macro Polymers Private Limited is planning a 15,000 TPM synthetic resin manufacturing project at a cost of ` 250 million in village Chacharwadi, district Ahmedabad, Gujarat. Land acquisition is in progress. The project is waiting for clearances and is planned for completion on 1st April, 2014. Sika India Private Limited is implementing construction chemicals (waterproofing products) manufacturing project in Jhagadia GIDC, district Bharuch, Gujarat. As of June 2013, civil work is in progress and the project is scheduled for completion soon. Hindusthan Chemicals Company, formerly known as Cyanides & Chemicals Company, is planning an expansion of its sodium cyanide manufacturing project from 5,400 TPA to 12,000 TPA in Olpad, district Surat, Gujarat. As of May 2013, the project is waiting for environmental clearance. Work on the project will commence in 2014 and is planned for completion in 2016. Ardex Endura (India) Private Limited belonging to the Ardex Group, is planning a tile-fixing adhesive, flooring, water proofing and allied products manufacturing project at a cost of ` 100 million in Aerotropolis, Asansol, district Bardhaman, West Bengal. As of March 2013, the project is in planning stage and planned for completion in Q4 of 2014. The estimated land area is 3 acres.
• MINING Sri Venkatesh Granites is planning a colour granite mining project in Kamanpur, district Karimnagar, Andhra Pradesh. As of December 2012, environmental clearance has been received. The project will come up on 4.56 hectare of leased area. Global Enviro Labs is the environmental consultant. Western Coalfields is planning the Penganga open cast coal mining project (3 MTPA and peak capacity is 4.5 MTPA) on 781 hectare land in village Wirur, district Chandrapur, Maharashtra. As of November 2012, the project has been submitted in the 59 th EAC (Thermal & Coal Mining Projects) meeting held on 6 th November, 2012. Central Coal Fields is planning the 0.3 MTPA Ray Bachra underground coal mining project in district Ramgarh, Jharkhand on 1215.45 hectare land. As of September 2012, the project has been submitted in the 57 th EAC (Thermal & Coal Mining Projects) meeting held on 17 th September, 2012. Rajasthan Rajya Vidyut Utpadan Nigam is planning the open cast Parsa East & Kanta Basan coal mining project (10 MTPA) and a coal washery (10 MPTA) in Udaipur, district Surguja, Chhattisgarh. As of August 2012, the project has been submitted in the 55 th meeting of the EAC (Thermal & Coal Mining Pprojects) held on 28th August 2012. Odisha Power Generation Corporation is planning the Manohar pur open c as t c oal mining proje c t in d is tr ic t Sundergarh, Odisha. As of July 2012, the company is waiting for environmental clearance.
Ricela Health Foods is planning a Nutraceutical plant (Oryzanol concentrate) in district Sangrur, Punjab. As of January 2013, the project is in planning stage. Work on the project is expected to commence in 2014.
Chhattisgarh Mineral Development Corporation is planning open cast and underground coal mining project in district Surguja Chhattisgarh. As of July 2012, the company is waiting for environmental and forest clearance.
KPR Fertilisers, belonging to the KPR Group, plans to manufacture 50 TPD dimethyl sulphate,40 TPD linear alkyl benzene sulphonic acid, 50 TPD alum (ferric/non-ferric) and 50 TPD chlorosulphonic acid at a cost of ` 200 million in village Biccavolu, district East Godavari, Andhra Pradesh. As of October 2012, work on the project commenced in January 2013 and is planned for completion in December 2013. The unit currently manufactures 500 TPD single super phosphate, 800 TPD NPK mixtures, 30 TPD dicalcium phosphate and 300 TPD sulphuric acid and has a 3 MW co-generation power project.
Central Coalfields Limited plans expansion of its Churi Benti UGP coal mining capacity from 0.16 MTPA to 0.81 MTPA in district Chatra, Jharkhand. As of June 2012, MoEF clearance has been received and the project is planned for completion in 2 years from zero date.
JBF Industries is planning a 1.25 MTPA purified terephthalic acid manufacturing project in Mangalore, district Dakshina Kannada, Karnataka. As of August 2012, the land for the project acquired. The project will spread over 104 acres of land and is planned for completion in 2014. 56 • September 2013
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Zain Coke & Energy India is planning 150,000 TPA metallurgical coke manufacturing project at a cost of ` 450 million to ` 500 million in Chickanthapura, district Bellary, Karnataka. As of May 2012, The project is waiting for revenue and statutory clearance and is planned for completion in 10 months from zero date. Jaiprakash Associates is planning limestone mining project in village Kothar, district Satna, Madhya Pradesh. As of March 2012, the project is waiting for environmental clearance and the project completion date is yet to be finalized. Chemical Engineering World
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CEW Project Update
• NON-CONVENTIONAL ENERGY Favorich Sugars, belonging to the Favorich Group, is planning a 15 MW bagasse-based co-generation power project in Krishnarajpet, district Mandya, Karnataka. As of January 2013, the company is waiting for land approval from Karnataka Industrial Area Development Board. The project is waiting for financial closure and is planned for completion in 18 months from zero date. The state government had allotted 250 acres of land for the sugar project, distillery and mega food park. Vishwanath Sugar & Steel Industries is planning to expand its bagasse-based co-generation power project from 39 MW to 64 MW in Bellad Bagewadi, district Belgaum, Karnataka. As of October 2012, environmental clearance has been received and the project is planned for completion in 18 months from zero date. The project is coming up in the existing plant premises. The project is waiting for State Pollution Control Board clearance. Green Planet Energy Private Limited is planning a 11 MW biomass-based IPP in village Bir Pind, district Jalandhar, Punjab. As of July 2012, 30 acres of land for the project has been acquired. The project is awarded by Punjab Energy Development Agency on BOO basis. PPA has been signed with the Punjab State Electricity Board. Work on the project commenced in October 2012 and is planned for completion in the Q1 of 2014. • NON-CONVENTIONAL POWER IPL Sugars & Allied Industries, a group company of Indian Potash, is planning a 20 MW bagasse and rice husk-based IPP spread over 250 acres of land in village Motipur, district Muzaffarpur, Bihar. As of March 2012, the existing plant will be demolished and the new plant will be constructed. The project is planned for completion in 1 year from zero date. Tathagata Bio Energy Private Limited plans to set up 12 MW biomass power plant in Gaya, Bihar. As of May 2011, work on the project is under planning stage. • THERMAL POWER Jayaswal Neco Industries Limited is planning a 50 MW waste heat recovery-based independent power project (IPP) in villages Dagori, Ameri Akberi and Udgaon, district Bilaspur, Chhattisgarh. As of February 2013, public hearing for the project is over. MoU is yet to be signed with the State Government. The project is waiting for environmental clearance and is planned for completion in 20 months from zero date. Maharashtra State Power Generation Company is planning a 2×660 MW coal-based thermal power project near Manora, at Tiroda, district Gondia, Maharashtra. As of September 2012, preliminary activity for land acquisition is in progress. 58 • September 2013
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SKS Power Generation (Madhya Pradesh), group company of SKS Ispat And Power, is planning a 2×660 MW super critical coal-based TPP in village Rahiwada and Amarwada, district Chhindwara, Madhya Pradesh. As of August 2012, the project is waiting for environmental clearance and is planned for completion in 1 year from zero date. Rajuri Steels is implementing a 30 MW coal-based captive power project (CPP) in Mul MIDC, district Chandrapur, Maharashtra. As of June 2012, civil work was in progress. The project is scheduled for completion in Q1 of 2014. Jharkhand Sales Agencies is planning a waste heat recovery based thermal power project in village Marhand, district Hazaribagh, Jharkhand. As of April 2012, the project is in planning stage. • POWER GENERATION Sintex Power, belonging to the Sintex Group, is planning a 1720 MW (1×400 MW) gas-based and (2×660 MW) coal-based power project in village Lunsapur, district Amreli, Gujarat. As of June 2013, the project is waiting for the Government approval and is planned for completion in 1 year from zero date. The estimated land area is 600 acres. The main plant will come up on 350 acres, 175 acres land will be for ash pond and 65 acres land will be for onsite utilities. 10 acres land will be required for staff colony. Another 50 acres of land will be required for laying 16 km long water pipeline corridor. The coal required for the plant will be 5.6 MTPA and will be imported from Indonesia and South Africa. 1.65 MMSCD Natural Gas will be supplied by GSPCL. Heidelberg Cement India Limited is planning a 12.5 MW waste heat recovery based power project at a cost of ` 1,450 – ` 1,500 million in Narsingarh, district Damoh, Madhya Pradesh. As of February 2013, the project is in planning stage and planned for completion in January 2015. The project has been approved by the Board. The plant will produce approximately 12.15 MW of power from available waste heat of pyro-processing system of all three clinkerisation lines at Narsingarh. • FERTILISER TJ Agro Fertilizers plans an expansion of its fer tilizer manufacturing unit (single super phosphate from 24,000 TPA to 34,000 TPA and granulated single super phosphate unit from 10,000 TPA to 20,000 TPA) in Khadsupa, district Navsari, Gujarat. As of July 2012, the project is waiting for environmental clearance and is planned for completion in 1 year from zero date. Aero Agro Chemical Industries Limited plans to set up 600 TPM agro chemicals manufacturing unit in Bharuch, Gujarat. As of August 2011, the project is waiting for pollution clearance. Chemical Engineering World
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Who’s Who th 14 Edition
Who’s Who is an exhaustive listing & fact book on CHEMICAL PROCESS, PHARMA BIOTECH, HYDROCARBON INDUSTRY & INDUSTRIAL SAFETY
AN ISO 9001:2008 CERTIFIED COMPANY
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CHEM
Versatile and precise
High precision gear pump for the chemical industry The CHEM gear pump can be used for a wide range applications from low to high viscosity. It is well suited for high temperature, vacuum inlet conditions and high discharge pressure. Applications can range from liquid metering to basic transfer tasks. Pumps of this type can be supplied electrically heated, jacketed or without heating. The available materials of construction and design options provided by WITTE offers our FXVWRPHUV PD[LPXP À H[LELOLW\
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WITTE PUMPS & TECHNOLOGY GmbH
Goodie International Pvt. Ltd.
Esinger Steinweg 44a
67, Okhla Industrial Estate,
25436 Uetersen / Hamburg / Germany
Phase - 3, New Delhi - 20
T: +49 (0) 41 22 / 92 87 - 0
T: 011 4161 3643 - 44 - 45
F: +49 (0) 41 22 / 92 87 - 49
F: 011 4161 3646
e-mail: info@witte-pumps.de
e-mail: witte@goodiesons.com
www.witte-pumps.com
www.goodie.in
More information about our services and products is available on our website. Scan barcode with your mobile device and get more information.
September 2013 • 61
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CEW Book Shelf Cooling Water Treatment Principles and Practices: Charts and Notes For Field Use Authors Price Pages Publisher
: Colin Frayne : USD 42.75 : 50 [Paperback] : Chemical Publishing Company
About the Book: In this handbook you will find many helpful formulas for use in the field such as formulas for: Refrigeration in cooling towers, Conductive heat flow, General industrial and cooling water makeup contents, Coagulants and flocculants, Filter types, Water softeners, Commonly found corrosion types, Mineral and silica deposit types, Equations for solving pH, Common bacteria and Fungi types, Inhibitor components, A suggested biocide selection chart for comfort cooling systems, A cleaning and disinfection program for cooling systems, and Cooling water control parameters.
