Chemical Engineering World

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CEW

Contents CHEMICAL ENGINEERING WORLD RNI REGISTRATION NO. 11403/66 Chairman Publisher & Printer Chief Executive Officer

EDITORIAL

Editor Deputy Editor Editorial Advisory Board Contributing Editors

Maulik Jasubhai Shah Hemant K. Shetty Hemant K. Shetty

Sub Editor

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6 • March 2019

VOL. 54 | ISSUE NO. 04 | APRIL 2019 | MUMBAI | ` 150

NEWS Industry News

20

NEWS FEATURES Green Hydrogen to become affordable alternative by 2035 : DNV GL

10

FEATURES Challenges in Setting Up ETP for Refineries Satya Narayana Y V V – SFC Environmental Technologies Pvt Ltd

34

Modularization of Onshore Plants Karthik Nurani – Aker Solutions

40

More Than One Valve or Pump Choice for Every Application Todd Loudin – Flowrox, Inc

46

PROJECT UPDATE

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PRODUCTS

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EVENTS

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BOOK SHELF

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AD INDEX

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

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Chemical Engineering World

CEW News Features

Green Hydrogen to become affordable alternative by 2035: DNV GL DNV GL’s research paper ‘Hydrogen in the electricity value chain’ concludes that the electrolysis based hydrogen production will become competitive with the natural gas based production. The key finding of this research paper is: renewable energy based hydrogen will become an economic energy carrier to complement the electricity, to accelerate the industrial-feedstock-and-heat decarbonization, and to provide long-term storage solutions.

H

ow the Usage of Green Hydrogen Benefits: The research-result provides an encouraging outlook for the acceleration of the energy transition. As hydrogen doesn’t emit any carbon molecule while acting as an energy carrier, it has an immense potential to be used for long-term storage and heating applications. Electricity thus generated from the renewable energy sources (such as wind and solar energy) results carbonfree Green Hydrogen as an energy carrier.

The economically viable use of Green Hydrogen becomes feasible due to the increasing penetration of wind and solar power in the years to come. DNV GL’s Energy Transition Outlook forecasts that solar PV, wind energy, and hydropower will account for 80% of global electricity production by Yr. 2050. As this capacity increases, further opportunity to utilize its low-cost electricity becomes feasible to avoid curtailment: initially through the conversion into heat, then (daily) battery storage, and eventually into green hydrogen.

Prerequisites The rudiments for hydrogen to become an economically viable energy carrier are two-folds.

Firstly, the increasing time-prospect with low-cost electricity caused by an

oversupply of available energy owing to sharp rise of renewable energy sources.

Secondly, used cases for hydrogen applications are expected to be in support of low-carbon options.

With those parameters set, the electricity based hydrogen production can now compete with natural-gas based hydrogen production. It also provides a viable commercial business option for numerous applications, starting from industrial hydrogen feedstock.

Inference DNV GL’s energy experts conclude that the main reasons for the economic feasibility of hydrogen between Yr. 2030 – Yr. 2050 are driven by three key developments: • The electrolyzer-cost will go down caused by learning curve experiences; and the asset development cost is expected to decrease. Electrolysis based production from ‘surplus’ or ‘renewable-based low-cost electricity’ is an option for low-carbon hydrogen production without any carbon emission.

• Time period with zero or low costpriced electricity will be increased due to the rise of renewables, thus generating an energy-surplus to the power grid.

“As renewables capacity increases, opportunities to utilize its low-cost electricity for green hydrogen applications becomes feasible in next 16 years.”

10 • April 2019

• Penalization of carbon emissions – In the coming years, industries are expected to see a shift away from carbon-heavy activities. There will be carbon tax introduction and also the incentive concept for low carbon solutions.

Prospect As commented by Lucy Craig, the Vice President of Technology and Innovation of DNV GL – Energy, the prospect of delivering affordable hydrogen applications in the mid-term future provides a very encouraging signal to accelerate the global energy transition. The research validates, Green Hydrogen provides an optimal use for surplus electricity, which is expected to thrive for the rapid rise of renewable energy in the years to come.

In combination with electrolysis, hydrogen proves to be an economically feasible solution for the storage sector and also for the heat decarbonization.

Conclusion DNV GL’s researchers made a distinct progress in hydrogen production through renewable-based surplus electricity generation; and also through peak electricity generation by applying hydrogen as a fuel. This distinction emphasizes the underlying belief that the role of hydrogen in the electricity system competes with alternative solutions to the energytransition challenges and the increasing penetration of variable renewable energy systems.

Chemical Engineering World

CEW

Marketing Initiatives

Do Plastic Pumps Pump Plastic?

D

o you know what a plastic pump is for and when it is advisable to have one in your process? Here we are going to explain where non-metallic pumps are unbeatable and what their differences as well as limits are.

The selection of plastic-pumps is confusingly large. Flows start from just a few liters up to several thousand cubes per hour and manufacturers are to be found around the globe. Both, specialized companies as well as serial producers are long established in their individual markets. While the larger segment of small pumps (less than 1 m³/h) is mostly covered by standardized pumps, we see an increasing amount of special requests for which specialized pump manufacturers provide individual pump solutions.

At times, it is anticipated that the material

Proven Materials for Plastic Pumps Polypropylene [PP] Polyethylene [UHMW-PE] Polyether ketone

[PEEK]

Polyvinylidenfluoride [PVDF]

plastic is not a synonym for “cheap material”. Pump manufacturers know that specifications and decisions are sometimes based on this misconception, whereas metal pumps are always considered to be from superior quality. In fact plastic pumps today offer a surprisingly reliable and economical pump solution not just equal but often superior to those of metal pumps.

For very small flows and dosing requirements, the use of displacement pumps (i.e. diaphragm pumps) is often recommended. Though, the largest range of flow is being covered by centrifugal pumps (also: radial pumps).

These pumps can differ in design and characteristics but in general all wetted parts are made of or covered with plastics.

No More Corrosion!

As far as the operating temperature and pressure allows for, plastic pumps take the lead wherever the pumped fluid is corrosive. This can be just salt water or any inorganic acid and acidic liquid. Even alkalis can be handled easily. The list of successful plastic pump applications is rather long - you will probably be surprised!

Polytetrafluorethylene [PTFE]

The selection of metals being used as a pump material requires a high-level expertise, often linked to the specific application. Even with the correct selection, metals are then often limited in terms of fluid compositions and

Centrifugal plastic pump – PN16 acc. ISO 2858 with full armor (chem. industry)

Centrifugal plastic pump – PN10 for heavy industrial applications

Polyvinylchloride [PVC] Ethylene-Tetrafluorethylene [ETFE] Perfluroalkoxy PFA

12 • April 2019

Liquids where chemical pumps from plastic have proven well: Hydrochloric Acid Sulfuric Acid

HCL H2SO4 | H2SO3 HNO3

Nitric Acid Hydrofluoric Acid

HF

Phosphoric Acid

H3PO4

Fluorosilicate Acid

H2SiF6

Saltwater | Brine

NaCl

Chlorine- or chloride cont.

fluids

temperatures. Plastic pumps however usually cover a wide range of chemicals and temperatures. They even outperform their metal companions when it comes to abrasive fluids – a property that is often underestimated! A metal optimized towards corrosion resistance is likely to have weaknesses on abrasion resistance (i.e. metals with increased Nickel content).

Erosion corrosion, pitting or crevice corrosion, all common forms of corrosion in metal pumps, are unknown to plastic pumps. Just the three of them add up to a major part of the worldwide pump repair budgets for metal pumps. However, it is very likely you can find a matching pump from plastics.

Even in innocent looking applications with

Vertical centrifugal pump for installation in- side or outside tanks.

Chemical Engineering World

CEW

Marketing Initiatives Liquids where chemical pumps from plastic have proven well:

Surface Treatment - Steel Industry: Pumps from Polypropylene (Munsch NP) for circulation of acid in a steel pickling line (HCl 80°C)

Fertilizer Industry: Pumps from Polyethylene (Munsch Mammut) in a phosphoric acid plant (Fluorosilicic acid 55°C)

Environmental Technology: Pumps from Polyethylene (Munsch Mega-Mammut) for an exhaust gas scrubber in a sulfuric acid plant.

Chemical Industries: Pumps from PVDF in a Calcium chloride plant (food grade CaCl2) (Munsch NP).

Chemical Ind. - Chlorine Production: Mag drive pumps from PFA pumping brine, saturated with chlorine (Munsch CM).

Environmental Technology: Vertical plastic pumps in an exhaust gas scrubber unit (Munsch TNP).

slightly acidic liquids, where pH sometimes drops or the chlorides increase, pumps from plastic have proven successful for decades and saved operators from maintenance costs and downtimes.

and controlled. Pump manufacturers – including those of plastic pumps – do know the limits of their individual pumps very well. In fact, those suppliers with a high specialization and application expertise usually aim to get in touch with the operators and planners to find the best pump fit and the right protection equipment for their individual installations.

than -2 oC) even the best plastic pumps are at their limit. While fluoropolymers (PVDF, ETFE, and PFA) are good for up to 200 oC, the thermoplastics PP and UHMWPE, otherwise known for their outstanding ruggedness, are restricted to 100° oC. As the temperature of the fluid increases the allowable pressure of a plastic pump decreases.

Are These Pumps Safe?

Safety is of paramount interest in almost all applications. But what does it specifically mean for a pump handling a dangerous liquid? The most common answer is ‘The pump has to be tight’.

While displacement pumps mostly use static seal elements (such as o-rings, gaskets) radial pumps use dynamic seals (i.e. mechanical seals). In any case, including sealless pumps, operational safety strongly depends on how the pumps are being operated, installed

Centrifugal pumps from plastics are available in a vast amount of sizes and seal technologies. A large part of them even follows common industrial standards (among them ISO 5199, 2858, 15783 or 9906). They are, in terms of sizes and performance, comparable with their metallic kinship – without exception.

However, in very high and very low temperatures (more than 200 oC or less

“I was surprised to see that it's real industrial pumps!”

14 • April 2019

About Munsch: MUNSCH is a privately owned specialist for non-metallic pumps with a major focus on customer needs, high-quality and – efficiency. Our pumps are to be found in chemical industries where safety is a major issue and in all kind of industrial applications where availability, fast response and qualified support are required.

Contact us – we are looking forward to it: www.munsch.de Chemical Engineering World

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SOMETIMES THE CHOICE IS DIFFICULT …

… THE CHOICE FOR LEVEL 80 GHZ RADAR!

One radar sensor for liquids.

M

L

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MEASUREMENT IS EASY: One sensor for bulk solids.

Sounds simple, is simple!

RADAR LEVEL MEASUREMENT WITH 80 GHZ Industrial processes are becoming increasingly customized and complex. Now it’s even easier to select the right level transmitter for your needs. For a reliable non-contact level measurement solution, just choose VEGAPULS 64 for liquids or VEGAPULS 69 for bulk solids.

DYNAMIC RANGE

120 dB

Poorly reflecting media? Dust, condensation, or buildup? Radars with best-in-class dynamic range deliver constant visibility of your process levels.

PROCESS FITTINGS FROM

¾"

With small connections and a compact design, VEGAPULS 64 is the perfect fit in the smallest liquid containers.

FOCUSING

3°

No interfering signals from internal installations. A radar beam angle from 3° for liquids and 4° for bulk solids.

ACCURACY

+/-1 mm

Every drop counts with VEGAPULS 64.

It really scores points for accuracy, especially with high value liquids.

ADJUSTMENT 80 GHz radar sensors can be adjusted wirelessly with a smartphone or tablet. Did you know? All VEGA level sensors since 2002 can also get Bluetooth. Just click-in a new PLICSCOM display and adjustment module and it’s done!

More information: www.vega.com/radar Phone +91 20 6731 4000 | E-mail info.in@vega.com

CONNECT TO HIGHER COOLING EFFICIENCY AND CONTROL

UP TO

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FULL CONTROL

Trademarks displayed in this material, including but not limited to Grundfos, the Grundfos logo and “be think innovate” are registered trademarks owned by The Grundfos Group. All rights reserved. © 2019 Grundfos Holding A/S, all rights reserved.

INDUSTRIAL COOLING:

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So, if your daily operations includes a pump system for industrial cooling, Grundfos iSOLUTIONS can help you connect to higher cooling efficiency and control.

Read more about the benefits of Grundfos iSOLUTIONS and the cases to prove them at grundfos.in/industrialcooling

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4/9/19 14:25

CEW Industry News GSFC awards Thyssenkrupp Industrial Solution (India) LSTK contract for Cryogenic Ammonia Storage Tank

Sikka, Gujarat: Gujarat State Fertilizers & Chemicals Limited (GSFC) has inked a contract with Thyssenkrupp Industrial Solutions (India) to build a Cryogenic Ammonia Storage Tank with associated facilities at their Shore Terminal in Sikka, Gujarat on LSTK basis.

The 10,000 MT cryogenic storage facility will support the fertiliser major's Di-Ammonium Phosphate complex in Sikka.

The project will use Thyssenkrupp's extensive experience of cup-in-tank double-integrity suspended deck design that has been successfully put to use in a number of similar Cryogenic storage across India & overseas over several decades.

GSFC's association with Thyssenkrupp Industrial Solutions dates back to the mid-eighties, when the latter built the other 2 Ammonia Storage Tanks in the same location, also on LSTK basis. Over the years, the engineering major has implemented a number of projects for GSFC including the 3rd train of the Di-Ammonium Phosphate plant; and recently, the Additional Facilities Project for the Company's new Di-Ammonium Phosphate train.

Being based in South Africa, Fancraft is specialized in maintenance, problem solving, repairs, overhauls; and reconditioning of centrifugalreciprocating-and-screw compressor, steam and gas turbines, pumps, gearboxes, fans, blowers, and other rotating equipment. The company also provides high-quality spare parts to end users through agency agreements with some of the largest original equipment manufacturers in the rotating equipment industry. Fancraft is committed to meeting individual customer needs while maintaining excellent quality and high technical precision.

WoodServ, headquartered in Bahrain, is a leading gas compression technology provider for the oil & gas, and power & energy industries.

WoodServ caters to all OEM suppliers; and offers all types of modularized gas processing units, including but not limited to gas lift systems, wellhead compression, compressed natural gas (CNG), fuel gas boosters, and treatment plants. The company benefits from the experience of some of the world's most respected experts and engineers within the gas compression industry. They provide full turnkey solutions to clients, from engineering, site preparation, procurement, fabrication, feasibility studies, and equipment selection to evaluation, installation, commissioning, and start-up. They also provide training, operations and maintenance, field services, revamps and overhauls, machine shop support and spare parts.

"We are proud to be expanding our Authorized Service Partner Program", said Dean Lewis -- Cook Compression's VP Aftermarket, Europe & Russia.

He added, "Last year, we saw strong adoption of the certified valve and packing case repair services offered by our inaugural partners in Europe, and we are confident in delivering this high quality support to end users in Africa and the Middle East through these new partnerships." Fancraft and WoodServ join three other Cook Compression's Authorised Service Partners: Kompresory Veselý in the Czech Republic, Rudos Ruzomberok in the Slovak Republic, and Runtime Engineering AB in Sweden.