Thermoforming: A Plastics Processing Guide, Second Edition Authors : Geza Gruenwald Price : USD 199.45 Pages : 241 [Hardcover] Publisher : CRC Press About the Book : Dr Gruenwald has indicated the desirable properties of polymerics for differing applications; thus, the book is especially useful for polymer chemists who must “tailor” plastic materials for specific groups of applications. Engineers in extruding and calendering film and sheet will benefit from the intimate relationships elucidated between processing parameters imposed upon stocks employed in thermoforming and the products thereof. Mold designers are provided with a complete guide that will enable them to avoid the less obvious pitfalls and wasted effort so often experienced in the evolution of molds for (especially) complex parts. Quite likely, Dr Gruenwald’s suggestions will lead to considerable benefits to those who read and practice by this remarkable exposition of thermoforming technology.
Petroleum and Gas Field Processing Authors Price Pages Publisher
: H K Abdel-Aal, Mohamed Aggour, M A Fahim : USD 164.84 : 364 [Hardcover] : CRC Press
About the Book : The immediate product extracted from oil and gas wells consists of mixtures of oil, gas, and water that is difficult to transport, requiring a certain amount of field processing. This reference analyzes principles and procedures related to the processing of reservoir fluids for the separation, handling, treatment, and production of quality petroleum oil and gas products. It details strategies in equipment selection and system design, field development and operation, and process simulation and control to increase plant productivity and safety and avoid losses during purification, treatment, storage, and export. Providing guidelines for developing efficient and economical treatment systems, the book features solved design examples that demonstrate the application of developed design equations as well as review problems and exercises of key engineering concepts in petroleum field development and operation.
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Thermochemical Processing of Biomass: Conversion into Fuels, Chemicals and Power Authors : R o b e r t C B r o w n , Christian Stevens Price : USD 88.99 Pages : 350 [Hardcover] Publisher : Wiley About the Book : Thermochemical pathways for biomass conversion offer opportunities for rapid and efficient processing of diverse feedstocks into fuels, chemicals and power. Thermochemical processing has several advantages relative to biochemical processing, including greater feedstock flexibility, conversion of both carbohydrate and lignin into products, faster reaction rates, and the ability to produce a diverse selection of fuels. Thermochemical Processing of Biomass examines the large number of possible pathways for converting biomass into fuels, chemicals and power through the use of heat and catalysts. The book presents a practical overview of the latest research in this rapidly developing field, highlighting the fundamental chemistry, technical applications and operating costs associated with thermochemical conversion strategies. Bridging the gap between research and practical application, this book is written for engineering professionals in the biofuels industry, as well as academic researchers working in bioenergy, bioprocessing technology and chemical engineering. Chemical Engineering World
02-10-2013 21:27:44
Chemical Engineering World
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CEW Interview
Expanding the Product Basket
The ambitious integrated refinery expansion project at Kochi Refinery will increase total refining capacity of BPCL by 20 per cent from current capacity of 30.5 MMTPA and pump additional 5.3 MMTPA of petroleum products in the Indian market. Prasad K Panicker, Executive Director, Kochi Refinery BPCL, speaks exclusively to CEW and provides insights into the modernisation of existing units, upgrading of residue streams to produce value added products to the company’s basket and the proposed petrochemical complex.
What kind of production is BPCL targeting through proposed integrated refinery expansion project (IREP) at Kochi refinery? The demand of petroleum products is growing at a healthy rate which is encouraging refiners to increase their refining capacities. The IREP of BPCL, which is being implemented at Kochi, is an effort to meet the country’s growing
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energy needs and making auto fuels more environmentally friendly. Present refining capacity of BPCL is 30.5 MMTPA. Post implementation of IREP, the refining capacity would be 36.5 MMTPA which is about an increase of 20 per cent in refining capacity. An additional 5.3 MMTPA of petroleum products will be available in the market after the expansion.
The estimated cost of the IREP is `14, 225 crore. The project is targeted to be completed by December 2015. The project envisages increasing the current Kochi refining capacity by 6 MMTPA from the present 9.5 MMTPA to 15.5 MMTPA and producing propylene as the feedstock for BPCL’s proposed petrochemical complex. We are modernising the
Chemical Engineering World
02-10-2013 21:35:48
Chemical Engineering World
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CEW Interview refinery to produce auto fuels complying with Euro 窶的V & Euro V specifications and upgrading the residue stream from the refinery to value added products to minimise heavy stream generation from the refinery. The capacity expansion by 6 MMTPA will be facilitated with installation of a new state-of-the-art energy efficient Crude Distillation Unit (CDU) which will replace the existing 4.5 MMTPA CDU-1, is now quiet old and energy inefficient. This will result in substantial energy savings and reducing energy footprint. We have also envisaged associated process units like Delayed Coker Unit (DCU), Fluid Catalytic Cracker Unit (FCCU), VGO Hydro-treater (VGO HDT), Diesel Hydrotreater (DHDT) Sulfur Recovery Unit (SRU) and Hydrogen Generation Unit (HGU), etc along with matching Utilities and Off-site facilities as part of the IREP expansion at Kochi refinery. Tell us about the proposed plan of `6000 crore to venture into the downstream petrochemical business with the propylene supplies from the proposed expansion? As a value addition, we have envisaged propylene-based petrochemical unit through joint venture, and are currently in talks with some major petrochemical companies to partner for technology and marketing expertise. Propylene, a petrochemical building block produced directly from the refining facility, will be used as the petrochemical feedstock to produce niche petrochemical products like Acrylic acid, Acrylates, Super Absorbent Polymer (SAP), Oxo-alcohol etc. The petrochemical unit will be implanted in tandem with the refinery expansion project. What kind of opportunities will the expansion of Kochi refinery offer for the further downstream industry in Kerala and other Southern part of the country? Once the project is implemented the products available for the market include Propylene, Naphtha, Motor Spirit (MS), Liquified Petroleum Gas (LPG), Superior Kerosene Oil (SKO), High Speed Diesel (HSD), Air Turbine Fuel (ATF), Furnace Oil/Low Sulphur Heavy Stock (FO/LSHS) 66 窶｢ September 2013
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fuel oil, Bitumen, Sulphur, and Petcoke. Further, Kochi refinery will commence production of 1.3 MMTPA petcoke - a new product that will be offered as well. Petcoke can be used as fuel for the cement plants located in Andhra Pradesh and Tamil Nadu, and other than that there is also a possibility of setting up petcoke based power plant. The cost of power generation is comparable with coal and cheaper as compared with the power generated from other thermal sources such as naphtha. As instructed by the Government of Kerala, the teams of Kerala State Electricity Board (KSEB) and BPCL have carried out a joint study to prepare a Preliminary Feasibility Report for the proposal of setting up a Petcoke-based 500 MW capacity power plant in Kochi. Additional sulfur production will benefit Kerala based industries like the Fertilisers & Chemicals Travancore Ltd (FACT) and Travancore Titanium Products Ltd. Production of petrochemical derivatives of propylene and products like Acrylic acid, Acrylates, N-butanol etc will open multitude of entrepreneurial opportunities for investors to set up downstream units to produce petrochemical products. Which are the key markets earmarked for production and how do you plan to move the increase in production from the refinery to the users (India & overseas) There is a healthy demand of petroleum products in the country; however, we are targeting the Southern part of the country, mainly Kerala, Tamil Nadu and parts of Andhra Pradesh. We will supply the products partly to other major demand centers either in the Western and the Eastern regions as well. Additional products produced post IREP would be moved through rail, road and pipelines to the demand centres, and naphtha would be exported through tankers. Presently, there is a pipeline connectivity from Kochi to Coimbatore and Karur which we intend to extending up to Bangalore. Have you received clearances for the proposed Kochi Coimbatore LPG pipeline for transferring additional LPG and also extension to Devangonthi? There is a proposal to lay a LPG pipeline from Kochi to Coimbatore to transport
Product
Present
Post IREP
Propylene
50
500
LPG
480
1088
MS
1115
1894
SKO
360
240
HSD
4384
7882
ATF
400
600
Naphtha
392
617
FO/ LSHS
1400
0
Bitumen
250
250
Sulphur
33
277
Petcoke
0
1338
(TMT)
(TMT)
Table 1: Available products post implementation of IREP at Kochi Refinery , BPCL
additional LPG post implementation of planned IREP. The proposal is submitted to the Petroleum & Natural Gas Regulatory Board (PNGRB) for approval. We will get into action once we receive the necessary clearance from PNGRB. As far as extension of Kochi Coimbatore POL pipeline is concerned, the line will be extended to Devangonthi which is near to Bangalore. The proposed pipeline also needs clearance from PNGRB and the bidding process is going on. The bid will be opened by January 2014. How are you handling the subsidies imposed by the Government on the oil marketing companies? Subsidies are provided to compensate the under recoveries when retail products are sold to the customers. Refinery gets Refinery Transfer Price (RTP) which is calculated based on the international product prices. How has the depreciation of rupee against dollar by almost 44 per cent in the last two years impacted Gross Refining Margins (GRM) of Kochi refinery? It is a fact that the raw material has increased, but the GRM of our refinery has seen a marginal impact which is primarily due to corresponding increase in product prices globally. However the retail selling prices of some of the major petroleum products are capped and thus affected the market margins and the profitability of the company on the whole. Chemical Engineering World
02-10-2013 21:35:49
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CEW Interview
Balancing ‘Risks vs Rewards’ Equation
With many major projects in hand, Technip India is poised to play a crucial role in the development of chemical, petrochemical and oil & gas industry in India. In an exclusive interview with CEW, Samik Mukherjee, Country Head & Managing Director, Technip India, elucidates how the company has grown manifolds over the years, things that differentiate the company from other EPC players, and challenges the industry face today. EPC model has somehow not been very successful in the Indian context vis-à-vis other countries, where the manufacturers are ramping up the production facilities. Your comments ? Actually, EPC model in India is quite a popular practice amongst the public sector industries and most of the private players who do not have a large owner’s team. They prefer to partner with a company as a single point responsibility to deliver the Engineering, Procurement and Construction components of a project at a fixed cost within a defined schedule. Yes, a few private sector entities like the Reliance and Essar have their own resources to execute the Procurement or Construction part
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of the EPC chain. Also, we should not overlook that whenever a client goes in for financing, the lending Banks insist for an EPC mode of execution. What are the latest trends in globally & Indian EPC industry? The recognised model of project execution inside India is the lumpsum EPC model. In some cases depending upon own resources, some clients prefer the EPCM services model, where the contractor has to provide all services for Engineering, Procurement and Construction management, but the actual purchase of equipment and doing the civil construction and erection of the plant are done under