Mr P D Samudra, CEO & MD of Thyssenkrupp Industrial Solutions (India) said: ‘The project demonstrates the trust our Customer has in us and we put on record our gratitude for the same.We are proud to implement this project for our customer, and this prestigious project amply demonstrates our leading position in this sector'.

Evonik presents a new technology at the LOPEC trade Show

Cook Compression Adds Authorized Service Partners in Africa and the Middle East

The new materials are processed by conventional printing methods into very thin, flexible battery cells, thus giving the developer a high degree of design freedom. They allow electrical energy storage without the need for any metal or metal compound. Battery cells, produced with the Taettooz technology, do not require any liquid electrolytes and therefore cannot leak.

Creavis is now seeking development partners to integrate this Taettooz technology into new and existing applications.

Ellesmere Port, the U.K.: Cook Compression is proud to announce their two new Authorised and Certified Service Partnership with Fancraft (Pty) Ltd (serving South Africa, Namibia, Mozambique, and with Botswana) and WoodServ (serving the Middle East and Pakistan) to provide local compressor valve and packing case repairs.

With its extensive technical expertise and application knowledge, Cook Compression improves reciprocating compressor performance across the globe. The company offers high-performing products and materials with advanced capabilities, experienced engineering support, and expert-repairs to deliver lasting solutions.

Cook Compression Authorised Service Partners have passed a rigorous process and equipment audit. They adhere to strict quality standards, and guarantee their work for established warranty periods. Their service capabilities apply to any brand compressor valve or packing case. Further, each valve that leaves the partners' facilities is quality tested using a specially designed Cook Compression Valve Air Test Bench.

20 • April 2019

Essen, Germany: Evonik is unveiling 'Taettooz', a new material technology for printable batteries, at the LOPEC trade show. Taettooz has been developed on the basis of redox polymers by Creavis, the strategic innovation unit of Evonik.

Dr. Michael Korell, responsible for Taettooz development at Evonik, mentioned: "We have developed a technology with enormous potential.

It enables us to offer a solution to power small electronic circuits in an efficient, reliable, and eco-friendly way with printed batteries."

The Taettooz technology opens up new possibilities particularly in the spreading networking of everyday objects - the Internet of Things (IoT).

It may be used in multiple areas with series production. Medical sensors for monitoring vital functions could be worn far more conveniently when printed batteries are used. In the area of logistics and more specifically in packaging, intelligent sensors - operated by printed batteries - could monitor sensitive goods such as food or vaccines.

Chemical Engineering World

A world leader in chemical solidification and handling solutions Granulation, solidification and handling systems for different kinds of chemicals like resins, waxes, hot melts, antioxidants and residuals.

• High productivity – on-stream factor of 96% • Proven Rotoform technology – nearly 2000 systems installed in 30+ years • Complete process lines or retrofit of existing equipment • Global service / spare parts supply

ipco.com/applications

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18/04/2019 11:23

CEW Industry News Perstorp’s capacity expansion for pentaerythritol at Arnsberg, Germany, to go on-stream in May

add a new product to their Raven Carbon Black Product family.

The new solution, called Raven 5100 Ultra, will help customers to achieve unseen jetness level in waterborne systems, superior performance, and improved formulation costs.

"Our new Raven 5100 Ultra is the result of the transformational energy we're experiencing at Birla Carbon. We're constantly innovating to drive new ideas into the market, so we can ultimately deliver better customer experiences," said Todd Cottrell, President of Birla Carbon's Specialty Black's business. He added, "This is just the beginning and with our expanding global footprint, we look forward to serve more customers with our solutions, crafted by experts".

The expansion of Perstorp’s ISCC PLUS certified production site at Arnsberg, Germany, strengthens the company’s security of supply to meet the growing demand for Voxtar pentaerythritol from renewable sources.

(Photo Credit: Perstorp)

Malmo: As the global demand for Pentaerythritol ("Penta") keeps growing, Perstorp is increasing the effective annual Penta productioncapacity at its Bruchhausen/Arnsberg plant in Germany by 12.5%. The Penta polyols are widely used in resins for coatings in the building & construction and steel works industry, from architectural wood to marine paints.

"Our plant has successfully obtained the ISCC (International Sustainability Carbon Certification) PLUS, an important milestone in Perstorp's ambitious Pro-Environment quest to become FiniteMaterial-Neutral. The expansion work at Site Bruchhausen started in June 2018 and is well on track for completion in May," confirms Ulrika Andersson, EVP Business Area Specialty Polyols & Solutions at Perstorp. She supplemented, "The added capacity and ISCC site certification at Bruchhausen as well as introducing Voxtar production in Bruchhausen will significantly extend Voxtar's supply security, thus ensuring a continued security to meet our customers' increased ProEnvironment Polyols demand", Ulrika concludes. Together with the Company's Stenungsund and Perstorp sites in Sweden, Bruchhausen is now a part of Perstorp's strategic shift from fossil to renewable raw materials and energy. The independent third-party ISCC certified products comes with a Proof of Sustainability-Document, which states the products' contribution to sustainable sourcing according to the certified mass balance system.

"With Voxtar, back in Yr. 2010, we were the industry's first supplier to launch a renewable Penta," says Jan Secher, President and CEO of Perstorp. He continued, "In Yr. 2018, our Pro-Environment Polyols was honored with a Frost & Sullivan European Bio-Based Materials Product Leadership Award.

This Leadership Award, the recent ISCC Certification of our Bruchhausen site, and the addition of three new Pro-Environment families as well as full suite of Services underscores our committed support for advancing the circular economy. We offer this support through a shift towards the derivation of raw materials from renewable and waste sources."

Birla Carbon to Launch New Raven Product at 2019 European Coatings Show Mumbai/India and Atlanta/USA: Birla Carbon, a leading manufacturer and supplier of carbon black solutions, announced today that it is going to 22 • April 2019

The company plans to launch the new offering at the upcoming EuropeanCoatings-Show in Nuremberg, Germany in March. This show focuses on trends-and-technologies across all the production aspects of paints, coatings, sealants, construction chemicals, and adhesives.

"What better time and place to unveil our new solution than at the EuropeanCoatings-show?", said Cottrell.He continued, "As it is the industry's leading trade-show for coatings, it's a perfect opportunity for us to highlight our latest innovation and get real-time feedback from current and potential customers."

For more information on how Raven 5100 Ultra can improve your waterborne formulations, a meeting may be schedeuled with the Birla Carbon coatings' expert-team at Stand 1-424 in Hall 1 at the show. They will also present the technicalities of Raven 5100 Ultra on March 19, from 11.50 am to 12.10 pm at the Product Presentation Stand 1-133.

This will provide a deeper look at the product specification, features, and benefits.

Bentley Institute Received BIM Award for BIM Enabler/ Consultant of the Year Newcastle upon Tyne, the UK: Bentley Institute's Digital Advancement Academies have been named as the BIM Enabler/Consultant of the Year Award Winner at BIM Show Live 2019 in Newcastle upon Tyne, the UK. The annual BIM Awards, part of the national conference, honour and recognize the world's best BIM work by celebrating exceptional and innovative use of BIM in the built environment.

Iain Miskimmin, Senior Academies Manager for Bentley Institute's Digital Advancement Academies, said, "It's an honour for Bentley Institute to be recognised for the work we have been doing in this important area since Yr. 2012. Having helped to deliver some of the first projects in the UK to embrace a BIM strategy, it's inspiring to see how far we have come, and how our Digital Advancement Academies continue to support leaders and innovators in the digital built environment to advance digital (BIM) strategies."

The BIM Awards were judged by experts in BIM strategy and implementation for today's modern digital-built environment.

Awards were given in ten categories.The awards were announced the evening before the main programme kicked off for BIM Show Live 2019, which also featured presentations by experts in the construction industry, including David Philp, Global BIM/MIC Consultancy Director, AECOM and co-author of Building Information Modelling for Dummies.

Chemical Engineering World

CEW Industry News ABB and Ericsson join forces to accelerate wireless automation for flexible factories

Arkema highlights 3D printed innovative industrial applications at AMUG 2019 Colombes: "Arkema is focused on unlocking the next revolution of industrial opportunities by bringing full solutions and expertise to end users", said Guillaume de Crevoisier - Global Business Director of 3D Printing Solutions by Arkema, "AMUG has always been a great venue for us to discuss new product-applications and to forge new partnerships."

The AMUG Agenda features Arkema during two sessions on 3rd April 2019, viz., 'Top Material Companies Driving Innovation in the 3D Printing Market' and 'Material Specific Solutions for Transportation, Sports, and Dental Applications'. Arkema also narrated the below concepts at AMUG: Powder Bed Fusion: They displayed parts and highlighted "real world" production part case studies from its powder bed fusion partners. Rilsan Polyamide 11 powders are the only high performance materials available from a completely bio-based origin and they offer some of the strongest mechanical properties of all polyamide powders.

Hannover Messe, Sweden: ABB and Ericsson have strengthened their commitment to accelerate the industrial ecosystem for flexible wireless automation, which will enable enhanced connected services, industrial IoT, and artificial intelligence technologies in the future.

The partners signed a Memorandum of Understanding (MoU) at Hannover Messe 2019, establishing their joint vision for future flexible production with automation and wireless communication. This collaboration comes during the Industry 4.0 era and 5G connectivity that allow businesses to realize increased productivity with the help of automation and digitalization.

The MoU confirms the partners' agreement to continue their strong research collaboration, to explore improvements in manufacturing processes and automation, and to discover new business opportunities for the industrial ecosystem.

"We are very excited to extend our partnership with Ericsson as the world moves closer to the era of 5G technology," said ABB CEO Ulrich Spiesshofer. "ABB's leadership in Digital Industries combined with Ericsson's pioneering work in connectivity will open up new opportunities for customers to enhance productivity and competitiveness by digitalizing their businesses."

"Ericsson and ABB already have a strong collaboration in research for 5G and Industrial IoT technologies," Börje Ekholm, President and CEO of Ericsson said. He supplemented, "With this MoU, we strengthen our partnership to accelerate the industrial ecosystem and realize the full potential of flexible automation, unlocking new business opportunities enabled by combining 5G and Industry 4.0."

The two partners are already fast-tracking a new generation of intelligent factory technology introduction, with Ericsson deploying an intelligent automation system at its manufacturing facilities in Tallinn, Estonia. ABB has provided a fully automated flexible robotics cell solution that assembles 5G radios for Ericsson.

At the Hannover Messe 2019, ABB and Ericsson are exhibiting their latest and most innovative technologies, thus showcasing how they are enabling the "factory of the future" with the latest flexible robotics, wireless technologies, 5G, Industrial IoT, and motion control technology.

26 • April 2019

For the most demanding applications, parts made with Kepstan PEKK powders offer robust mechanical performance, extreme high temperature tolerance, low outgazing, low flammability, gamma stability, and extremely high chemical resistance. There will be several parts printed by Hexcel, a world leader in advanced composites for aeronautics, space and defense, using their formulation based on Kepstan and PEKK. Photocure: Arkema's Sartomer Division introduced eight new products from its N3xtdimension line of UV-curable engineered liquid resins. New launches include N3D-I200 for impact resistance, N3D-F2110 for flexibility, N3D-P2120 for high quality prototyping, N3D-C1700 for casting applications, and other unique resins for advanced performance. Sartomer's N3xtdimension resins offer customized properties and freedom of design. They are compatible with the main printing technologies – SLA, DLP, MJP, and BJ. Extrusion Printing: Arkema's partner - 3DXTech - will launch a filament made from Pebax elastomer. 3DXFlex TPE is the first commercially available Pebax TPE based filament developed for extrusion printing.

This lightweight elastomer is world renowned in sports markets for its outstanding energy return. Printed parts exhibit excellent layer to layer adhesion resulting in exceptionally strong parts. Also on display will be 3DX Tech's FluorX filament made from Arkema's Kynar PVDF. FluorX filaments are made from a patented formulation launched in Yr. 2018 that now has a print profile available on Ultimaker's Cura marketplace.

Kepstan PEKK is quickly becoming the preferred ultra-high performance polymer for extrusion printing systems. As mentioned previously, this material offers an excellent combination of processability, strength, chemical resistance, low flammability, and high temperature properties. Filaments made from Kepstan PEKK are available from several partners globally. There will be a live demonstration of large scale extrusion printing with Kepstan PEKK in partnership with Titan Robotics on Sunday, March 31, 2019.

Arkema has recently expanded its capacity for Kepstan PEKK materials with a new plant at its site near Mobile (AL – US). This new facility ensures a consistent supply to serve the growing needs of markets requiring materials that perform under extreme conditions, such as aerospace, oil and gas, consumer electronics, automotive, and additive manufacturing. Arkema is also expanding its capacity for N3xtdimension resins at its Nansha plant in China, and Orgasol Polyamide12 powder in Mont, France, to come on stream in Yr 2019. 3D Printing Solutions by Arkema is unlocking the next revolution in manufacturing.

Chemical Engineering World

CEW Industry News VDMA Compressed Air and Vacuum Technology For a uniform (vacuum) pump language Frankfurt, Germany: With the motto of "Compressed air 4.0 / vacuum 4.0: Predictive and Integrated intelligence", VDMA Compressors will participate at this year's ComVac in the Hanover Fair to provide information on Industry 4.0 and Energy Efficiency activities with regard to Compressed Air and Vacuum Technology. They will be located in Hall 26, at the Information Stand No. D17.

"At the information stand our demonstrator will show how a manufacturerindependent cloud-based communication can work in future with the help of OPC UA, Pumps, and Vacuum Pumps from various manufacturers", says Christoph Singrün -- Managing Director of VDMA Compressors, Compressed Air and Vacuum Technology. "Open Platform Communication Unified Architecture (OPC UA) is an open interface standard that enables machine and plant manufacturers to network digitally with the perspective of their products. The VDMA and its member-companies are currently drawing up OPC UA Companion Specifications for individual sectors.

Fixed daily demonstration schedule for OPC UA is from 10 am to 11 am.

Further demonstrations may be arranged on request. There is also a scope of further information for interested visitors, for example the VDMA Orientation Guide for Compressed Air 4.0 / Vacuum 4.0 users.

The VDMA represents more than 3200 companies in the medium-sized mechanical and plant engineering sector. With a good 1.3 million employees in Germany and with a turnover of 232 billion Euros (Yr. 2018), the sector is the largest industrial employer and one of the leading German industrial sectors overall.

Volvo´s EC950EL saves 20% fuel for Sagar Cements

also digs sumps to channel excess water away from the job site to prevent water damage to mines, while also supplying water to the plant and nearby residential community.

"When we heard about the new EC950EL excavators last year, we jumped in to grab it first in the cement industry of India, to try out," Ramana said.

"The EC950EL's excellent fuel-efficiency, top-notch performance and Volvo's strong brand were the main reasons why we chose this machine."