the direct responsibility of the client through orders placed with concerned vendors/contractors. As for global trends in the Industry, the most popular model because of growing size and complexity of projects is to adopt a FEED converted LSTK-EPC model, wherein the client selects a contractor based on a FEED bid along with stipulated conversion norms to an LSTK-EPC. After the FEED, it is normal for a contractor to give highly accurate cost estimate of the project. This minimises the definition uncertainties, improves the accuracy of the estimate for equipment and bulks and provides the right basis
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CEW Interview for construction costs. Also, it reduces the project execution time. This integrated client-contractor approach is applied by most of the large IOCs (International Oil Companies) for their projects. This mode of execution is yet to become popular in India. How has the company evolved as a strong EPC player over the years ? We have been able to achieve this position with our consistent focus on Energy business and our commitment to deliver safe and successful energy projects throughout the world for the benefit of our stakeholders. In the past years, our strategic acquisitions of companies like Coflexip has allowed us to move into the Subsea and Offshore market; Mannesmann that brought in KTI having a leading position in Ethylene, Hydrogen, Furnaces and Heaters; Global Industries that brought in experience in shallow water pipe laying expertise and assets; Stone and Webster’s Process Division that opened up a range of Process technologies and a host of smaller firms bridging small gaps that existed in our value chain of the Energy business. With a growing workforce of 38000 and presence in 48 countries, Technip is present across the value chain in 3 business segments – Subsea, Offshore and Onshore. In India, with more than 2700 people steered by a strong country management team and offices in Delhi, Mumbai and Chennai, we have strong expertise and capability to provide a complete range of services from licensing, basic engineering to full EPC projects – ‘Concept to Commissioning’ to Refineries, LNG, Petrochemical Industries and Offshore. How do you maintain transparency business relationships? Technip values all its stakeholders. Our core attitude is driven by our tagline “Take it further”. This is our approach to business, partnership and aspirations. Our value system ensures that we do the right thing, trust the team, build the future and ensure a fair return to all stakeholders. The value system guides us every day in our actions towards our clients, partners, suppliers and sub-contractors. What strategies the company has adopted to distinguish itself from other Players? Energy world is moving to harsher climates and deeper areas to seek resources with larger size of projects leading to innovation 70 • September 2013
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in technologies, complex and large equipment and cutting edge materials. Our R&D and innovation approach is to maintain a clear link with these trends. Our core expertise in all three segments i.e. Onshore, Offshore and Subsea helps us offer unique integrated solutions like FLNG that is pioneered by Technip. Our consistent focus on R&D, commitment towards safety, high skilled workforce and sustainable tie-up with quality suppliers, subcontractors and own process technologies through recent acquisition of Stone & Webster Process Division make us a ‘partner of choice’ for our clients. There is a very strong perception about the EPC contracts being more inclined towards the project owners as compared to the contractors. As an EPC player, what are the major that risks arise in such a scenario? EPC business is all about sharing the risks with the client associated with the setting up of a project. The risk vs reward equation needs to be more balanced. However, clients have the inclination to pass on significant risks towards the contractor which it cannot manage thus increasing the costs and risk of the project. Owners have more control on various parameters related to site information, permitting, third party management etc. Technip would like contract conditions to be fair for both the owner and the contractor. It would lead to low cost and timely completion of a project. Lack of manpower, machinery & efficient logistic mechanism are some of the crucial factors that cause delays of projects in India. Your comments? This is a high risk element during project execution. Managing risks and mitigating them continuously throughout the project execution phase is paramount for any successful EPC contractor. We at Technip, focus on a detailed planning taking all factors and risks associated to the project execution into consideration before venturing into any tender. Also, our worldwide skilled, welltrained growing workforce of 38,000, a strong talent oriented HR policy and our sustainable, long term relationships with leading equipment manufacturers and bulk material suppliers worldwide ensure us to deliver projects within timeline. Declining rupee has dampened the investors’ interest in Indian market and
companies are putting their plans to pursue new projects on the back burner. In such a scenario what are the strategies contractors are adopting to maintain the positive growth momentum? The declining rupee has two-fold effect with an upward cost of imports of raw materials to India but a decrease in the cost of services and material exported from here resulting an attractive positioning for India in the global market. Therefore, we need to have a good balance of domestic and international projects. Technip Group - with its global presence across the five continents and in 48 countries - has been able to sustain the growth momentum due to its large market access, presence in 3 segments, scale of operation and a talented resource pool closer to customers. How do you see the business climate in India for future investments? We do not foresee major changes in the EPC business till the second half of 2014 since the country is due for general elections. Clients and contractors have to work more in an integrated manner. Enhanced transparency, balanced sharing of risks, adequate and timely funding and partnering with a professional EPC contractor having a good hold on long lead equipment deliveries are few necessary steps to accelerate the pace of project execution. Tell us about your company’s on-going projects and future projects in the kitty? In India, our major ongoing projects are Reliance’s largest and first in the world 1.4 MTA refinery offgas cracker project in Jamnagar with our ethylene technology, JBF Industries world’s largest 1.25 MTA PTA plant in Mangalore with BP technology and a large process platform offshore project for ONGC with our own float over technology. Also, we are involved in BPCL’s expansion project in Kochi and Mumbai Refinery. In addition, we are just completing the engineering for the first FLNG project for Shell and a Refinery in Algeria together with Technip Group entities. Both in local and international market we are expecting to get few projects in the coming months in onshore and offshore segments. Further, we are keeping a close watch on non-oil & gas segments like nuclear, metals and mining, renewables and life sciences to seek areas where we can add value to our customers. Chemical Engineering World
02-10-2013 21:34:15
STRONGER COMPANY
STRONGER FOUNDATION Jasubhai Engineering Private Limited is a flagship company of Jasubhai Industries and a pioneer organisation in the field of Instrumentation, Equipment Supply and Engineering, catering to process industries, since 1979.
COMBUSTION ENGINEERING SOLUTION DIVISION • Oil and Gas-fired Burners • Hot Air Generators • Fuel Handling Systems
MATERIAL HANDLING DIVISION • The leader in Weighing, Packing & Systems Control • Electro-pneumatic Nett Weighers (EPG) • Automatic Loadcell based Nett Weighers (UBM-85) • Automatic Loadcell based Gross Weighers (AGE) • Mechanical Gross Weighers (AG) TURNKEY PROCESS AUTOMATION DIVISION • Project Engineering • System design & detailed Engineering • Procurement and Quality Assurance • Panel Integration • Installation and Testing • Erection & Commissioning Site Services PROCESS EQUIPMENT • Valve and Valve Automation • High Pressure Vessels
JASUBHAI INTERNATIONAL FZCO Jasubhai International FZCO is a pioneer organization setup at JEBEL ALI free zone at DUBAI to provide integrated & single point solutions to the need of Control Panels. Area of Specialisation • System Design and Detailed Engineering • Procurement & Quality Assurance • Installation, Testing and Commissioning
JASUBHAI ENGINEERING PVT LTD 110, Thacker Tower, Plot No 86, Sector 17, Vashi, Navi Mumbai - 400 705, Maharashtra, India. Tel: +91-22-42136300 / 6400 Fax: +91-22-42136399 Web: www.jasubhaiengineering.com,www.habonim.com
CEW AD - JEPL.indd 1
REGISTERED OFFICE AND MANUFACTURING FACILITIES 64/a, GIDC Industrial Estate, Phase -1, Vatwa, Ahmedabad - 382445, Gujarat, India. Tel: +91-79-25831042 Fax: +91-79-25831825 Website: www.jasubhaiengineering.com HEAD OFFICE 110, Thacker Tower, Plot No 86, Sector 17, Vashi, Navi Mumbai - 400 705, Maharashtra, India. Tel: +91-22-42136300 / 6400 Fax: +91-22-42136399 Email: sales_ces@jasubhai.com Vadodara 202, Concorde, R. C. Dutt Road, Alkapuri, Vadodara - 390 005, Gujarat, India. Tel: +91-265-2352647 Fax: +91-265-2337189 Chennai Jhaver Plaza, 1st floor, 1-A, Nungambakkam High Road, Chennai - 600 034, Tamil Nadu, India. Tel: +91-44-42327728 New Delhi 803, Chiranjiv Tower, Nehru Place, New Delhi - 110 019, India. Tel: +91-11-46745555 Fax: +91-11-26427404 Kolkata 44/B Creek Row, Ground Floor, Kolkata - 700 014 Mob: + 91 90380 57380 Tel: +91-33-22317344 / 7346 Fax: +91-33-24420176 INTERNATIONAL OFFICE Jasubhai International FZCO FZS2 AC01, P O Box: 18403, Jebel Ali, Dubai, UAE. Tel: +97-148860704 / 8862991 Fax: +97-148860705
OUR THREE VITAL COMMITMENTS CARE - Customers CA s Are re Re eally al y Everything ve erything n CO - CO COIN C ntinuous n Imp mprovements ve eme ments n are Needed TR - TR TRAC T aining a Acc c mp ccomplishes m lis lish he Competence m
03-10-2013 13:11:05
CEW
South Special
Company Profile
Glasfab Scientifics
G
lasfab Scientifics is one of the leading manufacturers of laboratory and process glass wares since 1956, and serving almost all the chemical, pharmaceutical, drug, aromatic, and allied educational and research institutions, In the recent years, we have gained government tenders and contracts in institutions like ISRO and IGCAR, and due to our dedicated service and skills of designing complicated and new equipment for these institutions we have been treated as one of the esteemed suppliers.
manufacturing, testing, graduating, and annealing facility. The company takes pride in complete installation facility to install and demonstrate the new equipment before dispatching them to the site.
Glasfab Scientifics was established in 1980’s by D Narayanasamy, one of the profound glass engineers in this field. D Narayanasamy gathering his experience since 1956 established Glasfab Scientifics as a very modern unit for glass blowing and for handling bigger projects - all under one roof.
Further, company’s new project is already set to take off at Bangalore with the collaboration with an American firm for manufacturing process equipment, PTFE and lined equipment which will hopefully start functioning at the end of 2014.
The company was then handed over to N Satheesh Kumar (Masters in Economics and Glass Engineering), who is now the proprietor of the company. Leveraging on Kumar’s expertise in process glass wares and process equipment, and Narayanasamy’s expertise in designing and manufacturing new lab equipment, the company achieved tremendous success in its domain. Glasfab’s facilities, located in Chennai and Bangalore are equipped with complete modern 72 • September 2013
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The organisation have an expert team of engineers to monitor and improve upon quality and at the time of installation at site.Due to immense strcitness from quality control department, the products have significant value in the market.
Contact Details: Glasfab Scientifics N Satheesh Kumar Mobile: 09444404538 Email: glasfab@hotmail.com Website: www.glasfabindia.com Chemical Engineering World
02-10-2013 21:39:38
First Indian company with Clean room coating facility. First Indian Coating Company to recieved Training at M/s. Solvay Solexis SPA Italy Coating Facility
www.ftcoat.in
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CEW
South Special
Interview
APIIC: Leveraging on ‘Andhra Advantage’
Jayesh Ranjan Vice Chairman & Managing Director, Andhra Pradesh Industrial Infrastructure Corporation
With a number of investments from domestic and international players, Andhra Pradesh has certainly emerged as a favourite destination for both start-ups and expansion of business horizons. Favourable business environment in the state has played a crucial role in attracting investment.