The EC950EL excavator offers an ideal combination of power and stability, to handle high capacity duties in the toughest applications. With a bucket breakout force of 424 kN and an arm tearout force of 408 kN, the EC950EL offers optimum digging force, particularly when working with hard and heavy materials.Powered by a 446 kW (606 hp) Volvo D16 engine, the EC950EL utilizes advanced technology built on decades of experience to ensure highly productive operations. Cycle times are cut to a minimum, thanks to the power and torque of the engine combined with the new fully electro-hydraulic system.

The EC950EL features a wide-track gauge, a long-track length, a retractable undercarriage and an optimized counterweight. The excavator's heavy duty structure reinforces 6 m3 bucket-result in a well-balanced, solid machine. All machine interfaces -- including joysticks, keypad and LCD monitor — are ergonomically positioned and designed for optimum control and efficiency. For increased versatility, the attachment management system enables the operator to use pre-set hydraulic flow and pressure through the in-cab monitor.

"Our operators really enjoy using EC950EL with its spacious and airconditioned cabin and its ability to toggle between 10 different modes with ECO option for different conditions," Ramana said. He added, "The machine's safety features (such as falling object guard and falling object protective structure in certified cabs, Rear View Camera, Auto Fire Suppression System, Engine cut-off system), various Error-WarningSystems, and Care-track.

MATRIS Performance-Monitoring-System gives us peace of mind. We highly recommend Volvo's EC950EL to the prospective buyers."

Facts and Figures on Minebea Intec

Andhra Pradesh, India: In just one year, the EC950EL excavator has already helped lowering the fuel consumption for Sagar Cements Limited, a cement producer based in Andhra Pradesh, India. The EC950EL from Volvo Construction Equipment (Volvo) is now a centerpiece of the Company's limestone mining operations.

Hamburg, Germany: Minebea Intec is a leading manufacturer of industrial weighing and inspection technologies and headquartered at Hamburg, Germany. The company has been offering products and services for over 147 years, which has become synonymous with innovation, performance, and reliability. Its product portfolio includes Platform Scales, Load Cells, Vessel-and-Silo Scales, Checkweighers, Metal Detectors, X-ray Inspection Systems, and user-friendly software solutions.

"With the EC950EL, we lowered the fuel consumption by 20% compared to similar class excavators from other brands. EC950EL saves cost for us with every ton," said K. V. Ramana, Senior Vice President of Sagar Cements Limited.

He added, "The Volvo excavator's excellent performance and wide range of features have also helped us to meet production deadlines effectively."

With around 1000 employees worldwide, 19 sites, and a network of over 185 certified international distribution partners,-- Minebea Intec is a global player in its industry. Having sold more than 90,000 inspection systems, 3,50,000 industrial scales and indicators, around 1,00,000 industrial load cells, and services worldwide, the company can be relied upon by its customers and partners from a wide range of industries.

Since the time of purchase in August'2017, Sagar Cements has deployed the excavator at their limestone quarry at Mattampally, Telangana. This 95-ton class excavator loads the blasted limestone into 60-ton dump trucks for easy transportation to a nearby crusher. The EC950EL plays a vital role in keeping cement production on schedule and moving between 6,000 to 8,000 tons of limestone for 10 to 12 hours per day. This excavator

Minebea Intec is a part of the Minebea Mitsumi Group. This group is a leading supplier of the high-precision production components (such as ball-bearings and engines), as well as high-quality electronic components (such as sensors, antennae, and IoT solutions). Being based in Tokyo, the Group has over 78,000 employees worldwide and reported a consolidated net turnover of JPY 880.000 million (approx. EUR 6.7 billion) for Yr. 2017.

28 • April 2019

Chemical Engineering World

CEW Industry News Global Steam Generators for Nuclear Power Market to Grow Modestly to Reach $1.02bn in 2026, Says GlobalData

took precedence contributing to a growth in the replacement markets of America and Europe. Moreover, the need to generate electricity from nuclear as securely and safely as possible will continue to drive the replacement market and support the development of nuclear power plants with the highest level of safety.

Rajasekaram adds: "Currently, the industry faces concerns regarding project funding, processing of nuclear waste, safety issues, aging of nuclear facilities, lack of skilled workforce, and social acceptability. However, with the industry striving for the highest standards and commitment to safety, upcoming nuclear power plants could sway opinions in an overwhelming favor for increased nuclear power adoption globally."

Ravindra-Heraeus sets up first pyrometallurgy smelter in India for precious metal catalyst recycling

London, the United Kingdom: The global market for nuclear power steam generators is projected to grow marginally to reach $1.02bn in Yr. 2026, with a 0.5% compound annual growth rate (CAGR) between Yr. 2019 and Yr. 2026, according to GlobalData -- a leading data and analytics company. The market for steam generators will be dominated by new installations; however, replacements will witness higher growth over the forecast period.

The company's latest report: ‘Steam Generators for Nuclear Power, Update 2019' reveals that the market for new installations is expected to hold steady, whereas replacements will witness significant growth. With countries shifting towards low carbon power generation and resource diversification, nuclear will remain vital to the power sector development for many countries across the world. However, the push towards nuclear power adoption is not uniform worldwide, with anti-nuclear sentiments defining the pathway for nuclear power development in certain key markets.

APAC is expected to dominate the market with $4.8bn by Yr. 2026. The inclusion of nuclear power in China and India will drive the new installations market, whereas Japan and Republic of Korea will see their market to slowdown. Other countries within APAC (such as Vietnam, Bangladesh, and Uzbekistan) have strong projections for nuclear, driving the regional market for steam generators. Although second to APAC, Europe is likely to be the fastest growing market, with the market value expected to grow at a CAGR of 11.4%, supported by Russia and the UK. Nirushan Rajasekaram,Power Analyst for GlobalData, commented:"Several factors such as increasing demand for electricity especially in developing regions, low power generation cost, high efficiency, and carbon emission concerns are prompting the utilization of nuclear power. Unlike renewable energy, nuclear provides low carbon electricity with a significantly high degree of reliability and is already supplying to power demand on a large scale."

The Fukushima disaster in Yr. 2011 was the watershed moment for the nuclear power industry, following which anti-nuclear views grew and governments opted for measures that restricted nuclear power growth.

Countries across the world such as Japan, Germany, France, and Republic of Korea proposed reducing the role of nuclear power. Operational safety 30 • April 2019

Udaipur, India: Ravindra-Heraeus, India’s leading precious metals service provider, has set up the first pyro-metallurgical smelter (Plasma Metal Recovery System) in India. The Indo-German joint venture is notably investing to satisfy Indian customer request by expanding its precious metals’ recycling capacity. The new technology, featuring a capacity of about 1,500 tons per year of auto-catalysts and equivalent, will allow Ravindra-Heraeus to recycle Platinum Group Metals from the growing number of spent automotive emission, insoluble aluminium-based catalysts and a wide range of diverse high-melting oxide-based catalysts per year.

Platinum Group Metals are used in homogeneous and heterogeneous catalysts in a wide range of applications, such as production of chemicals, gas purification, and chemical processes. India has no natural resources for Platinum Group Metals and thus relies either on imports or recycling specialists, such as Ravindra-Heraeus. The investment in the new technology will complement Ravindra-Heraeus' chemical-based hydro-metallurgy processes and allows the company to create ten new high-tech jobs in the region.

"Our new plasma facility underlines our market leadership in India in precious metals processing. We will be the only fully integrated Precious Metals refiner in India, offering pyro- and hydro-metallurgy in our facility. This will allow us to offer new services to our customers in the whole country", said Shailesh Choksi – the Managing Director of Ravindra-Heraeus Pvt. Ltd. The new Plasma Metal Recovery System will be one of the most efficient recycling systems worldwide. The less valuable material is free from hazardous material and can be used in the Cement and Construction Industry, thus saving other resources and energy, while the refined precious metals will be available for new Industry products.

Chemical Engineering World

CEW Industry News Fluor Joint Venture Completes Construction Work on Sasol Project in Louisiana

Akzonobel sheds light on “paint that paints itself” Amsterdam, the Netherlands: Do you see Dry-Paints get interesting these days? That's because, Akzonobel is into the development of a hi-tech coating that paints the surfaces on its own by harnessing solarenergy. Once a small amount is applied manually, the paint spreads over the chosen surface on its own with a photosynthesis-like process, which converts solar-energy into chemical energy. The secret lies in the lightloving nanotechnology embedded in the pigments, which act like invisible paint brush. This procedural on-and-off is to be controlled by the usage of a special 'Containing Tape' which marks the area, designated for painting.

This highly innovative quoting technology is still at the germination stage in Company's labs and are meant for hard-to-reach external parts of the buildings and structures, thus making maintenance safer and easier.

IRVING, Texas: Fluor Corporation has announced that its joint venture with TechnipFMC has successfully completed its engineering, procurement, and construction management services scope of work on Sasol's worldscale petrochemical complex in Westlake, Louisiana. The joint venture will continue providing assistance to the Sasol team with remaining activities by working with Sasol in parallel on transition plans for each unit and system.

The joint venture team will also aid in performance testing for the complex.

A 1.5-million-ton-per-year ethane cracker is at the heart of the complex, which also includes six downstream chemical units and associated utilities, infrastructure, and off-sites.

"This milestone is the culmination of nearly seven years of hard work

by Fluor's project team and we are proud to have successfully delivered our scope," said Mark Fields, President of Fluor's Energy & Chemicals Business in America. "We brought our extensive U.S. Gulf Coast construction and mega-project expertise using our integrated solutions approach, and we are proud of the lasting positive impact this project will have on Southwest Louisiana."

Started in November 2018, Fluor's joint venture began incremental asset transitions to Sasol upon completion of each unit or system. All units have been transitioned to Sasol except the low-density polyethylene unit, which will be handed over by the end of March 2019. The project achieved first steam in August, 2018. Utilities supporting the early process units were fully operational by the end of November 2018 and the linear low-density polyethylene unit achieved beneficial operations in February 2019.

More than 6,000 staff and craft were on site at peak to build the complex, which use the ethylene produced by the cracker to manufacture high-value chemicals for everyday-consumer-products. The project team strengthened and widened over two roadway-miles in the community to support the completion of more than 500 heavy haul transports to the project site.

The Fluor joint venture integrated a team of 30 main construction contractors and worked in collaboration with Sasol to strengthen the local economy, with more than 4 billion USD committed to Louisiana businesses.

AMECO, Fluor's Equipment Division, provided construction equipment to various subcontractors onsite.

The joint venture also invested in the local community by contributing more than 1,85,000 USD to local schools and charitable organizations throughout the project.

32 • April 2019

"We've taken a leaf out of the nature's book by using renewable energy to empower our paint", explains Akzonobel Scientist and Project Lead -- Opal Lofri, "Our innovation embraces all areas of product development including application. Here we have adopted nature's methodology to make it super-special. You may say, our paint grows on you!"

Expected to become a shining example of innovation at Akzonobel, this Synthesystem technology depends on various factors - such as the intensity of the daylight , the size of the area to be coated, etc.

"There's still some way to go to perfect this formula; but the initial trials have been promising", adds Lofri, "It all grew from the seed and now it seems anything is possible. Who knows how far we can go?"

Load Sensing by Light: SKF at the Hannover Messe Gothenburg, Sweden: SKF's new sensing technology takes monitoring to the next level, thereby equipping engineers with new insights on machine performance. SKF's this break-through technology uses optical fibers to measure forces in real time, in difficult environments, and without the use of electronics. The technology provides an instant overview of equipment performance by measuring load, speed, temperature, and many more other parameters. This also creates new opportunities to open up and to control the closed-loop processes. It also allows engineers to proactively prevent problems before they lead to costly shutdowns. And, this can be unfavourable running conditions, misalignments, or wear-n-tears.

SKF's Fiber Optic Sensing Technology offers many advantages that make it right for real industrial conditions. The technology uses light instead of electronics intervention thus enabling safe measurement in hazardous environments. The absence of electronics means the sensors are safe in electromagnetic field. The fibers transmit light at the long distance ( in terms of kilometres) without any disturbance, where wireless technology cannot be used, and which enables remote monitoring.

Victoria Van Camp, CTO AB SKF comments,"The theme of this year's Hannover Messe is co-creation and innovation through a partnership with Sweden; and for SKF as a result of their collaboration with Swedish Co-Lab, Fiber Optic Sensing Technology exhibits what Swedish Industry excels at. We combined our specialized industrial knowledge with the digital expertise of our leading partners and customers. The result revealed the performance of certain parts of a machine - previously remained in shadows - by only using this power of light."

This technology has been exhibited at Hall 27, Stand H30 of Swedish Paviliion in the Hannover Messe from 1st to 5th April 2019.

Chemical Engineering World

CEW Features Technical Article

Challenges in Setting Up ETP For Refineries Petroleum refining is a complex operation and unit operations within refineries vary depending on the type of crude and the type of end products. Refining is a water intensive operation which generates large quantity of waste water that needs to be treated so as to avoid environmental degradation. A proper understanding of the unit operations as well as pollutant loads is necessary in order to set up a suitable Effluent Treatment Plant (ETP). This article discusses about various challenges that we have faced in the designing and operating of several Refinery ETPs in India.

C

haracterisation Of Waste Water In order to design an ETP for an upcoming refinery, design parameters like the flow rate, Biological Oxygen Demand (BOD), Chemical Oxygen Demand (COD), Suspended Solids (SS), Oil & Grease (O&G), Sulfides, Phenols, Ammonia etc., have to be assumed.

The selection of the scheme and the estimation of unit sizes depend on the inlet characteristics and hence it is imperative that the assumed design parameters be as close to the actual parameters that will be encountered once the plant is commissioned. It is quite normal to assume higher values while designing the plants.

However, one should keep in mind that some processes do not perform efficiently when they are over designed.

separator followed by a Dissolved Air Flotation (DAF) or Induced Air Flotation (IAF) unit.

• Flow Equalisation: Flow of wastewater generated from refinery from various manufacturing process units is not uniform. The flow variation is equalised by providing an equalisation tank of sufficient capacity and constant flow is maintained in all downstream treatment units. This makes the process control much easier.

• Removal of Suspended Solids: This is achieved using a clarifier or it can be combined with O&G removal in a DAF unit

Typical Treatment Scheme The treatment philosophy adopted to treat refinery waste waters consists of a series of steps to sequentially remove the pollutants so that the treated wastewater meets the required regulatory norms. The typical treatment steps are:

• Removal of Sulphides: Lower sulphide concentration can be handled in biological treatment system. However, high concentrations of sulphides need to be taken care before wastewater enters into biological treatment system.

Oxidation of sulphides using Hydrogen Peroxide is most popular method of oxidising them.

• Removal of O&G: This is necessary as downstream operations are sensitive to the presence of high levels of O&G. In a refinery wastewater treatment system, two steps of oil removal are typically required to achieve the necessary removal of free oil from the collected wastewater prior to feeding it to a biological system. This oil removal is achieved by using an American Petroleum Institute (API) or Tilted Plate Interceptor (TPI) or equivalent oil water

• Biological Treatment: Various biological systems have been adopted including Activated Sludge Process, Bio-tower, Sequential Batch Reactor, Anaerobic reactors, Membrane Bioreactors etc. Every process has its own inherent advantages and disadvantages and a suitable system has to be selected by the designer based on factors such as organic load, treatment efficiency required, land area available etc.