APIIC 6th Floor, Parisrama Bhavan Fateh Maidan Road, Basheerbagh Hyderabad – 500 004 Andhra Pradesh, India Tel: +91 40 2323 7622; 2321 2798 Fax: +91 40 2323 3393; 2323 3251 Email: hyd@apiic.in
74 • September 2013
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Will you please brief us on Andhra Pradesh (AP) favourable business environment? AP is among the top 3 states of the country for preferred industrial investments. Leveraging on various advantages such as second largest mineral store house of India, second longest coast line of 974 kilometres, presence of top 85 global corporate houses, huge agriculture and horticulture production capacities, an exclusive Aerospace SEZ and helicopter cabin manufacturing facility by TATA in JV with Sikorsky Aircraft Corporation, globally recognised and fastest growing base for IT & IT enabled services, investor-friendly and proactive policies which are rated one of the best in the country, Andhra Pradesh (AP), over the years, has emerged as a favourite destination for investment. The state is an important producer of iron and steel, and also known as the granite power house of the country. Besides, AP is the first to sign MoU with Hindustan Petroleum Corporation Limited (HPCL) for Petroleum, Chemicals and Petrochemicals Investment Region (PCPIR) between two industrialised regions namely Visakhapatnam and Kakinada which are spread over an area of 604 Sq KMs. The state has been able to be on the forefront in building its intellectual capital with well-known institutions in the world and number of centers of excellence for training. AP is known as Tourist and business traveller’s paradise and boasts of good quality of life with wide ranging facilities for leisure, culture and recreation. What are the advantages for Pharma Industry? Hyderabad is the Bulk Drug Capital of India accounting for one-third of the total production. The state produces a majority of 500 basic drugs produced in the country that makes it second leading exporter of bulk drugs. Over 2500 pharma companies are located in AP. The state is the leading centre for biotechnology and known as Vaccine Capital of India. The industry accounts for 43 per cent of the total biotech revenue generated by companies in South India (US$ 1104 million). There are
lots of opportunities for manufacturing of bulk drugs & pharma, generics, pharmaceutical formulations and contract R&D. The state also takes pride in a strong R&D base as several prominent institutions are present in the state. ‘Hyderabad is known as the Pharma capital of India and AP as the pharma state of India. According to you what set of factors led to the growth of pharma industries in AP? AP has grown into a pharma hub for bulk drugs basically for two reasons. Historically, it is because of Indian Drugs & Pharmaceutical Limited (IDPL) and entrepreneurship & availability of adequate talent pool in the state. The Indian pharmaceutical Industry, today, is in the front rank of India’s science-based industries with wide ranging capabilities in the complex field of drug manufacture and technology. A highly organised sector, the Indian pharma industry is estimated to be worth $ 4.5 billion, growing at about 8 to 9 per cent annually. It ranks very high in the third world, in terms of technology, quality and range of medicines manufactured. From simple headache pills to sophisticated antibiotics and complex cardiac compounds, almost every type of medicine is now made indigenously. The sector is highly fragmented with more than 20,000 registered units. It has expanded drastically in the last two decades. The leading 250 pharmaceutical companies control 70 per cent of the market with market leader holding nearly 7 per cent of the market share. It is an extremely fragmented market with severe price competition and government price control. The industry, which is now meeting over 95 per cent of the country’s pharmaceutical needs, was almost non-existent before 1970. With the compound annual growth of 19.8 per cent, the industry has grown from `4 billion in 1970 to ` 290 billion in 2003. The pharma sector has shown tremendous growth over the years. Bulk drug manufacturing is largely concentrated in AP, which accounts for more than one-third of the country’s total bulk drug production, followed by Gujarat. Chemical Engineering World
02-10-2013 20:43:31
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Chemical Engineering World
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CEW
South Special Infrastructure Facilities in Andhra Pradesh Connectivity
Power
• Hyderabad International Airport – First Greenfield Airport in Asia • Existing Visakhapatnam and Tirupati Airports are being upgraded to International Airport • Existing Chennai International Airport is just one hour road drive from TADA Industrial Park • Existing Bangalore International Airport is just one and half hour drive from Hindupur Industrial Growth Centre, Ananthapur District • Andhra Pradesh is considered to be the secondhighest cargo handling state in India • The state has one major port at Visakhapatnam, two intermediate ports and 11 minor ports within the state • One more major port is planned in AP by Government of India
• The state has been awarded as the Best Power Utility in the country for 2010 • Total installed capacity in AP is 15,768 MW – second largest power utility in the country • Capacity addition of 5000 MW by June 2014 and 17,000 MW planned by June 2015 • Power Tariff for industrial consumers is one of the lowest in the country
AP Boast of strong R&D Base • Defence Research Development Organisation (DRDO) • Defence Electronics Research Institute • Defence Metallurgical Research Institute • Indian Institute of Chemical Technology (IICT) • Centre for Cellular and Molecular Biology (CCMB) • National Institute of Nutrition (NIN) • Centre for DNA Fingerprinting and Diagnostics (CDFD) • International Crop Research Institute on Semi-Arid • Tropics (ICRISAT) • ICICI Knowledge Park • Central Institute of Tool Design • DuPont R&D Centre • NEKTAR R&D Centre • National Technical Research Organization (NTRO) The Indian bulk drug industry has lately been gaining significant presence in the global market as foreign and multinational companies are looking to sourcing APIs and intermediates from Indian manufacturers. Factors favoring the industry are vast resources of technical people, state-ofthe-art manufacturing facilities, low cost and the advantage of the English language. As a part of government’s support to increase exports, Special Economic 76 • September 2013
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Zones/Duty Free Zones have been set up and several manufacturers of bulk drugs have been shifting their facilities to these areas. As a result, the diverse spread has now started getting consolidated and concentrated in certain regions across the country. Today, there are six SEZs in the state developed for pharmaceuticals industry. Today, AP-based pharma companies manufacture the maximum number of APIs. Thus, Andhra Pradesh is home to many pharmaceutical units.
expo is expected to be high which would bring more exposure and promotion to their business. The companies expect to take advantage of the B2B meetings during the show and expect to improve their networking which would result in improved sales. We (all participating companies from AP) expect to take advantage of the new technologies in the fields of chemical, pharma and automation being displayed in the expo and would explore the possibility of adapting new technologies in our companies so as to become cost effective and more profitable. The number of companies expected to participate in the expo from the state of Andhra Pradesh is about 8 to 10. The companies expected to participate are from the Bulk Drug and Pharmaceutical sectors.
What services does APIIC offer? • APIIC has fully fledged Engineering wing • Provides Infrastructure facilities to all IPs/SEZs/IT Parks • Services include provision of : • Internal Roads and External Connectivity • Water Supply • Power Supply • Storm Water Drains & Internal Drainage arrangements • Buildings works • Deposit contribution works to Government Departments • JV Projects • CETPs and STPs • Obtaining Environmental Clearance What are your comments on ChemTECH South 2013? The expo being organised in Chennai has advantages for Andhra-based companies due to the proximity of the location to the state. The number of visitors to the Chemical Engineering World
02-10-2013 20:43:32
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CEW
South Special
Guest Column
Outokumpu: 80 Years of Duplex Experience While some people may perceive duplex stainless steel to be a relatively new phenomenon, Outokumpu has been producing grades of this leading material for over 80 years. Describing duplex as the most sustainable steel, the company supplies a wide range of industries and continues to innovate to provide the best possible value-added products and after-sales services to its diverse customers around the world. The article explains the company’s long history, the many uses of this versatile metal and emerging applications for duplex stainless steels in the global market.
Yatinder Suri
Country Head,Outokumpu India Pvt Ltd
O
utokumpu’s history in producing duplex dates back to the 1930s when the first grades were developed to overcome shortcomings in the austenitic grades available at that time such as limited strength, susceptibility to intragranular corrosion due to difficulties to reach low carbon contents and issues related to stress corrosion cracking especially in the pulp and paper as well as chemical industry. Originally production was focused mainly on castings for the pulp and paper, chemical and petrochemical industries. Today, while the oil and gas and chemical processing industries are the main consumers of duplex stainless steels, significant quantities are also used for architecture and construction, pulp and paper, desalination plants and chemical tankers.
Outokumpu India Pvt Ltd 609-612, Hemkunt Tower Nehru Place, New Delhi-110019, India Tel: +91 11 4651 8440 / 41 Fax: +91 11 4651 8439 Email: yatinder.suri@outokumpu.com Website: www.outokumpu.com
Technological developments for stainless steel production in the late 1960s and 1970s such as the AOD converter technology made it possible to have lower carbon contents and to put more nitrogen into the steels and particularly into duplex, leading to the production of the so-called ‘second generation’ of duplex grades. These are renowned for their improved properties such as mechanical strength and corrosion resistance. Duplex grade 2205 is still the working horse in oil & gas applications. In the past decade another trend has emerged: lean duplex grades. Duplex stainless steels with
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low contents of expensive and volatile alloying elements such as nickel and molybdenum content giving low alloying costs are starting to replace commodity stainless grades like 304 and even 316. It’s also meant that it has become interesting to consider using duplexes for ‘commodity’ applications, where the requirements for the corrosion resistance are moderate but where the customer can benefit from the outstanding mechanical properties of the steel. For example demand for duplex in the building and construction industry in particular has grown due largely to these latest developments. Outokumpu have also been promoting lean duplex grades for storage tanks, from food and beverage applications, where tanks are used for anything from wine to olive oil, to tanks for the chemical and petrochemical processing industries where duplex performs extremely well. Recent Duplex Projects When considering where most duplex stainless steels are being used today there is no denying that tube manufacturers are placing very large orders, particularly those located in Germany and Italy. However new end-users are also turning to duplex. German pump and tank manufacturer Börger approached Outokumpu when they needed to fabricate larger biogas tanks than ever before, starting at 4,000 m 3 . The company chose the Outokumpu’s proprietary duplex grade LDX 2404 ® for storage tanks and a combination of LDX 2404 ® and LDX 2101® for its Chemical Engineering World
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Portable Ultrasonic Flowmeter, Image Courtesy: Cole-Parmer
process tanks. Switching from austenitic to duplex stainless steel reduced the weight of the tanks by 25 per cent. For a project for Dow Chemicals in the Netherlands, Outokumpu received an order for lean duplex material to be used in two tanks at Dow’s Terneuzen plant, the first time they have applied this lean duplex material. While the weight saving potential is always a factor – the tanks measured Ø22 x 21 m – the main focus was to optimise maintenance and inspection requirements. Terneuzen is located on the North Sea coast in a corrosive marine environment where carbon steel tanks need to be coated internally with epoxy resin and even stainless steel equipment is painted externally to prevent corrosion. Duplex stainless steels are not prone to chloride stress corrosion cracking like standard austenitic stainless steels, therefore painting can be avoided. The higher strength of lean duplex compared to carbon steel and austenitic stainless steel enabled the customer to down-gauge the wall thicknesses, saving both material and fabrication costs. Ultimately this results in lower life cycle costs as there is no need to renew the coatings, resulting in uninterrupted availability of the tanks as there is no longer a need to empty the stored water for maintenance purposes. It is this kind of life cycle thinking that makes duplex a sustainable material. Clearly there are applications 80 • September 2013
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around the globe utilising carbon steel tanks and construction elements, where lean duplexes could be used to eliminate painting and maintenance and improve availability. The offshore industry is also driving developments in duplex grades. The ultradeep oil reserves in Latin America mean the operating pressure for equipment is increased, the riser pipes bringing the oil from the well to the surface need to be longer and therefore heavier, and the wells are more corrosive. Simply put, we need materials with higher mechanical properties that can carry their own weight, creating a need to look into higher mechanical strengths for duplex grades. Outokumpu is working in cooperation with oil and engineering companies to develop lean duplex grades for structural components on oil rigs. This is largely motivated by maintenance and safety issues; lean duplexes eliminate the need to paint equipment which is a costly exercise on an oil platform. The weight factor is also important in this environment; using a material with higher mechanical properties means you can decrease wall thicknesses and reduce weight. Identifying the Right Grade How to identify the right duplex grade to use is a multi-dimensional is a challanging
question. The most relevant factors are the combination of strength and corrosion resistance required for each individual application. Duplex grades cover a wide range of corrosion resistances, from grades that are ‘only’ as corrosion resistant as standard 304 stainless steel to super or hyper duplex that can withstand extremely harsh environments where a 6 Moly grade of austenitic steel would be needed. There is always a grade of duplex that is suitable for your specific environment. The main advantage for end users is that the strength of duplex is much higher than that of austenitic stainless steel, providing opportunities to save on materials because you can use less. Besides the reduction in the material required, there will be also less costs for transportation, material handling, fabrication, welding consumables etc. However, there are other situations as well where the higher mechanical properties and better wear resistance of duplex can be taken advantage of such as in applications with very abrasive conditions. A good example of the benefit duplex offers is a rebuilding project of rapid channels in the Finnish city of Tampere where LDX 2101 ® was chosen for all main structural parts for sluice and flood gates used for hydropower generation. The high surface hardness of the material protects the gates against wear caused by ice and floating debris. In this particular project the benefits of using duplex were manifold: material saving by utilising the high strength results in a lighter duplex structure needing less hydraulic force to operate the gates, adequate resistance to both pitting and universal corrosion, excellent resistance to stress corrosion cracking, and good machinability and weldability. Additionally, the relative price stability of lean duplex, owing to low nickel content, ensures that the stainless steel material costs are kept stable during long projects – an important factor for companies involved in public sector projects.