34 • April 2019

• Polishing of Treated Waste Water This step includes units like Pressure Sand Filters (PSF), Dual Media Filters (DMF), Activated Carbon Filter (ACF) to remove the residual suspended solids as well organic pollutants that have passed through the earlier treatment steps.

• Reuse and Recycle : As the refinery consumes a large quantities of water, it is imperative one must try and reuse the treated waste waters back in the process. Additional treatment units like Microfiltration, Ultrafiltration or Reverse Osmosis may be adopted in order to meet the reuse water quality that is required Challenges and Solutions in Biological Treatment of Refinery Wastewater The key treatment step in the refinery ETP is the biological treatment as the bulk of the pollutants are removed in a cost effective manner in this step. Hence it is important to design this system in a robust manner so that it can operate efficiently. It is important to note that in the biological treatment step, the pollutants are degraded by microorganisms and it is imperative that a conducive environment is maintained such that the microorganisms can operate up to their maximum potential. A list of various factors that influence the design and operation of the biological system are given below: • Fluctuation of Wastewater Characteristics: One of the main challenges in refinery wastewater treatment is its variation in characteristics.

As mentioned earlier, when assuming the Chemical Engineering World

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CEW Features in a biological system of a refinery is shown here (Figure 1).

Figure1: Foam in refinery

Figure2: Typical Refinery ETP

pollutant load for design of the ETP, it is normal to assume higher values so that the designs are ‘safe’. This causes problems during the operation of the ETP when the actual pollutant load is much lower.

Also, based on variations in quality of crude and refining process, wastewater quality also varies. The biological system should be selected to take care of these variations. The biological system should be able to vary process parameters such as air supply, Mixed Liquor Suspended Solids (MLSS), Food to Microorganism (F/M) ratio, etc., to suit variations in feed.

Modular design of biological process also helps in handling variations of wastewater quality. If provided with multiple process tanks, plant can be operated based on the actual pollution load by using all process tanks or part of them.

• Oil & Grease: The performance of the O&G removal equipment is sometimes upset due to a surge in the inlet O&G quantity due to dumping of oil within the refinery. This causes O&G to slip into the biological system affecting the microorganisms. This also causes foaming in the aeration tanks that affects the quality of the treated water. A figure showing the foaming 38 • April 2019

• Sulphides: Refinery wastewaters contain high levels of Sulphides that are toxic to microbes and hence have to be removed prior to the biological treatment.

In case sulphides slip into the biological system, it exerts demand on the aeration system since it consumes the oxygen that is meant for the respiration of the microorganisms. Hence it is normal to consider a safety margin in the design of the air blowers so that it can meet any contingency due to sudden air demand because of sulphides. Care should be taken that sulphide concentration in biological system are below toxic limits.

• Complex Organic Compounds and Heavy Metals: Complex organic compounds such as phenols, benzene products, etc. are also part of refinery wastewater. Their concentrations depend on the source and quality of crude oil. These compounds are not easily biodegradable and may be toxic to biological system at higher concentrations.

Hence, the ETP should be designed to handle these complex organics in case they are present in wastewater. Heavy metals also pose problem to biological treatment.

Both complex organics and heavy metals should be taken care in pretreatment if present in higher concentrations.

• Nutrients: The growth and performance of the microorganisms depend on the availability of critical nutrients like nitrogen and phosphorous in the waste water.

Ideally, a BOD:N:P ratio of 100:5:1 is required for best performance. Normally abundant nitrogen is present in the refinery wastewater. However, it is important to constantly analyse the wastewater and add nitrogen (typically as Urea) and phosphorous (as Phosphoric acid or Di Ammonium Phosphate) to make up for any deficit.

Many a times, total nitrogen levels in the wastewater are much more than required which necessitates treatment to reduce them. Hence, the biological system selected should be able to remove excess nitrogen along with organic pollutants.

• Energy efficiency: The oxygen required for the microorganisms are delivered through fine bubble diffusers that release small bubbles of air from the bottom of the aeration basins. Air blowers are installed to supply air into biological process. Air blowers constitute major portion of power consumption in the ETP. Any steps taken to optimise energy consumption shall result in energy efficiency of the plant.

Biological process should be provided with oxygen control system to supply air as per the organic pollution load coming into it. Dissolved Oxygen (DO) or Oxygen Uptake Rate (OUR) based blower control optimizes both energy consumption and process performance. Energy efficient blowers further improve the energy efficiency of the ETP. • Process Automation: Due to variations in wastewater characteristics, it is advisable to install process automation to control vital process parameters such as DO, OUR, MLSS, Sludge recirculation, Sludge wasting, etc. This helps in automatically keeping the process parameters at their optimum levels and generates consistent quality of treated wastewater.

Conclusion Refinery wastewater characterisation is very complex exercise that requires an understanding about the refining processes involved. The designing of the ETP is a challenging job as treatment units have to be robust enough to handle continuous variations in the concentration of pollutants.

The operation of the biological system governs the performance of the ETP, as it removes the bulk of the pollutants.

Ideal operating conditions have to be provided for the microorganisms in order to ensure effective treatment. The biological system should be selected to handle any variations in flow and characteristics of refinery wastewater.

Author’s Details Satya Narayana Y V V SFC Environmental Technologies Pvt Ltd satya@ctechsbr.com Chemical Engineering World

FIRST-CLASS REFINING OF CATALYSTS Rely on our refining services to recover precious metals like Platinum, Palladium and Rhodium from used catalysts.

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CEW Features

Modularization of Onshore Plants Modularization is a plant design concept that is fast gaining acceptance across the construction industry as a means to reduce cost, improve quality and speed up construction. This article attempts to discuss the various factors that serve as drivers for modularization techniques, as well as the pros and cons of the concept.

What is a Modular Plant?

Simply put, a modular plant consists of a skid on which the various plant components such as equipment, piping, structures, supports, insulation, distribution boards, control consoles, fire alarm panels, cable trays and cabling and even light fittings are all mounted. Each module is thus a fully contained process unit and could represent an entire plant, or part of a plant. This skid is then transported to the project site and installed at the location with minimal effort.

•

• Drivers behind the Modularization Concept The traditional approach to design and construction of a plant involves in-situ construction of the facilities using locallysourced labor, resources and material.

However, in specific cases, EPC companies nowadays are increasingly going for modularization.

•

The factors that influence the decision to go in for modularization are as follows: • Remote site locations: Remote site locations throw up a variety of challenges, especially in terms of availability of skilled labor, and the transport of materials to the job site. This is where the biggest advantage of module-based construction lies. A modular plant can be constructed in an altogether different location, far away from the job site, and then be transported to the site.

• Hostile weather conditions: Vagaries of weather, such as extreme hot and cold conditions, pose a threat to productivity, worker safety and associated parameters such as quality. In such cases various parts of the plant could be modularized and fabricated at a location where more favourable conditions for construction exist, leaving only the bare minimum 40 • April 2019

•

work and module interfaces to be carried out at site. field construction costs: High Construction cost can form a major component of the overall project cost, especially if labor costs are high. It would therefore help reduce the project cost if field work is minimized and most of the work is modularized. The module could be fabricated in regions such as Asia or Eastern Europe where labor is relatively cost-efficient.

Crashed schedules: With modularization of a plant, work can go on in parallel on different modules. Even multi-storied structures can be handled in this manner.

This can help in improving schedules as opposed to the linear construction sequence of stick-built designs.

Where repeatability or duplication is possible: Companies are already exploring the options of breaking up a large capacity plant into smaller modules of lower capacities. Thus an in-situ conventional natural gas liquefaction plant with a capacity of 2.5 million metric tons per year (MMtpy) could be broken into 10 typical modules, each of 0.25 MMtpy capacity, shaving off an entire 12 months from the construction schedule.

Where reusability is a factor: In a bid to be competitive in an already crowded market, companies are looking to reduce costs all the time. Modules designed to be reused across locations can greatly reduce capital investments.

Modularization as a concept has been used widely in the offshore industry, but is now making its way into the onshore industry for the reasons stated above.

At the same time, some projects may not lend themselves to modularization.

If the project site is in a location where infrastructure is good and skilled labor is abundantly available, there may be no point in using modularization.

It is to be noted however that while modularization can complement in-situ site work, it cannot totally replace it.

Certain activities such as site grading, civil foundation work, large equipment erection and interfacing between the modules can only be performed on site.

Planning and Execution: While a modularization strategy seems to offer all the solutions to typical in-situ construction problems, it is important that it is thoroughly planned out during the early and detailing phases of the project, and engineered efficiently.

A few important points to be considered are: • Evaluation of the strategy: While modularization can have major cost and schedule benefits, it could lead to complexities if not evaluated properly.

The plant must be of a nature such that parts of it can be modularized. The added design and coordination costs along with the transportation costs must be carefully estimated. The modes of transportation that are likely to be employed (truck, rail, barge etc.) and the availability of a roll-on/roll-off (RORO) jetty in port or at site must be determined at the beginning of the project as they also have an impact on the way design is carried out. Ultimately the modularization must provide definite cost benefits over the in-situ method.

• Deciding which part of the plant lends itself to modularization: The dimensions and weight of a module have a direct bearing on the shipping cost of the Chemical Engineering World

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CEW Features

•

•

Figure1:3DModelofaprocessmoduleforanonshoreplant.Notetheextentofdetailingthathasbeencarriedout.

module, and must therefore be evaluated carefully. For example, very long or heavy equipment cannot be a part of modularization as they would result in large module sizes. These would be difficult to transport, and in fact may end up being more expensive than the in-situ method. In projects which involve extremely tight schedules, multiple module fabricators may be considered, but the coordination between them is critical.

• Advancement of engineering activities: One of the success factors in employing modularization is to have the modules delivered to the construction site as soon as the foundations or structures to receive them are ready. Modules therefore have to be engineered in advance so as to extract the full advantage of the concept.

• Minimizing revisions to documents: As mentioned above, the construction of modules should start early in order to have them delivered early. Engineering revisions can have a negative impact on the module progress, and must be avoided. A project that is likely to see concurrent engineering may be a bad candidate for modularization.

42 • April 2019

When using • Procurement: modularization, it may be a good idea to let the module fabricator procure the majority of the module components so as to reduce interfaces within the module.

This will also give the fabricator a freer hand in developing the module.

• Monitoring: Adequate monitoring of the module constructor’s progress is essential, though too much interference can be counter-productive. In case the purchase of materials is not in the module builder’s scope, it is important to monitor the supply of materials to the module minutely to ensure that module construction is not affected.

•

•

Design Considerations: While modular designs do not differ greatly from conventional design methods, they need some special design considerations.

Some of these are listed below.

• A clear scope split between the module vendor and the contractor is essential.

The scope document must clearly define the contents of the module as well as the termination details. Since the module vendor will be working with limited space, it may not be possible to accommodate

•

scope additions at a late stage without causing a major impact on cost and delivery. The termination details such as pipe ends, flanges and junction boxes should be located towards the edges of the module so that field construction has minimal (or preferably no) interface inside the module.

The module size and weight are the governing factors and will drive the layout, rather than the layout considerations driving the module size. The size of the transporting truck or the capacity of the barge that is used to transport the module will usually drive the design. The module vendor will therefore work within a very limited space.

However modularization does not provide any concessions on the basic safety distances to be maintained between facilities within the module, access and egress requirements, operability and maintenance requirements. All these are to be met within the given size, and this poses the biggest challenge to design.

Modules may be oriented differently during module construction and transportation as compared to the final position in the field. It is therefore extremely important for the design team to be aware of the fabrication and transport details and account for any additional forces in design.

Modules will be subject to lift forces as they are being lifted for transportation and erection.

Such lifting points must be clearly identified and the corresponding forces determined. The modules will also encounter acceleration forces during transport, including pitching, surge, sway and rolling if they are being transported to the job site by ship or barge. The structures must thus be designed not only for design and operating considerations, but also for lifting and transport.

In other words, modular structures need to be designed to be safe in the assembled module as well as in the final erected form. Additional strengthening may be provided to avoid damage to the structure under different circumstances. On account of the Chemical Engineering World

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Figure2:Modularpiperacksbeingerectedatsite.Thealignmentofthefoundationsisextremelyimportantinsuchcasesasamismatchwoulddirectlyresultinmisalignedpipes at the interface. Note the gaps between the pipes in the module. A make-up piece is field-welded in the gap and takes care of any site tolerances.

additional considerations of orientation, lifting and transport, modular structures usually use more steel than in-situ ones.

• Weight management is an important aspect that often gets overlooked while designing modules. Determination of the weight and the center of gravity (COG) is a key component in the weight management process. The weight and COG are also important factors for transportation as they will proportionately increase acceleration forces. Some allowances should be made in the weight and COG calculations initially so as to provide a degree of flexibility during design. These allowances can be gradually reduced during the course of detailing when more definitive information is available.

Pros and Cons: Based on the above, the pros and cons for the modularization concept can be summarized as follows: 44 • April 2019

Pros: • Higher productivity • Shorter construction schedules • Heavy construction equipment such as cranes need to be deployed for a shorter duration • Minimum field inventory • Better quality • Increased safety • Cost benefits

In short, modularization adheres to the ageold principle that it is prudent to spend extra efforts and resources in the engineering office rather than spending more time at construction sites!

Modularization can be a cost and time saving alternative to the conventional insitu construction methods. With good initial planning, a clear scope split and proper follow-up, it can be a winning strategy.

Cons: • High module transportation costs • Heavier cranes and machineries to be deployed for construction to handle complete modules as compared to individual components • Heavier structures since transportation and lifting must be factored into design • Detailed planning is required upfront • Increased coordination required between multiple agencies

Author Details

Karthik Nurani Deputy General Manager, Projects Aker Solutions Chemical Engineering World

CEW Features

More Than One Valve Or Pump Choice for Every Application With hundreds of different types of valves in the industry today and thousands of manufacturers globally how do you know which is the best product for your process? Chances are that there may be several good alternatives that could serve you well with a high mean time between failure (MTBF). But the solution is not always 100 per cent clear. The reason there is not a one size fits all. Solution is that every process has variables. The variables can be numerous and certain types of valves will perform better in one set of variables than another. It is often not as simple as just the pressure, temperature and the medium.

P

ressure, temperature and medium are excellent starting points though. But what about other variables?

Other factors that may impact your valve selection may be: • Specific gravity of medium • Percent solids • Vertical valve installation • Isolation required in both flow directions • Minimum, normal and maximum flow • Manual, pneumatic, electric or hydraulic • Supply air pressure provided • Size of valve • Threaded Connections • Velocity of flow • Percent solids • Horizontal valve installation • Isolation required in only one direction • Concentrations of chemicals contained • Required tightness of valve • Voltage of electricity provided • Pipeline material in which the valve be installed • Flanged connections The valve manufacturer or representative who asks a high number of questions and requires specific information will probably be the ones that you should trust. By capturing as much information as possible hopefully leads to less headaches and troubles for the owner.