For a project for Dow Chemicals in the Netherlands, Outokumpu received an order for lean duplex material to be used in two tanks at Dow’s Terneuzen plant, the first time they have applied this lean duplex material. Chemical Engineering World
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September 2013 • 81
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The use of light yet high strength duplex for sluice and flood gates in a Finnish hydropower project enabled material savings and meant less hydraulic force was needed to operate the gates.
Overall, life cycle cost considerations are essential when evaluating a duplex solution. On top of direct material savings, duplex enables longer design life – 200 years in the case of the rapid channel project. Thus, you should not only consider the initial investment costs, but also any eventual costs for maintenance if you want to replace carbon steel. It’s of benefit to the end user that there are so many grades available because together with the experts they can then choose the best option for their particular application. When we consider austenitic stainless steels most people only know about 304 or 316 but there is also a very wide range of austenitic stainless steel grades available that have been developed to meet certain requirements, and this is now the same for duplexes. While we can see that there are a few commonly used duplexes, there are other grades that will remain niche products for very demanding or special applications.
Outokumpu duplex grades
A customer who is not yet using duplex should be open to listen to all the benefits duplex grades can offer. They should not only focus on the kilo price but grasp the whole story to understand the full solution. Duplex offers excellent opportunities to constructing challenging and durable structures. However, due to the high strength of the material, the working process is in some points different than with austenitic steels. Customers should keep an open mind to have a competitive edge. We are always willing to provide support wherever necessary for issues such as welding and fabrication. We have a lot of knowledge and we are happy to share about this sustainable stainless steel.
There is still some room for new developments in Duplex. Certainly some new grades with tailor-made properties will be developed; however, I don’t foresee any radical new products emerging, rather Outokumpu will continue to fine tune existing grades. This is especially true with the inclusion of alloying elements such as chromium, molybdenum, tungsten and especially nitrogen, which is an important alloying element in duplex grades because it increases the mechanical properties and corrosion resistance. I expect that we will see some fine tuning to further explore the benefit of nitrogen. The expansion of usage temperature range of duplexes might also be a focus area. Looking to the lean compositions available today, the main room to develop lies in finding solutions which are cheaper than the standard grades we have today. Other developments will be in the range of products offered; for instance Outokumpu offers value-added products such as beams and profiles for construction elements. This is an area which we will continue to focus on in future, to bring more value to the customer. 82 • September 2013
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Chemical Engineering World
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CEW
South Special Feature
Raj Process: Evolving with Continuous Evaluation The Chakan facility of Raj Process has separate divisions for manufacturing different products. The uniqueness of the plant is that it has all the fabrication processes in house which makes them to manufacture a product much faster then its competitor.
Anil Pise
Managing Director, Raj Process Equipments and Systems Pvt Ltd
R
aj Process Equipments and Systems Pvt Ltd is an ISO 9001 – 2000 company with businesses in chemical, pharmaceutical and food process equipment and turnkey solutions. Presently Raj Group’s activities span design, manufacture and commissioning of spray drying plants, distillery plants, food processing plants. Besides this, it also does large fabrication of vessels, reactors, heat exchangers, crystallisers etc. as per customers’ design or in-house design. Last year, it added new products in its product basket to cater to boiler, electrical and automation segments. In boilers, it manufacturers package boilers, captive plant high capacity boilers, waste heat recovery boilers etc. Similarly, in electrical and automation segment it manufactures MCC panels, PLC panels, HT/LT panels, instruments and control panels etc.
Raj Process Equipments and Systems Pvt Ltd Jai Ganesh Vision, ‘B’ Wing, 3rd floor, Jai Ganesh Fame Building, Akurdi, Pune 411 035, India Tel : + 91 20 4071 0010 Fax : + 91 20 4071 0009 E-mail : sales@rajprocessequipment.com Website: www.rajprocessequipment.com
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“Through continuous evaluations, evolution and up-gradation of products, quality systems and infrastructure we are setting foot in unventured sectors like refineries, gas, critical high temperature & pressure vessels and reactors, material handling, bio-diesel and atomic energy,” says an elated Anil Pise, Managing Director, Raj Process Equipments and Systems Pvt Ltd. The Facility Raj Process’s first manufacturing facility came up at Bhosari MIDC area in Pune, which is spread over an area of 22,000 sq ft. However, Bhosari facility is now converted as full-fledged R&D centre. “Our steady growth is due to our strong R&D. This year, we are investing more which is around 3-4 per cent from our total turnover,”
says Pise. The growing business compelled them to come out with another factory at Chakan in Pune. The Chakan plant is a sophisticated one and spread over an area of 1,70,000 sq ft out of which carpet area at present is 1,10,000 sq ft. The facility has sophisticated machineries and fabrication equipment like CNC plasma cutting, CNC welding, hydraulic bending, CNC milling, horizontal boring, special purpose milling, drilling and lathe having capacity to machining up to 4 metre into 12 metre length. All these machines help them provide better quality products to its customers. The plant manufactures, mixer, dryer, evaporator, products for distillery plant, starch plant, boiler, equipment for food and pharma sectors etc. Interestingly, the Chakan factory has separate divisions like mixer division, assembly division, distillery division and dryer & evaporator division. It also installed handling overhead and mobile crane facility up to 50 tonne. Raj Process has achieved ASME ‘U’ stamp certification for Chakan plant. As far as inspection tests are concerned, it regularly conducts radiography test, ultrasonic test, die penetration test and hydro test. In their endeavour to provide quality products to their customers it recruits only qualified wielders. Not only that, each wielder is engaged in wielding only one particular product where their expertise lies. To ensure quality, service and delivery it is imperative to have complete manufacturing under one roof. “We have more than 800 working manpower working under 40 production and 35 quality control engineers,” says Pise. Fabrication, which involves various activities like pressing, rolling, bending, and machining Chemical Engineering World
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is done in the factory itself. It means all facilities are available under one roof. “That is why we are making our job much faster than others. We can deliver a product in one month to our customers and for the same product our competitors take 45 days,” claims Nilesh Sonune, Manager-Works,Raj Process Equipments and Systems Pvt Ltd. Turn Key Projects Currently Raj Process is focusing more on turn-key projects like distillery plant, detergent powder plant, starch and glucose plant, gur and gum plant, zero liquid discharge plant etc. Distillery Plant Production and consumption of alcohol is an age old practice. But with time, the areas of usage as well as production techniques have gone through drastic changes. Apart from potable purposes, alcohol today finds application in a varied mix of industrial areas. “Here, we provide techniques and systems that bring out much higher quality of the product while effectively lowering production costs,” asserts Pise. Their fermentation system design based on crucial parameters which helps reduce loses of alcohol in fermentors and increase the yield of alcohol by controlling the unwanted byproducts. The features include high fermentation efficiency, minimal
waste water generation, rugged operation etc. “We design it in such a way where flexibility to operate continuously as well as sycronised mode of operation, depends on characteristics of feed stock,” claims Pise. One of the key technologies (devised by Raj process) in the distillery plant is Zero Liquid Discharge Technology. This technology provides comprehensive, cost-effective and reliable operating systems and services. Evaporation & Drying The evaporation system consists of single or multiple calendrias (Tubular shell and tube heat exchangers) followed by drying systems. Evaporation systems are designed with consideration of higher fouling fluids, rugged operation, less maintenance and operating cost, easily stable with fluctuation on steam or feed side. For drying they offer rotary and spray dryer considering the suitability and nature of the product to be handled. “The dryers are highly efficient having low operating costs and easy operation,” asserts Pise. Starch & Glucose Plant Starch is a polymer of glucose found in most plants. Starch is organised in 1-140 um granules in plants. Starch is produced from various raw materials like maize, cassava/tapioca roots, potatoes, wheat, rice etc. According to Pise, the technology or the manufacturing process of starch differs according to the raw material used.
Manufacturing process at the Chakan plant. Raj Process has achieved ASME ‘U’ Stamp certification for Chakan plant.