Acceptable MTBF varies from process owner to process owner and also in various 46 • April 2019

applications. In some brutal processes, a valve that needs to be repaired every six months may be acceptable. In certain processes, if a valve fails or needs repair every 10 years then that valve can be considered poor quality or the wrong choice for the application. If your process is clean and non-corrosive you may choose from a wide variety of inexpensive ball valves.

Even when there are corrosive chemicals, you still choose a ball valve with different alloys that are able to survive in corrosive chemicals. Ball valves are produced by the thousands and are widely utilized in a high number of industries.

Dealing with Abrasive Mediums What choices do process owners have when they have an extremely abrasive slurry?

The valve selection quickly becomes more limited. Of course the owner can decide to standardize and stick with a ball valve or similar. However, by doing so they are likely to face frequent repairs or replacements of that valve. If the slurry is 35 per cent solids, lime slurry, or 60 per cent minerals slurry then the options for a valve with long MTBF becomes even more limited. For instance, lime slurry is unique slurry utilized in a multitude of industries such as chemical processing, mining, pulp and paper, power production, iron and steel, and many more.

Lime causes many troubles for various types of valves because it combines the abrasive aspect of the slurry as well as the tendency to scale inside the pipeline and on stationary surfaces. Lime does not dissolve in solution but rather is a suspended solid.

It is necessary to keep lime slurry in motion or the particles will settle out of solution and

create more process problems. Valves that have areas for material accumulation will likely have problems dealing with lime slurry.

For instance, with a ball valve, the metal ball will become coated with a build-up of scale and this scale will be dragged through the Teflon seats when the valve is opened or closed. This action will begin to destroy the Teflon seats and the valve’s ability to continue to close tightly. Also the body cavity area of the ball valve will collect build-up that will force operating torques continuously higher. This can lead to the valve actuator stalling and ball valve stem breakage.

In slurries containing minerals of up to 6080 per cent solids, a standard valve will not be likely to survive the abrasive nature of the medium. So process owners might consider different alternatives than their standard valves. Two types of valves that are suited for abrasive slurries are rubberlined knife gate valves and pinch valves.

Pinch valves utilize a rubber sleeve that lines the entire inside of the valve body.

This rubber sleeve completely isolates the internal moving components during normal operation. In most On/Off applications the valve sleeve is 100 per cent full bore and has no areas for material accumulation.

A pinch valve is also one of the only selfcleaning valves available. Any material build-up on the interior of the rubber sleeve is cleaned when the valve is closed. The rubber sleeve is flexed with each opening and closing thus breaking up scale and the build-up material is flushed downstream.

Also, having all moving components of the valve isolated from the process medium insures smooth trouble-free operation.

Chemical Engineering World

CEW Features

Figure1.FlowroxPVEpneumatically-operatedpinchvalve

Figure 2. Flowrox SKW Rubber Lined Knife Gate

Figure 3. Flowrox LRD Rotary Disc Valve

Rubber-lined slurry knife gates also use rubber sleeves to combat extreme wear caused by abrasion. Many rubber-lined knife gates incorporate a flushing port on the bottom of the valve. This allows builtup material to be pushed out the bottom of the valve to allow for trouble-free operation.

With scaling and highly sticky medium, the process owner might be wise to use a Tefloncoated knife gate to prevent and allow easy release of any scaling material on the gate.

In a large majority of mineral-based slurries the Teflon-coated knife is not required. A secondary seal in the valve body helps to clean the gate of material build-up.

high-pressure slurries up to 1,500 psig and higher temperatures.

Progressive cavity pumps can be a viable alternative as well. This type of pump can vary substantially regarding the per cent solids it can handle and is greatly influenced by the nature of the medium being pumped. For instance, with a waste water sludge this type of pump can handle between 8-20 per cent solids. However, if the medium is homogenous then it may be capable of up to 65 per cent solids. One key downside to a progressive cavity pump is that it cannot be allowed to run dry or damage will occur to the rotor and stator. New designs incorporate evenwall stator technology and 2D and 3D rotor geometry. These newer designs can result in up to 17 per cent greater hydraulic efficiency and more pressure produced per stage. The result is progressive cavity pump that runs at lower RPMs resulting in less wear and greater pressure produced in a smaller footprint. One other new advancement is the ability to change the mechanical seal without disassembling the rotor and stator or the motor and frame.

This can save numerous maintenance hours and allow a mechanical seal to be removed and replaced in approximately one hour without removing the pump from its location.

Another unique valve is a rotary disc valve.

This product operates similar to a knife gate valve with a linear operation of the closing mechanism. However, instead of a metal gate used for closing, it utilizes a rotating disc. The disc rotates in a circular fashion on every opening and closing. The advantage is that the sealing surface is constantly being rotated so that the slurry does not continuously impact a single location every opening and closing. The disc secures tightly into a wedge upon closing and can incorporate rubber and polyurethane sealing in the seating area.

This type of valve is suited for extremely 50 • April 2019

Pumps like valves face the same types of challenges. Pump selection can be much more costly compared to valves if the incorrect pump is chosen. Pumps are dynamic and a working piece of machinery.

If the pump is not running then the process is not flowing. Selection of a pump with a low MTBF may result in numerous process stoppages per year and costly maintenance and repairs. Similar to the above discussion of valves, which pump should you choose when dealing with abrasive and high per cent solid slurries?

There are multiple alternatives but let’s examine a few well-known styles. The first highly-utilized type is centrifugal pump. They are very good for slurries up to approximately 40 per cent solids.

In most cases these pumps will have rubber -lined internals and rubber-lined impellers. Certain manufacturer’s do in fact manufacture and sell pumps for slurries up to 50-60 per cent solids. However, process owners may learn that by pumping such thick slurries with this style of pump may increase repair frequency and repair costs quite substantially.

The final pump product that is capable of very abrasive mediums up to 80 per cent Chemical Engineering World

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Figure 4. Flowrox C Series PC pump with Even-Wall Stator and 3D Geometry Rotor and Removable Mechanical

solids is the peristaltic pump. This style of pump can run dry for extended periods without damage to pump. By pumping 80 per cent solids, a massive amount of water can be eliminated when trying to move mineral-based slurries. If a process owner moves a significant amount of minerals or slurries then the entire process plant can be downsized by pumping 80 per cent solids versus 30 per cent solids. A peristaltic pump also has the ability to perform suction lift applications. The nice feature of a peristaltic pump is that the only two normal wear components are the rubber hose and a small amount of glycerin in the housing.

that is generated. Also, this older shoe style design compresses the hose twice per revolution, which results in early hose failure.

It is important to mention that not all peristaltic pumps are similar. One style incorporates two metal shoes that compress the rubber hose. This style generates a significant amount of heat and requires a massive amount of glycerin in the pump housing to dissipate the heat

Conclusions

Figure 5. Shoe design Peristaltic Pump.

52 • April 2019

New peristaltic designs incorporate a single roller that rolls over the rubber hose only once per revolution. This design eliminates the requirement for massive amounts of glycerin in the pump housing. Also, since the rubber hose is only compressed once every 360 degree revolution, the hose typically lasts 2-5 times longer than shoe design peristaltic pumps. The single roller design allows peristaltic pump availability to be significantly greater than old designs

When dealing with abrasive process mediums, users may have to invest more time and effort to find the best products to survive in these processes. The time spent trialing various products may reap some significant rewards. Process downtime and

Figure 6 Flowrox LPP-T Rolling Peristaltic Pump

frequent costly repairs can be minimized.

Certain types of valves and pumps can result in repair costs in excess of $100,000 per year. As technology advances there may be better alternatives that can eliminate or severely minimize these costs. When dealing with slurries of an abrasive nature, total cost of ownership (TCO) can have an extreme impact on the operating cost bottom line.

Todd Loudin President/CEO North American Operations Flowrox, Inc E-mail: Todd.Loudin@Flowrox.com Chemical Engineering World

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owder mixing is a critical process in chemical product manufacturing, ie, micro nutrients, pesticide, herbicide, coating chemical, metal powder, thermostat regin, etc, because the desired final product is purely dependent on the mixing of products and its attributes.

Hence, the experts always suggest using proper equipment for an optimum mixing.

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Single-Shaft Paddle Mixer This horizontal single shaft batch mixer of A&J Mixing Technology, Canada is the most popular, ideal machine to guarantee the perfect mix, high throughput and economic operations. It is versatile and ideal for adding shear.

The horizontal mixer can support bags with ingredients; the operators do not light the bags. Hence, Toshniwal offers PTS product.

Powder Transfer System Toshniwal introduced vacuum conveying system and offer solution for the transfer of powder, granules and flakey ingredients with expertise in vacuum technology more than three-decades.

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those under vacuum or pressure in a totally safe way preventing the dust formation, the system can be retrofitted/ integrated into the existing production line.

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54 • April 2019

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Novel Mobility Aid Master Batch Improves PET Bottle Production Efficiency

N

ovel mobility aid additive master batch for ISBM PET Bottles helps maintain clarity, eliminates need for spray coatings, keeps PET production running without interruption.

Sukano launches a novel master batch that allows Bottle makers and brand owners to run conveyor belts and robots at maximized speed, increasing productivity and yields.

Thanks to this state-of-the-art mobilityaid additive master batch, problems like release, scuffing, and sticking are a thing of the past.

Schindellegi, Switzerland - Sukano, a global leader in the development and production of additive and color masterbatches and compounds for polyester and specialty resins, has announced the launch of a new mobility aid additive masterbatch for Injection Stretch Blow Molded (ISBM) PET bottles. This new additive masterbatch allows bottle makers and brand owners to run their conveyor-belt systems and production robots without the need for a spray coating.

Bottles must rotate freely as they pass through the production conveyor, as forced rotation caused by friction can lead to a blockage on the line. The new Sukano mobility-aid solution, believed to be the first commercially available for this application, is provided as a solid PET masterbatch that is blended with virgin PET or RPET material during molding or processing. Even at low concentration, the masterbatch disperses consistently through the PET material, reducing its coefficient of friction (COF), and modifying the surface texture with a microstructure.

Benefits of a masterbatch mobility aid over spray coatings This new masterbatch produces a siliconelike mobility aid effect in PET material, yet has been engineered to preserve material clarity with minimal impact on haze. It is well suited to clear, translucent, and colored bottles produced for personal care, household and cleaning, cosmetics, as

56 • April 2019

Photo Credit: Sukano

well as food and beverage applications. It is also widely applicable, as PET material containing the new masterbatch can be run on existing ISBM bottle production equipment without modification.

Sukano is currently assisting a customer in the US to optimize its production process.

"Our customer, a key and leading global player in the consumer goods industry, reported that PET bottle mispicks by their production robot decreased by sixfold when using our Sukano Mobility Aid masterbatch," stated John Price, Director of Technology and Operations in the US. The consistency and even distribution of the masterbatch lead to improved performance. The additive masterbatch preserves secondary processing steps that require adhesion, like labelling and printing. It also helps to eliminate the cost and cleaning requirements associated with spray coatings, which leave a waxy residue on bottles and packaging equipment that must be removed through regular cleaning. Additionally, the Sukano Mobility Aid masterbatch avoids the potential risk of microbiological contaminations of bottle surfaces by aqua-based coatings, which may require additional additives or application in a clean-room environment.

Expertise drives innovation Significant effort was needed to engineer a product that combined the necessary properties with good thermal stability and performance-enhancing benefits to preserve material clarity and transparency.

To develop the new PET additive masterbatch, Sukano leveraged its over 30 years of experience with masterbatches for film extrusion in packaging applications into the bottle packaging PET application and broadened its expertise in this field.

Sukano Mobility Aid offers a valuable and safe alternative for bottle makers who, until now, have had to apply spray coatings to PET preforms and bottles to manage the production problems associated with ISBM production," said Michael Kirch, Global Head of R&D. "Bottle makers and Brand owners can now run their conveyor belts without interruption and minimize the mispicks by production robots, thereby improving productivity and maximizing yields, allowing the highest efficiency rates. Our high-performance masterbatch technology is applicable to any conveyor systems", Kirch added.

Circularity as a decisive design criterion Chemical Engineering World

CEW

Marketing Initiatives to Sukano’s products placed in the market PET recyclability is essential in an increasingly environment-conscious world — and Sukano's innovative mobility aid makes no compromise in this area, as it is formulated according to the European PET Bottle Platform (EPBP) guidelines. These enable the industry to innovate and bring new PET bottle packaging solutions to the market without disrupting the existing clear PET recycling value chain, with special focus on bottle-to-bottle recycling.

Sukano is firmly committed to achieving the concept of a "Circular Economy", and as such is an active member of the Association of Plastic Recyclers (APR) and Petcore Europe, which recently joined forces with Plastics Recyclers Europe (PRE) to create the Global Plastics Outreach Alliance and publish a globally harmonized definition of plastics recyclability.

Chemical Engineering World May 2019 Special Issue

Specialty Chemical Industry – Challenges & Prominent Trends

The new mobility aid supports the PET value chain to keep and further enhance its circularity goals to meet the voluntary pledge of exceeding the Plastics Strategy targets for recycled PET rates by 2025.

Product commoditization, communicating differentiated value, fluctuating raw material cost, appropriate response strategy to aggressive customers, etc. are some of the mentionable challenges the Specialty Chemical Industry is facing these days.

The industry is also experiencing prominent positive trends in ‘Sustainability and the Circular Economy’, ‘Digitalization’, ‘Innovation’, and ‘Accelerated Globalization’.

For details contact: Erika Ahvenainen Senior Communications Specialist Hexagon PPM E-mail: Erika.ahvenainen@hexagon.com

In light of all these aspects, our May 2019 issue of Chemical Engineering World (CEW) will have a major focus on Specialty Chemical Industry – it’s challenges and major trends.

Please stay tuned with us!

Marcel Veldhuizen Vice President Fabrication Solutions Hexagon PPM E-mail: Marcel.veldhuizen@hexagon.com 58 • April 2019

Chemical Engineering World

CEW

Marketing Initiatives

Innovative X-ray inspection systems Dymond D and Dymond S for flexible product design and optimum quality assurance

W

ith the innovative Dymond D side shooter and a new edition of the Dymond S, Minebea Intec is now offering a modernised portfolio of premium products for horizontal X-ray inspection.

With the addition of these devices, the leading supplier of weighing and inspection solutions wants, among other things, to make it easier for its customers to decide on which packaging materials to use.

For uncompromising quality assurance, the use of an X-ray inspection system as a critical control point at the end of the production line is essential. Particularly in the food, beverage and pharmaceuticals industries, having full control of all packaged products gives you a valuable opportunity to reliably detect foreign objects such as pieces of glass, stones, metal or plastic parts before the contaminated product reaches the consumer. Which X-ray inspection system is right for me?

Alongside systems for bulk materials and smaller products, Minebea Intec now offers not one but two advanced innovations for tall, upright packaging. Both systems are designed for the reliable inspection of tins and Tetra Packs for example, as well as

other tall, upright packaging made from glass, metal or plastic. Both systems have been developed for use in highly automated processes and to meet the challenges of Industry 4.0.

Dymond S and Dymond D – the perfect side shooters for easy installation and optimum inspection With its horizontal X-ray inspection systems Dymond D and Dymond S, Minebea Intec has seized the opportunity for optimisation, reworking the safety concept with improved emergency stop-switches and relays.

On top of that, the company has also launched a re-designed cooling system which is protected against water and dust penetration; and therefore ensures that the system is easier to clean. For systems in the Dymond S series, the Nema 4X cooler comes as standard.

As an extra bonus feature, the Dymond S also has a fully integrated 500 W Monoblock generator. This eliminates the need for active water cooling and therefore guarantees easier installation and maintenance. With the new generator boosting performance

The Dymond S side shooter, guarantees reliable X-ray inspection of tins, Tetra Paks and more, in a compact, hygienic design

from 320 to 500 W, the system can now handle a higher throughput and even more precise inspection of products with higher densities.

What makes Dymond D stand out is its maximum detection performance. The high sensitivity of its powerful image processors, combined with intelligent image processing, means it is able to detect even those foreign objects that are positioned vertically or lay hidden at the edge or at the bottom of the container.

Highly automated processes horizontal communication

and

For maintenance communication, statistical process control, and optimisation of automated production processes, Dymond D and S are available with Ethernet, OPC UA, Modbus, and SPC Enterprise connection.

Thanks to horizontal communication, these systems represent a first step towards Industry 4.0. The side shooters communicate with other systems along the production line to coordinate regular, automated and timely calibration.

Dymond D – uncompromising safety for better sustainability

The completely revised version of the Dymond D offers a variety of benefits, including reduced space requirement, improved mechanical structure and hygienic design 62 • April 2019

With the new edition of its flagship Dymond D, Minebea Intec is hoping to send a positive message to the food and beverage

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Thanks to its double-beam technology, the Dymond D can even reliably detect pieces of glass in glass containers, regardless of their position or direction

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industries. “The Dymond D side shooter with orthogonal double-beam technology addresses the issue of viewing direction and makes the invisible, such as pieces of glass on the sides of glass containers and contamination beneath lids or in the base of containers, visible”, explains Dr Thorsten Vollborn, Global Product Manager at Minebea Intec, “Together with the flexible operating software for filling and volume control, this technology opens the industry up to more design possibilities for glass containers and container sizes, without jeopardising safety for consumers. We are delighted to be able to make it easier for food and beverage manufacturers to decide whether to use glass or other product packaging materials that may be more sustainable and practical.” To ensure easy and environment-friendly cleaning, the design of the X-ray inspection systems already complies with the stringent hygienic design directives of the EHEDG, thus continuing the success of the Dymond series. These hygienic design features include polished steel housing, bevelled surfaces, and the IP65 protection class inspection tunnel.

All our publications are available online on their respective websites.

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Elmar Loof Minebea Intec GmbH Meiendorfer Str. 205 A D-22145 Hamburg, Germany Phone: +49.40.67960. 468 Web: www.minebea-intec.com Registered office of company: Hamburg Chemical Engineering World

April 2019 • 63

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Wacker Opens New Lab for Food Applications in Shanghai

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unich and Shanghai: Wacker Chemie AG opened a new laboratory for food applications in Shanghai. This specialized lab will enable Wacker to provide its customers in Asia with even better support in developing innovative and customized products in the fast-growing food market. The focus is on food ingredients, for e.g. free baked goods, whipped toppings or functional beverages; on dietary supplement ingredients such as highly bioavailable curcumin; and on chewing-gum applications, for instance moldable sugar-free gum.

Asia’s food market is flourishing. China’s food industry, in particular, is profiting from the strong purchasing power of its middle class consumers. At the same time, the sector must face new challenges.

Consumers are attaching ever-greater importance to healthy and sustainable nutrition, as well as to the products that are quick and easy to prepare. “We offer solutions to the challenges currently facing by the food industry”, says Dr. Gerhard Schmid, President of Wacker Biosolutions, “With our new range of services in Shanghai, we are strengthening our position as an innovative partner to the food sector on the Chinese market.”

Wacker Biosolutions is the Life Science and Biotechnology division within the Wacker Group, which in terms of nutrition mainly focuses on ingredients for food and dietary supplements. In order to optimally support its customers in different regions around the world, Wacker already operates three specialized food laboratories in Burghausen (Germany), Adrian (USA), and Singapore (Southeast Asia).

With the lab for food applications in Shanghai, Wacker is broadening its range of services in the fast-growing Chinese market. The Wacker Shanghai Center, the headquarters of our Wacker Greater China subsidiary, already houses a regional technical competence center, where Wacker experts tailor silicone and polymer products to the specific requirements of their Chinese customers. This technical center now also boasts an application laboratory for food-sector customers.

64 • April 2019

Wacker Chemie AG’s Regional Technical Centre in Shanghai now boasts an APPLICATION LABORATORY specifically for innovative food, dietary supplements, and chewing-gum applications.

Photo Credit: Wacker

“China is already the world’s largest market for food and beverages. And its growth continues to be strong. With our new lab for food applications, we are able to accommodate our local customers’ needs even better,” says Paul Lindblad, President of Wacker Greater China, “We offer support in developing innovative solutions that satisfy consumer tastes and expectations.”

The new laboratory, which covers an area of some 150 square meters, focuses primarily on applications involving cyclodextrins, cyclodextrin complexes and cysteine, as well as chewing-gum applications.

Cyclodextrins are ring-shaped sugar molecules, which Wacker bioengineers from plant-based raw materials such as corn or potato. They have different functionalities to be used in different food applications, such as dairy, bakery, desserts, and sauces to make them free from animal-based emulsifiers, cholesterol, or solid fats. Furthermore, cyclodextrins protect sensitive ingredients such as vitamins and coenzymes from harmful influences, for example oxygen or light, and they increase the bioavailability of hydrophobic substances like the natural antioxidant curcumin. Additionally, the sugar rings can mask the bitter taste of

health-promoting substances such as green tea extract. Wacker’s fermentation-based cysteine can serve as a vegan and halalcertified raw material for savory flavors and as a processing auxiliary in baked goods.

Wacker’s solid resins Polyvinyl Acetate make it possible to produce top-grade chewing-gum. The Candy2Gum technology developed by Wacker enables to produce sugar free gum with depositing technology to make the chewing gum in different shapes. Moreover, Wacker experts have developed the world’s first 3D-printing gum technology. The 3D printer that is available in the new food lab in Shanghai can be used to produce tailor made gum in specially designed color, shape, and flavor.

This opens up entirely new possibilities for the confectionery industry.

For details contact: Agnes Fröschl CORPORATE COMMUNICATION Wacker Chemie AG Hanns-Seidel-Platz 4 81737 München, Germany Tel. +49 89 6279 1588 agnes.froeschl@Wacker.com Website: www.Wacker.com Chemical Engineering World

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

CHEMICALS Shalimar Paints lays down the foundation of its Nashik manufacturing plant with a planned monthly capacity of 2,180-kilo-litres. Set to commence operations by April 2019 with a planned production capacity of 2,180-kilolitres per month, Shalimar's state-of-the-art Nashik facility will increase the brand's overall production capacity by 65 per cent. It is also expected to stimulate the local economy by creating around 200+ employment opportunities for prospective jobseekers in the region. The newest Shalimar plant hints at the brand's aggressive push to capitalise on the growing market demand for its high-quality, high-performance paint and coating products, as well as to further consolidate its position as one of the fastest growing paints companies in the country. Shalimar has also pledged further investment into its Nashik plant and aims to establish it as a key component within its regional distribution network, as well as its pan-India supply chain. The paint industry has been growing at a rapid rate in India and measures between 1.5 to 2 times GDP growths. Rapid urbanization, better transparency and consumer evolvement has been leading the growth of the industry.

Songwon Industrial Co Ltd a specialty chemicals company of South Korea has launched its new pilot plant in Panoli (Gujarat), thereby strengthening the organisation’s overall specialty chemicals development capability. Built on Songwon’s Indian site with all the necessary main unit operations, the new plant is equipped with the most up-to-date technologies and materials for producing a wide range of chemicals for a broad spectrum of applications - from one kilo up to several hundred kilo samples. To reinforce the organisation’s position in existing areas of business and enhance its ability to enter new areas, the new pilot plant will be supported by the Songwon’s strong local R&D team in Panoli, as well as its central technology innovation center located in Maeam, Korea.

Insecticides (India) Ltd has announced a ` 200-crore expansion plan to increase its capacity in the next three years. In the first two years, it would spend about ` 100-crore, followed by an investment of ` 100-crore in 2020. The firm is planning to set up an Export Oriented Unit in Gujarat with an eye on increasing export component of the business. Exports contributed about ` 35-crore in the total turnover of `1,109-crore in 2017-18. The firm has a share of about 5 per cent in the ` 18,000-crore crop protection market in the country.

MINING Coal India (CIL) is expected to put another 25-30 million tonnes (MT) of coal under the hammer in the ongoing quarter. This comes after e-auction volumes dipped following the decision to pump more coal into the coalstarved power sector through fuel-supply agreements (FSAs). The coal behemoth has been able to book 54-MT of coal through e-auction till December (first three quarters) as against 79-MT in the similar period of the last fiscal year, registering a 31.65 per cent dip. On the other hand, its offtake via the FSA route to power plants increased by over 12 per cent. As more coal gets routed via the FSA route, e-auction volume will be low. Production in January-March was expected to be substantial, which will leave Coal India with more to offer in auctions. It is expected that another 25-30 MT of coal will be offered this quarter on the auction platform. Coal consumers in the non-power sector have long been Chemical Engineering World

complaining about scarcity because most of this fossil fuel is being routed to feed coal-starved thermal power plants. Coal India’s production, as well as offtake, was hit in December owing to industrial unrest in its key production zones in Jharkhand and Odisha and cyclones, which disrupted production and supply lines. Besides, the availability of rakes from the Railways also constrained the company from supplying coal. South Eastern Coalfields (SECL), its most important subsidiary, registered a 13.1 per cent fall in production in December at 12.52 MT while Mahanadi Coalfields, the second-largest subsidiary, registered a 3.2 per cent dip at 13.05 MT. These two subsidiaries account for more than 45 per cent of Coal India’s production. Sales were low at 52.77-MT, which is a 1.2 per cent fall compared to December 2017-18. However, in the next fiscal year, the e-auction volumes are expected to dip further. E-auctions directly add to Coal India’s bottom line because the prices are often higher by at least 60 per cent over the notified price. Thus, effectively while the miner spends the same amount of money to mine the coal which is either sold as linkage or put under the hammer, it earns 20 per cent higher in auctions.

Prices in the e-auction, however, are expected to remain stagnant in the ` 2,400 a tonne level backed by muted global coal prices. According to S&P Global Platts, the price of FOB Kalimantan 4,200 kilo calorie per kilogram GAR (gross as received) — which is imported in huge volumes by both India and China — has declined almost 22 per cent since October 1, given the sagging demand in China and improving supply in Indonesia.

NTPC Ltd hopes its captive coal production will reach 100 million tonne as soon as its five coal blocks commence operations, aided by faster regulatory clearances and the part-privatization model of Mine Development and Operator (MDO). The success of the plan would determine fuel security of the operations of India's largest power producer.

Coal India aims to raise output from its troubled Rajmahal mine in Jharkhand to 60,000 tonnes a day by March 2019, having resolved land-acquisition related problems which had crimped production to 20,000 tonnes per day. Coal from the Rajmahal mine helps NTPC run close to 4,200-MW of power generation plants in eastern India, which supply power to Bihar, Jharkhand and West Bengal, and also to northern India including Delhi and Uttar Pradesh. NTPC’s generation capacities were faced with depleting coal stocks and lower power generation as supplies from Rajmahal dwindled. Reserves at Rajmahal within the land acquired by Coal India were almost exhausted and required expansion to keep production levels intact. However, land acquisition at two villages - Bansbiha and Taljhari - spanning 160 hectares, adjacent to the existing project turned out to be a lengthy process, as sorting out ownership issues resulted in inordinate delay. It led to drastic fall in supplies and stocks at the coalfield, as well as at two critical power plants in the region - at Farakka and Kahalgaon. At present, Coal India is using 15 goods trains to transport coal from the Rajmahal mine to power stations in the region.

One goods train can load up to 3,500 tonnes of coal. Coal India is also sending five loaded goods trains from West Bengal’s Ranigunj coalfields to augment supplies at power stations. At present, the entire production from Rajmahal is getting delivered to power plants and there has been no stock buildup yet.

CIL, ONGC to produce coal-bed methane from 10 new mines: support SAIL in one more. The Coal Ministry has identified 11 mines to produce April 2019 • 65

CEW

CEW

Project Update coal bed methane (CBM). Of these, 10 will be worked on jointly by ONGC and Coal India Ltd (CIL). The two entities will also work on one mine with SAIL. Initially, ONGC will harness the gas and then CIL will extract coal from them. In addition to the mines with CIL, the two (ONGC and CIL) will also help develop Steel Authority of India Ltd’s Parbatpur coal block (Jharkhand). Here too, ONGC will first harness the CBM. SAIL had surrendered the Sitanala and Parbatpur coal mines. In its representations while surrendering the Parbatpur mine, SAIL had said there was a reduction in the area available for coal mining due to overlapping of mining area.

SAIL had engaged MECON to prepare a techno commercial viability report, which declared the project unviable. The SAIL board had then decided to return the Parbatpur mine to the Coal Ministry.

JSW Energy, part of the Sajjan Jindal-led JSW Group, is believed to be in the race for buying out the thermal power assets of Monnet Power and Jindal India Thermal Power Ltd (JITPL) in Odisha. Monnet Power’s 1,050-MW coal-based power plant near Angul was in advanced stage of commissioning. Monnet Power’s parent company, Monnet Ispat & Energy had won the Mandakini coal block in Odisha in competitive bidding, it surrendered the block later on grounds of economic unviability. Monnet Power had accumulated debt in excess of ` 5,000-crore. Though lenders had earlier denied a haircut in JSW Energy’s prospective deal to acquire majority equity in Monnet Power, the Sajjan Jindal-owned firm is still believed to be in the hunt for the asset. Besides Monnet Power, JSW Energy is also eyeing takeover of BC Jindal controlled JITPL’s 1,200-MW coal-based plant at Derang near Angul. The first unit (600-MW) of the 1,200-MW plant had begun commercial operations and started power supplies to the Odisha grid. This project has been completed at a cost of ` 7,537-crore which includes a debt component of ` 5,900-crore.

JITPL has power purchase agreements (PPAs) with Odisha’s Gridco Ltd, Kerala State Electricity Board and Tata Power Trading Corporation.