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One of the important aspects of starch processing or extraction is that starch is produced according to the requirement of of the end users depending upon changing reaction condition (Temp, pH2 additives) and strict process control methods. To facilitate these aspects of starch extraction or processing, Raj Process has designed and developed starch processing equipment and plant that meet varied requirements in manufacturing plant. “Our advance fabrication facilities, team of industry professionals and technical know-how enable us to meet client’s specific requirement by developing custom design machinery. We also excel in establishing of complete plant for starch extraction and execute turnkey projects,” says Pise. Zero Liquid Discharge Plant One of the reasons for Raj Process’s success is the tradition to come out with new products when industries need it most. Their zero liquid discharge system is an example in this direction. In the current scenario, zero liquid discharge systems have become necessary for many industries which are generating liquid effluents. To address the problem Raj Processor’s zero liquid discharge plants have the features like higher steam and power economy, optimal space requirement, capacity range from 1 kl per day to 1000 kl per day, PLC controlled systems etc. Future Plan It is setting up another plant in Satara Road 60 km from Pune. Once completed, it will be the largest plant for the company. This plant will have ultra-modern facility. In the first phase it is investing ` 50 crore for the project. Currently, Raj Process exports its product to countries like USA, Italy, UK and Malaysia etc. At present, apart from Pune, it has marketing offices in Delhi, Ahmedabad, Hyderabad and Chennai. It also has branch offices in other countries like Malaysia, Indonesia, Ukraine, Russia, Israel, UAE and Kenya. Plans are afoot to open offices in African countries as well. In their endeavour to become a reputed world class company, it is looking for joint ventures with some foreign companies. “We want to become one of the leading engineering MNCs within a decade having strong presence in domestic and global markets,” concludes Pise. Chemical Engineering World
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Ad Index CEW Sr No
Client’s Name
Page No
Sr No
Client’s Name
Page No
1
Aero therm Systems Pvt Ltd
89
30 Jasubhai Engineering Pvt Ltd
71
2
Arctic Sales (Bry-Dry)
79
31 Kevin Enterprises Pvt Ltd
27
3
Atomic Vacuum Company (Exports) Inside Cover I
32 Khosla Profil Pvt Ltd
29
4
Avians Innovations Technology
11
33 Kirloskar Brothers Ltd
5
Bhavya Polymers
81
34 Korea Chem
65
6
BHS-Sonthofen (India) Pvt Ltd
49
35 Kwality Process Equipments
51
7
Boeger Pumps Asia Pte Ltd
45
36 LIST AG
8
Bonfiglioli Transmissions (Pvt) Ltd
43
37 Malvern Aimil
35
9
Bush Vacuum
63
38 Mazda Ltd
83
39 Outokumpu India Pvt Ltd
55
69
40 PPI Pumps
73
53
41 Raj Process Equipments & Systems Pvt Ltd
19
10 Chempro Technovation Pvt Ltd 11
Chemtech World Expo 2015
12 D V Polymers
104
Inside Cover II
Front Cover
13 Dip-Flon Engineering & Co
9
42 Ravel Hiteks Pvt Ltd
89
14 Dupont Chemicals
5
43 RG TexIn Manufacturing Company Pvt Ltd
83
15 Emjay Engineers
81
44 Sachin Industries
59
16 Everest Transmission
67
45 Samarth Engineers
89
17 Evergreen Technolgies Pvt Ltd
41
46 Seal Excel (India) Pvt Ltd
77
18 Flexim GmbH
75
47 Sharplex Filters (India) Pvt Ltd
31
19 Flowchem Engineering Pvt Ltd
85
48 Shree Ganesh Process Equipments Pvt Ltd
15
20 Fluorotech Engineering Works
73
49 Suraj Ltd
77
21 Forbes Marshall
37
50 Swagelok
23
51 Swam Penumatics Pvt Ltd
47
22 Gea Process Engineering
Back Cover
23 Goodie International Pvt Ltd
61
52 Telelec Heating Equipment Pvt Ltd
75
24 Gopani Products Systems
85
53 Transflow Asia
89
25 Grundfos Pumps
17
54 Uhde India Pvt Ltd
39
26 Heat Transfer Research Inc 27 Hitech Applicator 28 HRS Process Systems Ltd 29 Integraph Consulting Pvt Ltd Chemical Engineering World
AD Index 68.indd 91
Inside Cover
55 Ultra Drytech Engineering Projects Pvt Ltd 79
13
56 Uni Klinger Ltd
57
7
57 UNP Polyvalves
33
58 Warade Automation Solutions Pvt Ltd
21
25
September 2013 • 91
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CEW
South Special
Company Profile
Nagman Instruments & Electronics Pvt Ltd Ć
Ć
Ć
V Nagendran Chairman & Founder Nagman Instruments & Electronics Pvt Ltd
Ć
Micro Controller Based Universal Temperature Calibrators (MTC Series)
N
agman has been serving - with dedication and distinction - industries and projects worldwide for 4 decades. The company is developing and introducing at least 2 new - on demand ă novel, innovative, unique products and systems every year over the past 2 decades. Our customers have supported us thought our journey. And, we will continue to strive hard to serve them with enhanced dedication and distinction in the years to come. Nagman - Success Story Nagman has emerged as a well-known global brand name in „Calibration Solutions,‰ and it all happened due to: Ć Close association and co-operation with several reputed world leaders in „Instrumentation - especially in calibration‰ adapting the technology & expertise. Ć Support from their captive ISO 170252005 accredited calibration laboratories - in Chennai, Mumbai and Delhi - with unique facilities including DWT recalibration & unique capabilities to offer consultancy for setting up „Calibration Labs‰ from concept to completion. Ć A strong & dedicated „Development Team,‰ working to develop and introduce 2 or 3 new products - based on customer demand every year.
92 • September 2013
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Ultimate customisation and flexibility in tailoring products, systems and software to suit specific requirements of customers. Constant improvement in products - features and specifications (ranges / accuracies / stability etc.) - to suit market demands. Showcasing products and systems in most Instrumentation / automation exhibitions around the world and collecting valued feedback for improvement. A strong marketing and distributor network in India and worldwide.
The Products - Latest Developments Nagman expanded its success over years with temperature and pressure calibrators & systems to level and flow - equally critical process parameters - and developed unique, innovative and novel calibration systems for these parameters. Ć LTR** - Level Test & Calibration Rig - a unique platform for testing and calibrating multiple type level devices (upto 4000 mm Span) - worldÊs first and probably the only such system Ć FLOCAL** - Flow Meter Calibration System - for DN 10 to DN 150 (consult on extension to DN 300) - with unique 2 tier accuracy level masters to choose (0.2% to 0.05%) n- enabling calibration of a variety of Flow Meters - low and high accuracy models in a single System - saving on cost, space & time. FLOVEL - a combination calibration system (2 in 1) for calibration of both level and flow Parameters - flow meters in sizes from DN 10 upto DN 80 (expandable upto DN 150) masters to choose. Level upto 3000 mm with 0.05% F.S. or 1 mm accuracy of master, diverse types of level devices can be calibrated in this device - worldÊs first such novel concept system. Contact Details: Nagman Complex Chembarambakkam, Chennai - 600 123 Tamil Nadu, India Telephone: +91 44 2681 1700/01/02 Email: mani@nagman.com; support@nagman.com Website: www.nagman.com Chemical Engineering World
01-10-2013 20:01:03
South Special
CEW
Company Profile
Rasaii Flow Lines Pvt Ltd
16 INCH Teflon Sleeved Plug Valve Class 150# made out of WCB Body with CF8M Plug
S Ć Ć Ć Ć Ć Ć
tarted in the year 1980, Rasaii Flow Lines Pvt Ltd (RFL) is a reputed manufacturer of following Industrial Valves.
PTFE Sleeved Plug Valves (PFA/FEP) Lined Plug Valves (PFA/FEP) Lined Ball Valves (PFA/FEP) Lined check Valves (PFA/FEP) Lined Sight Glass ÂVÊ Notch Control Ball Valves
RFL have been manufacturing and supplying these valves for over 30 years now. RFL is in a position to manufacture and supply valves meeting API & ANSI, DIN, BS and JIS standard specifications. RFL also supplying valves made out of SS 316, 304, WCB, WCC, LCB and high alloys like Nickel CZ100, 904L, Duplex St. St. 2205, 4A, 5A. Located in Chennai, RFL has been supplying to around 450 customers in India in various manufacturing segments like petrochemicals, fertiliser oil and gas, power plants, atomic energy, heavy water plant, chemicals processing industries, pulp and paper, sugar mills, food and beverage, polyester synthetic industries and sewerage plants. The company has been exporting their products to 18 countries across the world, Chemical Engineering World
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Valve with limit switch for atomic energy
RFL is ISO 9001:2008 all its products are CE full Quality Assurance to Directive 97/23/EC Ltd approved.
certified company and certified confirming to (Module H) according and Engineers India
The company has established a good quality management system which ensures high quality of production. 100 per cent of valves delivered are tested before delivery in line with the various standards. Recently, the company modernised its manufacturing facility with the addition of many VMC & CNC machine facility and additional testing facilities. This has resulted in increase of production capacity and therefore RFL is keen to expand their sales to USA customers. The organisation, today, is in a position to hold stocks to start with quality products in enough quantity in USA and offer immediate supplies. RFL shall guarantee full transparency and high level of Integrity in all its dealing with its clients. Contact Details: Super Autoforge Inc, 42400,Grand River Avenue, Suit 205,Novi, MI,USA ă 48375. Telephone: +1 248 3449988, FAX: +1 248 344 9993 Email: admin@rflvalves.com Website: www.rflvalves.com September 2013 • 93
01-10-2013 19:59:07
CEW Interview
BEGINNING
A MAN WITH A Dipl. Ing. Heinz List (1912-1988) The founder of LIST AG, and a pioneer of modern industrial processing technoloy
VISION
In the 1940s, Germany’s biggest chemical industry conglomerate established a committee to explore screw technology in mixing and kneading applications. Three men who served on that committee would go on to become founding fathers of modern processing technology. One of them, Heinz List, became the first engineer to seriously explore the feasibility of concentrated solid-fluid reactions. Until then, such processes had been thought to be impractical due to the presence of highly viscous, solid, and crusty phases. Heinz List believed he could overcome these difficulties, and that the future lay in solvent-free processing.
L
ist’s first design was a single-screw machine that combined oscillation with rotation, and ultimately evolved into the commercially successful Co-Kneader. By 1965 he had developed the twin-shaft All Phases processor, the first machine that could reliably and safely process highly viscous, pasty and crust-forming products. The vision had become reality.
Though Heinz List died in 1988, he is remembered both as a pioneering engineer — one of only 26 members of the Polymer Processing Hall of Fame at the University of Akron, Ohio, USA — and as a business leader. Under his sons Jörg and Klaus List, the company has thrived and expanded into new industries: polymers, fibers and food. Today, LIST technology and
know-how for processing in the concentrated or “dry” phase are at the heart of many industrial processes. Working with key innovators in our customers’ organisations, we have revolutionised several production methods and significantly changed others. Through imagination backed by sound engineering, we have helped our customers to become leaders.
In 1966, Heinz List established his own company to further develop the field of high-viscosity processing. Under his leadership, the young company pioneered the revolutionary LIST KneaderReactor technology. The company’s first successes were in simple drying and kneading applications. Subsequently, LIST KneaderReactor technology showed that it could effectively combine multiple phases and process steps — reaction, crystallisation, drying, melting, mixing, kneading and evaporation — in a single machine. 94 • September 2013
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LIST Headquarter, Arisdorf, Switzerland Chemical Engineering World
03-10-2013 17:32:12
Interview CEW
LEADERSPEAK
Dry Processing Intelligent Processing
Martin Fischer, President Global Sales, LIST AG feels India as a key strategic market for company’s proprietary technologies. During his business trip to India, Fischer talked exclusively to Mittravinda Ranjan and Harshal Y Desai about what LIST AG has to offer to the Indian market to spearhead industrial growth.
LIST AG – the global leader in processing in the concentrated phase has been practicing ‘Process Intensification’ since the time it had not become a buzzword in the industry and the manufacturers were really not looking out for advanced processes. It took almost two decades for Heinz List’s innovative technology to get acceptance from the industries. The foresighted technocrat founded LIST AG in 1966 in Switzerland, which has now grown to become one of the global leaders in solvent free or solvent light processing thus enabling companies to bring significant reductions in CAPEX & OPEX. How long have you been associated with LIST AG? My journey with LIST AG started in 2002 in the USA. Prior to assuming this new role and joining the core team in Switzerland, I was heading the company’s operations in the USA as the Managing Director. Meanwhile, Klaus List, the owner & Chairman of the Board stepped down from his position in 2011 and I was offered this role to charter the future course of growth of the company. LIST AG has witnessed sharp increase in growth during the last ten years driven by the increasing demand for sustainable technologies by the manufacturers from the west, and now the Asian region is providing significant positive momentum. We have bagged three major Chemical Engineering World
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projects - two going to Saudi Arabia and one for installation in Russia recently and are confident that the Asian markets will provide a major impetus to the growth of our organisation. LIST AG has expanded in the Asian region and set up sales and service centres in Singapore and Japan. How does this fit into the company’s business strategy? Proximity matters! Our approach is to be closer to our customers, and that is the whole idea behind setting up centres in Japan and Singapore. Japan has been a technology centre for various industries where many projects are conceived and conceptualised; and later executed across the world markets.