Apart from JSW Energy, JITPL also had competing offers from Adani Power and Singapore’s SembCorp. The valuation of the prospective deal is not known. JSW Energy refused a comment on the status of its takeover plans of Monnet Power and JITPL. NLC India (formerly Neyveli Lignite Corporation) which is in the hunt for buying out power assets, is understood to have shown interest in the 700-MW Odisha plant of Hyderabad-based Ind-Barath Power Infra Ltd (IBPIL). The power plant located at Sahajbahal, near Jharsuguda, has commenced commercial operations. Though the exact size of the potential deal is not known, the valuation could be anywhere in the range of ` 5,000-5,500-crore.

In August last year, NLC India had floated an Expression of Interest (EoI) from companies owning coal and lignite-based power projects, for a possible acquisition. NLC India’s installed thermal power capacity is 3,240-MW. It runs a 10-MW solar power unit and wind power assets with a capacity totalling 37.5-MW. Western Coalfields has received the environment clearance for its ` 263-crore expansion project in Nagpur district, Maharashtra. The proposal is to enhance the production capacity of the Gokul open-cast mine to 1.875-million tonnes per annum (MTPA) from the existing 1-MTPA. The mine, located in 767.17-hectare, has a mineable reserve of 14.50-million tonnes. The clearance to the project is subject to certain conditions. Total cost is estimated to be ` 263-crore. Among the conditions specified, the company has been asked to get 'Consent to Operate' certificate from the State Pollution Control Board for the existing production capacity of 1-MTPA and also the 'Consent to Establish' for the proposed capacity of 1.875-MTPA prior to enhancing the production capacity. With regard 66 • April 2019

to transportation of coal, the company has been asked to carry out by covered trucks and take mitigative measures to control dust and other fugitive emissions all along the roads by providing sufficient numbers of water sprinklers. The company has been informed to adopt controlled blasting techniques to control ground vibration and flying rocks. It has also been told to implement a progressive afforestation plan covering an area of 376.04-hectare at the end of mining. Of the total quarry area of 231.73-hectare (on floor) and 291.21-hectare (on surface), the backfilled quarry area of 115.39-hectare should be reclaimed with plantation and there will be no void left at the end of the mining operations. The land after mining should be restored for agriculture purpose.

OIL & GAS Chennai Petroleum Corpn Ltd (CPCL), Indian Oil Corpn's (IOC's) group company is planning to set up a greenfield refinery at Nagapattinam in Tamil Nadu, at a cost of ` 27,460 crore. The products, including motor spirit (MS) and high speed diesel (HSD), which will be produced from the refinery will help meet the latest BS-VI specification in the southern States. The new refinery will be part of the Govt of India's plan to set up a petroleum, chemicals and petrochemicals investment region (PCPIR) in this region. The boards of CPCL and IOC have accorded in-principle approval for the 9 million metric tonne per annum (MMTPA) refinery at CBR at an estimated investment of ` 27,460 crore, plus or minus 30 per cent.The investment includes ` 2,800 crore for setting up a polypropylene unit of around 500,000 metric tonne (TMT) per annum capacity. Detailed feasibility report (DFR) preparation is underway and is expected to be completed by April 2019. The refinery is expected to be operational by 2023-24. The products from the refinery will meet the latest BS-VI specifications. CPCL's new refinery complex will come up with the latest technology and it will include a polypropylene unit to maximise value addition from the complex. It will produce valuable products, including liquefied petroleum gas, petrol, diesel, aviation turbine fuel, polypropylene, etc, besides petrochemical feed stocks. The petrochemical complex will also feed stocks to downstream industries, including pharma, paint and lacquer, printing inks, adhesives, coatings, chemicals, automobile lubricants and PVC, among others. CPCL operates two refineries with a total capacity of 11.5 MMTPA (10.5 MMTPA at Chennai and 1 MMTPA near Nagapattinam) in Tamil Nadu. The company's crude throughput increased to 10,789 TMT in 2017-18, from 10,256 TMT in 2016-17. Its profit after tax stood at ` 913 crore in 2017-18, as compared to ` 1,030 crore in 2016-17.

Reliance Industries Ltd has secured backing of the key expert appraisal committee (EAC) in the Ministry of Environment, Forest and Climate change to expand the capacity of its export-oriented refinery in the special economic zone (SEZ) at Jamnagar by 5.8 million tonnes (MT).

The planned expansion will raise the installed capacity of the SEZ refinery to 41 MT from 35.2 MT and lift the overall capacity of the Jamnagar refinery complex to 74 MT. The additional terms include prior transfer of environment clearance issued on March 30, 2010 to Reliance Jamnagar Infrastructure Ltd to Reliance Industries Ltd (the entity that applied for the environment clearance). The Jamnagar refinery processed 69.8 MT of crude in FY18, exceeding its installed capacity of 68.2 MT. Higher refinery utilisation helped the company cater to growing demand for transportation fuels. Between April and December 2018, Reliance refined 52.3 MT of crude. Reliance Petroleum Ltd, a unit of Reliance Industries, built its first refinery at Jamnagar with an installed capacity of 18 MT which was later expanded to 27 MT. Chemical Engineering World

Project Update The capacity of the Jamnagar refinery and petrochemical complex was further expanded by Reliance Industries to 59.7 MT during which the production was split between Reliance Petroleum (26.7 MT) as an only for exports refinery unit and Reliance Industries (33 MT) that sold most of its products in the local market. The capacity of the SEZ refinery was further expanded by Reliance Jamnagar Infrastructure Ltd to 35.2 MT from 26.7 MT. Great Eastern Energy Corpn (GEECL) and Essar Oil are upbeat about shale gas reserves in the CBM blocks of West Bengal, as GAIL looks for more buyers as it is poised to start business with city gas distribution. H Energy is looking for opportunities to supply imported gas from Malaysia to GAIL in a bid to get a price advantage over GAIL’s supplies from Dahej.

While West Bengal finance and industry minister Amit Mitra hopes that the shale gas reserves in the state would attract ` 60,000 crore worth of investment in production, supplies and creating infrastructure, Y K Modi, executive chairman, GEECL, said that it has found proven reserves of 6.6 trillion cubic feet of shale gas in the CBM blocks of West Bengal, which would require ` 15,000 crore worth of investment for exploration. Mitra said Essar Oil has reported the same amount of reserves and it could change the state’s economic landscape by 2020. Modi said the Centre, through a notification in August 2018, has allowed exploration of shale gas in its CBM blocks. GEECL has drilled over 150 wells, which has CBM reserves of 2.6 trillion units. Essar for CBM has drilled around the same number of wells and is poised to increase CBM production to 2.3 million standard cubic metre per day from the present 1 mscm per day. Mitra said GAIL, which is steadily progressing with its construction of Haldia -Jagadishpur pipeline, is poised to start business in West Bengal with city gas distribution. S Bairagi, GAIL’s chief general manager-marketing, said out of its ` 15,000 crore investment for the 2,600 km Haldia-Jagadishpur pipeline, West Bengal would get an investment of ` 3,600 crore. The pipeline in Matrix Fertilizer, Durgapur, would reach by July this year, whereas the pipeline is expected to reach Haldia by December 2020. An official said GAIL, besides Matrix, has tied up with Bhusan Steel, Himadri Chemicals and other small players for sale of gas but it needs more buyers to utilise its pipeline capacity, which can carry 9 million metric cubic metres per day. For city gas distribution, the government has signed an agreement for supplies of 1.2 mmcd but GAIL was looking for a 2.5 mmcd market.

However, GAIL’s present focus is to build infrastructure for gas distribution for which they have formed a JV with State-run Greater Calcutta Energy Supply Corpn and incorporated the JV on January 4, Mitra said. He said the zero date for starting construction work of the 448-km pipeline in and around Kolkata is April this year, and GAIL is committed to supply to 14 lakh consumers, including the transport sector by 2020. This would entail an investment of ` 5,000-6,000 crore. The economic life of the project is for twenty years. Bairagi said the company was creating a pipeline network in Kolkata, Howrah, Hooghly, North and South 24 Paraganas and Nadia districts with compressor pressure of 14,62,101 kg per day.

For the city gas distribution, GAIL – apart from sourcing gas from Dahej – is looking at other sources. H Energy was building an LNG terminal at Kukrahati near Haldia on 47 acres, from where it was building a pipeline up to Khulna in Bangladesh. This would entail an investment of ` 1,500 crore for the terminal and another ` 2,200 crore for the pipeline, said Darshan Hiranandani, MD and CEO. He said the company would import LNG from Petronas Malaysia and is committed to supply 2 million tonne to Bangladesh and keep 1 million tonne to market domestically. GAIL Chemical Engineering World

may be a potential buyer for the city gas distribution, Hiranandani said.

Indian Oil Corpn, with the final clearance from the National Green Tribunal (NGT), is all set to re-start construction activities at its ` 2,200-crore LPG import terminal-cum-pipeline project at Puthuvypeen near Kochi.

Necessary orders in this regard have been issued by the Kerala government and the work is expected to commence in January. The NGT judgment has made it amply clear that there is no environmental pollution in the Puthuvypeen project. IOCL has adopted global standards on safety measures and one-third of the cost is being spent on safety. The risk analysis study conducted by Projects & Development India Ltd has estimated the risk factor in a million chances per year.

The Kochi terminal, with the pipelines connecting the bottling plant, will eliminate the movement of bulk LPG by road, citing the removal of LPG tanker lorry movement from Mangaluru to Tamil Nadu after the commissioning of Ennore terminal. The Kochi project consists of an import terminal, multi-user liquid terminal (MULT) jetty, Kochi-Salem pipeline and the bulk LPG terminal at Palakkad with a total investment of ` 2,200-crore. Of this, the ` 225-crore jetty is ready and the company has invested another ` 160-crore for construction activities.

The physical progress of the work is only 40 per cent complete, which includes ground improvement, land development, etc. Kerala presently has an average waiting period of 15 days to receive a LPG refill. This could go up if the infrastructure expansion does not happen. Referring to LPG consumption in the State, it was 8.4 lakh tonnes in 2016-17, which would touch 13.2 lakh tonnes by 2022 and 22.7 lakh tonnes by 2028. India imports 50 per cent of its LPG requirements. With the boom in LPG requirement, imports are expected to go up. To meet the huge growth in volumes, infrastructure must be improved. LPG is imported through the major ports on the coast and there are 13 import terminals. Kochi is next on the list. The design of the terminal has been approved by regulatory agencies, which will inspect during the construction stage and prior to commissioning.

CPC Corp of Taiwan is planning to invest $6.6 bn in petrochemical project in Paradip, Odisha. In this regard, delegation led by CPC president Shun-Chin Lee met the Indian Minister for Petroleum & Natural Gas to discuss the proposal. With an annual production capacity of 15 million tonnes, the Indian Oil Corpn’s (IOC), Paradip Refinery was selected to host the new project, which will utilise the refinery’s feedstock. It will have many downstream units for the production of a wide range of end-products and petrochemical intermediates.

Indian Oil Corpn (IOC) plans to invest ` 20,000-crore in city gas distribution (CGD) projects in the next five to eight years. IOC, which owns a third of India’s oil refining capacity identifies compressed natural gas (CNG) replacing some of the petrol and diesel consumed in vehicles today and LPG replaced by piped cooking gas in households. The company plans to invest at least ` 20,000-crore for the CGD business in those projects won during the ninth round of bids. The investment will mainly include setting up of CNG dispensing stations as well as laying pipelines in cities to transport gas to households for cooking purposes and industries for commercial use. According to oil ministry figures, India needs to invest an estimated $100 billion in natural gas infrastructure by 2022, including setting up a gas grid across 228 cities, April 2019 • 67

CEW

CEW Products Levelling Elements

Indexing Plungers

Elesa+Ganter has always focused on satisfying the designers needs, thanks to the wide variety of standard machine elements, various types of assembly and the range of customization. This philosophy has led to the introduction, as standard to the wide range of Elesa+Ganter products, of new levelling elements with AISI 304 SS stem with adjusting square and LSQ.A-SST, LVQ.A-SST, LVQ.F-SST and LVQ.FOSST technopolymer bases. The stems with adjusting square are manufactured efficiently through machining of AISI-304 SS round bar. They represent a cost-effective solution and offer a high ease of use: the adjusting square giving a rotation angle by 90o.

Corrosion resistance, hygiene and material quality are properties which are highly appreciated in the pharma industry, food industry, in hospital engineering, fresh water supply and wastewater engineering, the aerospace industry, conveyor engineering and in machine and plant construction. For these industries Elesa+Ganter’s standard machine elements has added to its product range of index plunger Models GN 613/GN 617 and GN 617.1 the design variant with stainless steel knob - the first all stainless steel index plunger.

The GN 613 indexing plungers have no collar and boast extremely small dimensions, designed to absorb axial forces in their end position. The GN 617 and GN 617.1 indexing plungers are each fitted with a collar, with the GN 617.1 indexing plunger featuring an additional indexing lock. These are used if the index pin is temporarily not allowed to protrude. To engage, the knob is turned by 90o after pulling out. An index notch prevents the disengaged knob inadvertently turning back under the impact of vibrations.

The stems of the new levelling elements with adjusting square SMQ-SST have standard threads (M8, M10, M12, M16, M20 and M24) and same static load as the SM-SST with regulation hexagon and can also be used combined with LS.A, LV.A, LV.F and LV.FO technopolymer bases (tables of the possible combination bases/stems). Products technical data sheets, along with drawings and tables with codes and dimensions, are available on website www.elesa-ganter.in For details contact: Elesa and Ganter India Pvt Ltd A-54, Sector 83, Noida, Uttar Pradesh 201 305 Tel: 0120-4726666 Fax: 91-0120-4726600 E-mail: info@elesaganter-india.com or Circle Readers’ Service Card 01

All SS indexing plungers are made in consistently high quality and feature a long service life. Options Ganter has to offer include the holding fixtures GN 612.1 and GN 412.1 as mounting aids for indexing plungers, cam action-indexing plungers and positioning bushings (GN 412.2). Find out more at www.elesa-ganter.in For details contact: Elesa and Ganter India Pvt Ltd A-54, Sector 83 Noida, Uttar Pradaesh 201 305 Tel: 0120-4726666 E-mail: info@elesaganter-india.com or Circle Readers’ Service Card 02

Nitrogen Gas Nitrogen gas is odourless, colourless gas and makes up approximately 78.09 per cent by volume of the air we breathe. It is non-flammable gas and does not support combustion. Nitrogen gas is required in many processes of the pharma and chemical industry. There is multi-usage of nitrogen gas in various industrial sectors such as metal manufacturing process, chemical, pharma, petroleum, fertilizer, rubber and plastic, food and beverage industry.

Thermal flow meters directly measure the mass flow rate of gas with no need of temperature and pressure correction.

PCD thermal mass flow meter TMF Series offer rugged, leak-proof construction, high turn-down ratio of 100:1 with high accuracy, which makes the flow meter user demandable.

For details contact: Process Control Devices Plot No: 22 Rautara Indl Estate Shil-Mahape Road, Shil Phata Thane, Maharashtra 400 612 E-mail:sales@pcd-flowmeter.com / sales.pcdpl@gmail.com or Circle Readers’ Service Card 03

68 • April 2019

Chemical Engineering World

Products CEW Console Gear Pump Drive The new Cole-Parmer Console Gear Pump Drive is compact and cost-effective, offering simple variable speed control for many fluid handling applications. When coupled with an appropriate gear pump head, this new drive handles system pressures up to 21 bar, differential pressures greater than 5 bar and flow rates as high as 5,850 mL/min - ideal for applications like pressure filtration, but also excellent for many other laboratory- and industrial-scale, continuous-duty flow applications.