They have an enormous appetite for new technologies and setting up technology centre made absolute sense since this gave us ample scope to stay close to the market and leverage on our strengths. Our second service centre in Asia is in Singapore, which has been there for two decades and was set up primarily to offer sales services to the Chinese & Korean markets; however, with the increase in demand from this region, we have extended the facility to other Asian markets. We followed the similar approach in American market which has been a great support in consolidating our position in the US. We also have an innovation centre in Switzerland for technology demonstrations to our customers. September 2013 • 95
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CEW Interview How have LIST AG’s technologies evolved over the past four decades and accepted across various industrial applications? Heinz List, the Founder of LIST AG invented the predecessor of the technology that we offer as Co-Kneader technology, and was granted patent in 1945, while he was working for another Swiss company. His employers allowed him to commercialise the Kneader Technology and encouraged him to develop the technology further. It was in 1966 when he decided to get into entrepreneurship and parted ways with his employers. Later, he went on to develop the advanced solutions for high viscosity processing and now the innovation team at our head office in Switzerland is taking the tradition of innovation forward. Initially, the application of Kneader technology was confined to pharma industry; however, it took nearly two decades for industry to realise the true potential of our proprietary technology in the crystallisation and polymerisation applications. With our patented Kneader technology, we have made many strides and the last ten years have been most rewarding for us - the best period of growth so far in the history of our organisation. Innovation is in the DNA of our organisation and our research team constantly keeps innovating the existing technologies at our Technology Centre in Switzerland, working very closely with the user industry to provide customised solutions. Are LIST AG’s technologies confined to batch processing only or can these be applied even in continuous processes? Well! Initially the technologies were meant for batch processing; however, now over 95 per cent of applications are there in continuous processing. Our technologies are implemented globally in many large scale plants and well integrated in the fully automated process plants. These technologies require little or practically no attention towards maintenance. Scalability of our technologies is a major plus point for the technology as it can be applied from small batch processes and with utmost ease integrated into large plant operations. What are various cutting edge solutions offered by LIST AG globally? We are focused on processing of chemicals, polymers, rubber, elastomers and fibres. Desolventising or Degassing is one of our fortes and we have proprietary technology 96 • September 2013
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for recovering Toluene di-isocyanate (TDI) from the production’s waste streams. TDI is a key ingredient in manufacturing of Polyurethanes (PU) which finds wide array of applications across the automobile and white goods industry. Globally, most of the TDI manufacturing facilities use our process to recover TDI which is extremely hazardous in nature and cannot be disposed in the environment. In India, We have supplied our technology to a well-known Indian company which has set up huge TDI production capacity in Dahej, Gujarat. LIST AG has some cutting edge solutions for critical applications in high viscosity elastomer processing for temperature sensitive products. There is a strong demand for our elastomer processing technology from the rubber manufacturing sector serving the automobile industry. Lyocell is one of the latest technologies that we have in offing for cellulose processing to produce natural fibres using wood or alternative feedstock such as bamboo instead of conventional materials like cotton or synthetic fibres. Further, we offer technology for processing of Superabsorbent Polymers (SAP), which find applications in the personal hygiene products such as diapers and other disposable products for female hygiene globally. We can proudly say that a large percentage of the world market for SAP is made by manufacturers that use LIST technology to produce SAP. So far, we have not supplied this technology in India but there is a good scope for this technology in the country. Is the Indian market ready for SAP technology? Well! The technology is currently not in use in India but the market is certainly looking up as there is a wide base of end user segment already existing and the demand is bound to increase. However, one of the main constraints with the technology is that it can be offered only to those with the ability to produce acrylic acid, which is the feedstock to produce SAP. Small scale capacities are definitely not a viable option for this technology. We have received some positive feelers from the Indian market and some of the manufacturers have shown interest but at this point of time we cannot disclose much on this front.
What kind of response do you expect for the cutting edge technologies offered by LIST AG from the Indian market? Worldwide, our dry processing technology solutions have successfully replaced the conventional wet processing techniques and enabled the processors to increase the top line margins, reduce overall operational cost along with achieve their environmental objectives. Our proprietary technologies in some cases completely eliminate the need of any side streams of solvent extraction or recovery thus making a significant positive impact on the overall cost. We are already getting some good queries and feedback for our technologies from some of the manufacturers who are expanding or setting up new facilities. Hopefully, five years from now we will have a strong customer base in India. How do you plan positioning yourself strongly in the Indian market & what would be your growth strategy? Twenty years back, LIST AG entered the Chinese market and witnessed remarkable growth over there because of the amazing industry response towards our technologies. We are following the same strategy in India and Raghunatha Kulkarni, Managing Director for our Indian operations will drive the growth in the Indian market. We plan to expand our team and also come up with a service centre in the country like we have done in other markets. Reaching the correct information to the customers is foremost on our priority list and we ensure imparting correct domain knowledge to all our sales personnel through rigorous training sessions. Most of our team comprises of engineers who are very well equipped with the knowledge about our technologies and their industrial applications. Our technologies are low maintenance, sustainable, flexible in terms of scalability and can be integrated with the large scale capacities for continuous operations. Indian manufacturers are looking at filling the technology gaps and are looking out for technology partners. As I have already mentioned, we are getting positive feelers from the Indian market because of the uniqueness offered by our technologies, we are very confident about India as one of the key markets for our technologies. Chemical Engineering World
03-10-2013 17:32:16
Interview CEW
FROM THE MD’S DESK
Upping the Ante
I
ndian petrochemical industry is one of the fastest growing industry in the country projected to grow at about 11-13 per cent over the next five years. The Indian refiners are expanding their refining capacities to cater to the growing domestic demand of petroleum products particularly - polymers, fibre intermediates, synthetic fibres and elastomers.
R M Kulkarni Managing Director LIST India
Per capita plastic consumption in India still hovers at 7 kg as compared to 46 kg in China and 65 kg in Europe, which indicates a huge scope for the plastic and polymer manufacturing industry in the Indian domestic market. There is a considerable shift in the market from cotton to comparable man-made lyocell fibers. LIST offers very innovative Masterconti process for polymer section of lyocell fiber production.
E-mail: raghunatha.kulkarni@list.ch info@list.ch Website: www.list.ch
India also has a strong vibrant rubber industry, the country has been relying largely on rubber imports due to less area under cultivation. Gradually the
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LIST’s cutting edge dry processing technologies have enabled some of the key global processing industry players reap excellent results in terms of reducing the CAPEX and the operational costs along with significant reductions in energy and carbon footprint. LIST India will serve the Indian market by evaluating and educating the market about LIST technology and enable the industry to stay competitive in the global market and meet long term financial and growth objectives.
LIST AG TIMELINE First commercial TDI Recovery system
LIST Twin Shaft Kneader Reactor enables thermal processing of products across the viscosity spectrum from liquid to solid
1970
Indian industry is inclining towards synthetic rubber, which is now growing faster as compared to natural rubber segment. Many processors are still using conventional technologies and there is strong thrust on advanced technologies for rubber processing typically in the devolatilisation step in order to reduce overall CAPEX & OPEX in order to achieve economies of scale.
1974
1979
Single shaft kneader reactor
First Large scale batch polymerisation reactor for SAP
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First world scale plant for continuous polymerisation of SAP
First complete direct devolatilisation system based on a single shaft CME for bulk stripping & a Twin Shaft Finisher (TSF)
Latest version of Twin Shaft Kneader Reactor technology
1988
First world scale devolatilisation plant of capacity > 20 t/h/ line
1992
1998
2002
First twin shaft kneader reactor for multiphase polymer processing
2003
2004
2006
First industrial-scale dissolving system
Launch of revolutionary CME technology and a kneader reactor for continuous bulk polymerisation
2007
2009
cellulose
First industrial scale kneader reactor for continuous bulk polymerisation
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CUTTING EDGE TECHNOLOGY Revolutionary Technology
T
oday’s process operators, especially in the chemical industry, face mounting pressure to move toward process intensification, cleaner production, and continuous optimisation. The emphasis is on cutting consumption of raw materials and energy, eliminating toxic substances, and reducing emissions and waste. The benefits include lower capital and operating costs, higher product quality, and greater process reliability.
The patented KneaderReactor technology developed by LIST has a unique combination of specialised mechanical and thermal features that no other technology can deliver.
Designed for high torques, KneaderReactor systems are extremely robust, and so capable of processing highly viscous, pasty, and solid products that pass through sticky and crust-forming phases. Such “difficult” materials are a common consequence of Dry Processing — processing in the concentrated phase, with little or no use of solvents. LIST technology allows large volumes of such material to be processed via intensive mixing and kneading, with effective heat transfer and vapor disengagement, and residence times of over fi ve minutes. The entire process takes place in a single piece of equipment that is compact and self-cleaning.
Filling a Technology Gap The patented KneaderReactor technology developed by LIST has a unique combination of specialised mechanical and thermal features that no other technology can deliver.
The benefits of Dry Processing include: • Process intensification, yielding smaller plants with greater throughput; • Maximum process yield per unit volume; • Continuous instead of batch processes; • Scalable, flexible processes; • Minimal use of solvents; • Reduced product handling; and • Lower energy consumption. Individually and together, these advantages help customers carry out their operations more efficiently and economically, and to design processes that would be inconceivable using conventional technology.
Feature
Benefit
Large heating/cooling surfaces
Uniform and precise temperature control
High-torque mixing and kneading
Efficient mechanical energy input, boosts surface renewal, enhances heat and mass transfer
Multiphase processing from liquid Simple, versatile process design through pasty/sticky to solid phases in a single unit Specialized inner prevent back-mixing
geometry
can Enabling liquid feed stocks to be processed directly through to a free-fl owing solid product, with no recycling of dry material
Large working volumes
Promotes high throughput, enables long residence times
Long residence times
Facilitates slow reactions diffusion controlled processes
and
Axial conveying rate is independent of Rotational speed can be adjusted for agitator speed optimal heat transfer, residence time, and control of attrition
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Effective self-cleaning
Maximizes heat transfer and prevents product accumulation
Large free sections
Easy vapor disengagement and low vapor velocities prevent carry-over even under vacuum
Mechanically robust
Safe processing of highly viscous products
Closed, contained design
Allows processing under vacuum and handling of toxic, explosive, or hazardous materials
Chemical Engineering World
03-10-2013 17:32:17
Interview CEW
A WIDE ARRAY OF APPLICATIONS List Fields of Application LIST technology and know-how set new standards in realising processes without the use of solvents while creating added value regarding safety, efficiency and sustainability. Polymers: LIST solutions for the polymer industries include: Polymerisation Efficient and economic polymerisation of monomers or pre-polymers at high conversions and with low or zero use of solvents. Operating below the glass transition temperature yields a granular, stable and free-flowing polymer in a single step. Polycondensation Efficient surface renewal at low shear rates under ideal plug-flow conditions makes LIST technology ideal for polycondensation reactions under high vacuum. Devolatilisation For removing solvents from polymer solutions and suspensions, LIST’s Continuous Main Evaporators and Devolatilisers are energy-efficient and environmentally sound. Compounding LIST custom compounding solutions combine operations such as blending, melting, reaction and final solvent removal into a single process step. The KneaderReactor is also extremely efficient for grafting reactions and reactive compounding.
Chemicals: LIST solutions for the chemical industries include:
KneaderReactor technology can combine high fiber quality with maximum throughput and minimum costs.
KneaderReactor technology for dissolving offers the fiber producers: • Consistent fiber quality despite fluctuations in the quality of raw materials; • A high degree of process safety, thanks to precise temperature control; and • Excellent process modeling to facilitate safe scale-up, parameter estimation, and process control. Food: LIST solutions for the food industries include homogenisation, mixing and kneading, thermal processing, chemical reaction, and drying, carried out either sequentially or in parallel in the LIST KneaderReactor. Food processors look to LIST for solutions that can handle highly viscous products, deliver precise temperature control — to avoid local overheating — and perform crystallisation. The KneaderReactor is also excellent for processes that demand long residence times, intensive surface renewal, degasification, and drying. Typical applications are the manufacture of chocolate crumb, crystallisation and drying of sugar substitutes, and production of polyphosphates.
Continuous Reactions in the Concentrated Phase Where the product of a homogeneous or heterogeneous reaction is a solid or a paste, the reaction is traditionally carried out in a solvent or diluent to control the heat of reaction and the homogeneity of the reaction mass. LIST KneaderReactor technology can handle the same reactions in the concentrated phase, under stoichiometric or nearly stoichiometric conditions. As a result, LIST reactors can increase process economy, safety, and product quality, while reducing space requirements. Drying of Difficult Materials Conventionally, processes involving multiple phase changes require the use of several distinct process steps — with substantial requirements for space, investment and operating costs. By contrast, LIST KneaderReactor technology with its large working volumes can combine several unit operations, including multi-phase processing, in a single unit. We call this “All-In-One Processing”. Fibers: Technical fibers, whether natural or synthetic in origin, are produced via a series of steps which transform the raw material into a viscous fluid for spinning. For fibers that require a dissolving step LIST Chemical Engineering World
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TESTING AND ENGINEERING Test Center The LIST Test Center in Arisdorf, Switzerland, helps customers turn their ideas into reality, confirming process feasibility while identifying and addressing potential problems. LIST works closely with its customers to develop optimal processes in the shortest times. At the heart of the Test Center is a specialsed team of engineers and technicians. Their many years of experience with LIST
technology helps them resolve process challenges quickly, efficiently, and costeffectively. The facility is fully equipped with LIST KneaderReactors and all necessary ancillary equipment, and operates in compliance with the latest standards for environmental protection, health, and safety. In the LIST Test Center, customers can quickly determine how LIST KneaderReactor technology can help solve their processing problems.
We can perform: • Process tests: feasibility studies, costing, process optimisation, scale-up; • Product tests: production of small samples; confirmation of product quality; and • Long-term tests: confirmation that the process will perform as designed for extended periods; operator training.
System Engineering The design and engineering of any process equipment begins with a thorough understanding of the specific environment in which the process will take place. LIST creates complete solutions which combine capital equipment and auxiliary technology in ways that satisfy all the operational and mechanical requirements of the process in question.
The LIST System Engineering Group is made up of experienced mechanical, process and systems engineers who carry out projects all over the world. They are responsible for the design of complete operational units, project management, workshop inspections, packing and shipping, and help with installation and commissioning.
Supporting the System Engineering Group is the Process Engineering Group, which works to optimize processes and ensure compatibility between systems and materials. In this way, LIST engineers ensure that the equipment supplied is a perfect match for each customer’s specific requirements, and that it arrives on time and within budget.
Service Centers and Partnerships The LIST Life Cycle Management (LCM) program is a partnership between the customer and LIST. Its objective is to ensure optimal performance over the full lifetime of the customer’s LIST system. LCM aims to achieve zero downtime through a combination of preventive maintenance,
continuous optimisation, and training. Together, these prolong the lifetime of the equipment, maximize its performance, and minimize the risk of untimely failures. The LIST LCM program includes a series of service modules which can be chosen and scheduled for best fi t with each customer’s overall maintenance program. Other modules provide updated training in operation and maintenance, ensuring continuous improvement in operating safety and process economics. The organisation operates a series of Tech Centers strategically located near our customers’ installations worldwide. Each Tech Center is fully equipped to support our customers with the responsive and efficient services they expect. LIST is convinced that our technology and expertise will change many chemical
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processes, today and in the future, and will create additional success for our customers. LIST wants to supply its customers with the most efficient technology for future chemical processes, while also adding value in terms of energy efficiency, sustainability, and a safer environment. LIST has a long-standing business philosophy of developing sustainable relationships with our customers and employees. These relationships are built on mutual trust, longterm cooperation, and our ability to offer the highest levels of technical expertise. LIST has the highest respect for protecting the mutual interests of our customers and LIST regarding safeguarding and managing of confidential information and intellectual property. Chemical Engineering World
03-10-2013 17:32:18
Interview CEW
SOLVENT FREE
Paradigm Shift in Polymer Processing R M Kulkarni Managing Director, LIST India With inputs from Prof. Dr.-Ing. Michael Bartke & Dipl.-Ing Andreas Diener, LIST AG
C
hemical processes, especially those involving polymerisation, are usually carried out in dilute systems which can be heterophasic, such as suspension and emulsion polymerisations, or homogeneous. In both the cases the polymer needs to be separated from the solvent and the monomer which involves multiple steps viz. coagulation, stripping, drying and finally mechanical or thermal separation to obtain the polymer product in desired form.
These conventional polymerisation techniques are highly demanding in terms of raw materials and energy. Solvent recirculation is a typical example which alone needs a processing capacity four to five times higher than that of the polymer itself. Since the polymerisation process demands only parts-per-million (ppm) levels of contaminants such as water, effective separation of water from the solvent is crucial to the energy balance of the process. LIST has introduced energy efficient alternative, state-of-the art LIST Kneader Reactor Technology to overcome these issues both for bulk polymerisation and downstream processing of polymer solution. The innovative horizontal large volume Kneader Reactor , with its superior mixing and homogenisation performance optimizes the process control and allows production of highly viscous polymers with high surface renewal rates under precise temperature control. Casing, shaft(s) and mixing elements are indirectly heated by heat transfer fluids and are dynamically self-cleaning. LIST has developed this polymerisation reactor to bring a paradigm shift in Chemical Engineering World
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conventional highly energy & feedstock intensive polymer processing to solvent free processing and enable the processors to reduce capital & operational expenditures. Energy Efficient Bulk Polymerisation Polymers like PMMA special biopolymers and adhesives are typically synthesized either using a solvent, which subsequently needs to be removed; or via bulk polymerisation in which the monomer also acts as the solvent with the disadvantage of limited conversion. LIST Kneader Reactor Technology can overcome both the disadvantages mentioned above, due to its inherent ability to process high viscosities. Polymerisation carried out in a highly concentrated phase will be highly energy efficient and environmentally friendly compared to the conventional alternatives. The major challenge in solvent or bulk polymerisation is the effective removal of the solvent for effective recovery of the monomer,
Advantages of Kneader Technology for Bulk Polymerisation • Processing of highly viscous material up to 100,000 Pa.s ; • Low energy consumption as no solvent is used and monomer utilisation is minimised • Highest product quality , including shear sensitive products; • Highest consistency of products through precise process control (temperature, pressure, concentration); • Very low potential for air & water pollution because of closed nature of equipment; & • High plant availability through robust design and easy procedures for shutdown and restart which requires several intermediate steps. The main challenge is to continue the process when the reactor content falls below a certain level and becomes highly viscous. LIST Kneader Reactors can handle the resulting high viscosities
Figure 1: Principle of LIST Kneader Reactor Technology to replace conventional technologies.
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CEW Interview temperature – can be controlled within a narrow window.
Figure 2: The Kneader Reactor concept is ideally suited to bulk polymerisation, in particular for highly viscous products.
due to their inherent technology features and robust design. LIST reactors offer conversion rates of up to 99 per cent as compared to large amount of conversion with the standard conventional processes. This technology requires much lesser quantities of the monomer and promises higher returns. In addition to higher yields, one of the unique advantages of LIST’s technology is avoiding the hot spots when it comes to dealing with the polymers that are highly sensitive to cross linking or gelling. Producing polymers of highest quality requires precise control of process conditions, especially the temperature. LIST Kneader Reactor technology operates at low shear rates, with combined ability to control pressure, temperature and concentration precisely, ensures the highest possible quality and consistency of the products. LIST’s innovation in combining evaporative cooling by internal reflux of monomer with efficient mixing in the reactor ensures sufficient heat removal even for highly exothermic reactions. The system is designed in such a way that the evaporative cooling does not hinder initiation, so the reaction can progress quickly to auto-
thermal operation without any ramping requirement. Typical conversion rates for radical bulk polymerisation of biopolymers and adhesives in the LIST Kneader Reactor are up to 85–95 per cent. Direct Devolatilisation of Polymer Solutions The same reactor concept and type of processing allows highly effective devolatilisation. The high surface renewal rate, even for highly viscous products, enables very effective disengagement of vapor. The Direct Devolatilisation process for polymer solutions does not require water coagulation, stripping, or drying. The solvent, which is typically an aliphatic or aromatic hydrocarbon, is separated from the polymer by flashing and direct evaporation in a closed system, with simultaneous solvent recovery. Polymers made in this way have exactly the same properties and meet the same product quality specifications as polymers produced via the conventional route. In fact the ability of high surface renewal enables Direct Devolatilisation to produce polymers with better specification in terms of volatiles content and degradation. In addition, a very tight specification is achievable since the process conditions – especially
Advantages of Kneader Reactor Concept in Devolatilisation • 30–50% less energy consumption, because no extra effort is needed for stripping and drying; • 50–70% less condensation effort, since no stripping medium has to be condensed; • 40–60% lower space requirement, thanks to the compact nature of the plant; • 90–95% less water and air pollution achieved through the use of a closed system; • Less solvent and monomer in the final polymer, if required; • High flexibility for new grades and special product properties; and • Competitive investment and operational costs because there are fewer process steps and the solvent is evaporated directly. 102 • September 2013
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Pilot Plant for Process Development and Scale-up A change to solvent-free processes represents a jump in processing philosophy. Such a change cannot be made reliably without new polymerisation know-how covering, for example, catalysts and mechanisms for initiation and termination. Laboratory and pilot-scale reactor systems help polymer producers to gain the expertise they need to optimize their processes for solvent-free operation and scale up to full production size. After initial theoretical review of the system, next step is feasibility test to confirm the chemistry and process parameters required to get the expected range of product properties, which is typically done in a batch mode. The concept may also be tested in the continuous mode depending on the process. It may be necessary to adjust the recipe to achieve the expected product quality; experience shows that in many cases it is even possible to increase product quality (in terms of volatiles level or gel content, for example) above that of the reference sample. LIST offers the range of machine types and sizes needed to successfully carry out the batch and continuous trials needed to prove the concept and generate data for scale-up at its test center in Arisdorf, Switzerland, In the final development phase it makes sense to test the concept and confirm the data for scale-up in a semi-commercial trial , which can be carried out at the Fraunhofer Polymer Pilot Plant Center in Schkopau, Germany. The Fraunhofer Center executes the trial, together with LIST and customers are invited to attend and more importantly participate. Trials in the Schkopau semi-commercial plant provide reliable confirmation of the expected product quality, process controllability, long-term stability and other important measures. With such highquality data, production-scale plants can be designed without significant risks and product properties can be guaranteed. LIST Direct Devolatilisation has been in worldwide industrial use for several decades. Solventfree polymerisation technology has been working successfully at production scale since 2009. Chemical Engineering World
03-10-2013 17:32:19
Interview CEW
Rubber production
Sustainable
Solutions for
Processing of New Generation
Rubbers
LIST Dry Processing
LIST Dry Processing replaces conventional wet rubber processes with new, trend-setting standards for efficient, economical and resource-saving processes. • • • •
Reduction of water usage due to elimination of steam stripping Low shear (100 s-1) – no Mooney change Low and high Mooney, sticky grades Proven for new generation rubbers K 2013 October 16 – 23, 2013 Dusseldorf, Germany Hall 9/C24
www.list.ch | www.list.us | www.list.sg
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