These modern, reliable pumps feature 100:1 speed-control to deliver fluid over a wide flow range.

A separate power switch enables the pump operator to maintain the speed setting when turning the drive On or Off. Convenient remote control of start or stop is available via a DB9 connector on the back of the drive. Gear pump heads - purchased separately - are available in cavity or suction-shoe configuration and offer smooth, pulseless, accurate and repeatable fluid delivery.

For details contact: Cole-Parmer India 403, A-Wing, Delphi Hiranandani Business Park, Powai Mumbai 400 076 Tel: 022-61394410, 61394444 Fax: 91-022-61394422 E-mail: vinita.singh@coleparmer.in or Circle Readers’ Service Card 04

UV-Vis Spectrophotometer Agilent Technologies Inc offers Cary 3500 UV-Vis system for the Indian market.

While the Cary 3500 UV-Vis system is an innovative spectrophotometer designed to help life science, pharma and biopharma research communities simplify their analyses, optimize laboratory productivity, and ultimately help bring new therapeutics to market faster.

Global growth in the development of biological drugs is leading to the evolution of many new biological entities (NBEs). Before these NBEs are adapted into therapeutics, laboratories must accurately characterize each new product and continuously monitor the quality of these products throughout the development process. The Agilent Cary 3500 provides a critical tool that allows laboratories to do this more quickly and accurately than is currently possible. Drawing upon from our 70 years of insight and customer collaborations, Agilent’s spectroscopy unit has created a faster, more robust system that comes with a lower cost of ownership.

The Cary 3500 represents the first significant advancement in UV-Vis architecture in decades. The new system enables laboratories to make substantial gains in efficiency as it can run multiple experiments simultaneously, allowing labs to obtain more results in the same amount of time - and it also extends the opportunity to design experiments in ways that have not been possible before.

The product harnesses the power of a state-of-the-art software platform and a fast and powerful Xenon flash lamp that is redefining UV-Vis spectrophotometry. Indeed, the system’s rapid, accurate, temperature control permits temperature experiments at ramp rates previously thought to be unattainable, providing more reliable and robust measurements.

For details contact: Agilent Technologies India Pvt Ltd Plot No: 8, ABW Elegance Tower Jasola District Centre New Delhi 110 025 Tel: 011-46237100 E-mail: customercare.india@agilent.com or Circle Readers’ Service Card 05 00 24

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April 2019 • 69

CEW Products Gas Chromatography Systems Agilent Technologies Inc offers two new gas chromatography systems for the Indian market. The new Agilent 8890 and 8860 GC systems extend the company’s industry-leading portfolio of robust analytical instruments. They will incorporate innovative and intelligent ‘self-aware’ predictive technology, expanding their suite of smart-connected GC instruments. Integrating intuitive colour touch interfaces, the 8890 and 8860 GCs are built on a next-generation electronic architecture platform, based on the innovative technologies of the Intuvo 9000 GC, Agilent’s flagship existing GC system. Continuous system monitoring, automated diagnostics and built-in troubleshooting routines will help labs avoid unplanned downtime and increase lab efficiency. Remote connectivity through mobile devices such as tablets and laptops, allows operators and managers to securely access instrument status and function while away from the lab. Agilent also introduced two powerful Blank and Detector Evaluation smart routines on the 8890 and 8860 GC systems, enabling automatic determination of system readiness. These new predictive functions will also be available for upgrade on Agilent’s Intuvo 9000 GC systems. The new GC systems have been designed with a clear strategy for providing customers with continual expansion of system intelligence functions. These new functions are also available for Agilent’s existing GC systems.

Automated diagnostics and troubleshooting routines will allow operators to attend to more high-value activities such as reviewing data and attending to new customer needs, helping them to grow their enterprises.

Agilent has incorporated the innovations of their previous GC designs and at the same time leveraged many of their proven oven, inlet, and detector technologies, recognized in the industry for their performance and quality. This will ensure streamlined method transfer for applications previously developed on legacy GC systems since it is an important consideration for a significant segment of existing customers. The 8860 system is designed to support many core routine applications, while the 8890 system is designed to support ultimate flexibility and expandability, supporting customer needs both today and tomorrow. The 8890 is not only intelligent but highly configurable, able to extend its capacity as lab needs grow – futureproofing the customer’s investment. While the 8860 is the GC for core routine applications, it is anything but routine, given its intelligent features.

For details contact: Agilent Technologies India Pvt Ltd Plot No: 8, ABW Elegance Tower, Jasola District Centre New Delhi 110 025 Tel: 011-46237100 E-mail: customercare.india@agilent.com or Circle Readers’ Service Card 06

Oil Removal Filters The efficient filtration of compressed air is a complex problem. And the new 2100 Series from ultrafilter offers the right solution by providing not only higher efficiency but also higher capacity at a lower price and a choice of quality pressure die-cast housings with the new generation of ultrafilter filter elements. Filters manufactured by Ultrafilter reduce wear and tear in pneumatic equipment, tools and instruments, cut down production stoppages, lower repair costs to improve the quality of production and reduce energy costs. The unique element has a three stage filtration effect. Oil and dirt laden compressed air flows through the filter element from inside to outside. The coarse particles of dirt and pipe scale are retained inside the pre-filter. Oil, water and the remaining fine particulate matter then pass to the main medium, a three dimensionally layered microfiber medium which provides the next two stages of filtration. Here, up to 99.99999 per cent of all oil and water aerosols and dirt particles down to a size of 0.01 micron are trapped. Liquid attach to the fibre and by coalescing the oil and water aerosol, bulk liquid is formed. This in turn is carried by the air flow to the outer foam sock which has a very high surface area. Within the cellular structure of the sock, the air and water separate, the air flows from the element in the upper section, whilst the water and oil gravitate to the bottom of the element and fall into the quiet zone at the bottom of the filter housing. The oil and water are discharged by a drain without the need of any maintenance.

For details contact: Ultrafilter (India) Pvt Ltd Plot No: 70, Bomasandra Indl Area Bengaluru, Karnataka 560 099 Tel: 080-41429900 Fax: 91-080-41419903 E-mail: info@ultrafilterindia.com or Circle Readers’ Service Card 07 24

70 • April 2019

Chemical Engineering World

Products CEW Roots Pumping Systems

Evaporators and Dryers Toshniwal provides solution to your vacuum application and are counted among the prominent manufacturers, suppliers and exporters of a wide range of roots pumping systems.

It replaces multi-stage water/liquid ring pumps, steam jet ejectors with compact vacuum packages. Available in a spectrum of specifications, these systems are used in distillation process, food processing, drying of powder and solids, and transformer evacuation.

The volume flow is from 180 to 97,000 m 3/hr. Energy savings resulting from low motor rating. Booster and rotary can be started at the same time. Built-in bypass value to protect from overloads.Features longer functional life high efficiency compact design For details contact Toshniwal Instruments (Madras) Pvt Ltd 267 Kilpauk Garden Road Chennai 600 010 Tel: 044-26445626, 26448983 E-mail: sales@toshwnial.net or Circle Readers’ Service Card 08

Concentration by evaporators of water and drying are very important operations in the food processing industry. Apart from the process performance, hygienic construction of the equipment and the facility itself play a major role. The final product is also defined by various qualitative characteristics such as mouthfeel, texture, colour, flavour, etc, which also decide the pricing of the product.

Special properties such as product size, instant properties are also important in some cases. SS Techno Ltd offers tailor-made turnkey plants with state-of-the-art evaporation and drying technologies for milk, tea, coffee, fruit juices/pulp, lactose, lactulose, etc. The plants are CIP compatible and are designed to produce the product with the required quality parameters. The type of evaporator and dryer, their combination and the total scheme depends specifically on the characteristics of the product.

For details contact: SS Techno Ltd 502 Mayfair Towers I, Wakdewadi, Shivajinagar, Pune Maharashtra 411 005 Tel: 020-66524431, Fax: 91-020-66524434 E-mail: marketing@sstechno.com or Circle Readers’ Service Card 09

Online Water Quality Analysers The new ORLAB WaterLine 2000 digital transmitter connects two digital sensors to monitor optical dissolved oxygen, turbidity, suspended solids, pH, redox, temperature, conductivity, salinity and sludge blanket (%), etc. Transmitter uses digital communication technology; two digital sensor inputs, two 4-20 mA outputs, 2 relay outputs and Modbus RTU output. Optical dissolved oxygen sensor uses luminescent optical measuring technique; Modbus RS485 communication; wide range of application and no drift and less maintenance.

Turbidity/TSS sensor uses IR optical measuring technique with fibre optics; measures turbidity (NTU) or TSS (mg/L); measuring range up to 4,000 NTU or 4,500 mgL; robust and water-proof for insitu mounting.

Suspended solids digital sensor measures suspended solids, turbidity and sludge blanket; digital technology for reliable measurements; optical sensor-based on absorptiometry; measuring range SS up to 50 g/l; turbidity 0 to 4,000 FAU and sludge blanket up to 100 per cent.

For details contact: Orbit Technologies Pvt Ltd B-50 Indl Estate, Sanath Nagar Hyderabad, Telangana 500 018 Tel: 040-67216354 Fax: 91-040-23801579 E-mail: orbit@orbitindia.com or Circle Readers’ Service Card 10

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April 2019 • 71

CEW Products Absorption Dryers The application of compressed air used in hi-tech machinery is highly essential. The damp atmospheric air compressed to 7 bar and then cooled down to working temperature results in condensation of water vapour in the compressed air line. The condensate binds the surrounding atmospheric gases such as CO2, CO, H2S and NO and becomes highly aggressive with pH values down to 4 and 3. The mixture of the condensate, atmospheric impurities and lubricating oil from the compressor is the destructive factor in all compressed air systems leading to downtime, increased wear, higher energy consumption, lower product quality and delays in delivery dates. High efficiency ALD/MSD dryers have everything you need to produce clean, dry, compressed air control system, prefilters, dryer, after filter, condensate drains and silencers, all as a single complete unit, and you save on installation. This complete dryer is easy to setup and install.

ALD/MSD dryers operate continuously between 9 and 100 per cent of its rated capacity providing constant compressed air quality.

For details contact: Ultrafilter (India) Pvt Ltd Plot No: 70, Bomasandra Indl Area Bengaluru, Karnataka 560 099 Tel: 080-41429900 Fax: 91-080-41419903 E-mail: info@ultrafilterindia.com or Circle Readers’ Service Card 11

Candle Filter SAP Microbac candle filter consists of elements made in multi-tubes of equal diameter either in metals and or plastics such as SS-304, SS-316, SS-316 L, SS-904 L Hastelloy or PP, PVDF and PTFE depending upon specific application.

The entire element is dressed with seamless filter bag tested at high pressure, depending upon the area worked out for enquired application. The length of the element is fixed considering installation qualification for the space provided, the diameter of the element remain the same.

The possible discharge may be dry or slurry form. The mode is back blowing the element with adequate pressure of permissible gas or liquid in process.

Slurry to be filtered is pressured with pump and enters the vessel where several elements are mounted on registers. The vessel is air-vented and then the outlet valves are opened and it is circulated for some time. During circulation max surface straining and surface filtration occurs and a precoat layer of high porosity is obtained on each bag which itself acts as a filter media. Other two mechanisms such as depth straining and depth filtration during circulation is minimum. Once the clarity is obtained circulation is switched over to filtration. As the slurry quantity exhausts the filter is scavenged either with air/nitrogen or steam and remaining is drained out and cake dried further. Lastly, cake is discharged by back blowing with gas and collected in bags for disposal. If the cake is pyrophoric in nature it is slurry discharged with mother liquer.

For details contact: SAP Filter Pvt Ltd Plot No: A-5, Sector 1 The Vasai Taluka Indl Co-op Estate Ltd Goraipada, Vasai (E) Dist: Thane, Maharashtra 401 208 Tel: 0250-3208273 Telefax: 91-0250-2458982 E-mail: info@sapfilter.com / sales@sapfilter.com

or Circle Readers’ Service Card 00 or Circle Readers’ Service Card 12 24

72 • April 2019

Chemical Engineering World

Products CEW Liquid Ring Vacuum Pump

Grammage Checking Kit

Toshniwal’s vast experience coupled with the countless installations in the field, allows them to offer any type of turnkey packages to meet the customer’s needs.

Pump system type HYDROSYS include liquid ring vacuum pump, cyclone type air-liquid separator, heat exchanger and associated accessories, all mounted on a fabricated frame.

For details contact: Toshniwal Instruments (Madras) Pvt Ltd 267 Kilpauk Garden Road, Chennai 600 010 Tel: 044-26448983, 27448558 Fax: 91-044-26441820 E-mail: sales@toshniwal.net or Circle Readers’ Service Card 13

Presto Stantest Pvt Ltd offers grammage checking kit.

GSM round cutter is a consistent tool useful for precise circular cutting of samples. Used to check the grammage of various sample it cuts a sample with 100 sq cm sizes rapidly and accurately.

For details contact: Presto Stantest Pvt Ltd I-42, DLF Indl Area, Phase I Delhi Mathura Road Faridabad, Haryana 121 003 Tel: 0129-4272727 E-mail: info@prestogroup.com or Circle Readers’ Service Card 14

Refrigeration Air/Gas Dryers The air given off by any compressor always contains water vapour the amount of which depends on the temperature and the relative degree of humidity. When the air is compressed, the volume decreases proportionately, but the exhaust water vapour still remains in the air. When temperature decreases and reaches a value at which the air becomes saturated, the water vapour in the air begins to condense.

This is called dew point. With an appropriate aftercooling unit which reduces the temperature of the air produced by the compressor, approxiamely 60-70 per cent of the water gets condensed.

The UE/UR Series dryers are basically made of two different circuits – a compressed air circuit, divided into two heat exchangers and a refrigerating circuit. The hot and humid inlet compressed air passes through the air – air heat exchanger and then reaches the evaporator (air-freon heat exchanger), where it is cooled by the refrigerating circuit until it reaches the preset dew point, thus condensing the moisture it contains. In the separator the condensed moisture is then separated and removed.

The advantages of such a system are essentially two: first of all the inlet air is pre-cooled, so the refrigerating system can be sized in order to guarantee a more limited thermal jump, with an energy saving of about 40-50 per cent, and secondly no cold air is conveyed through the compressed air line, thus preventing the overall formation of condensate on the external surface of the piping. Condensate corrodes piping, solenoid valve and pneumatic tooling, forcing the user to withstand expensive repair interventions, especially the expensive down time heavy costs which cannot be easily controlled. When compressed air is used as process air for painting equipment, in chemical industries, food processing industries, glass factories and in plants for conveying and handling hygroscopic raw materials, the installation of ultrafilter dryer is essential to eliminate the condensate which pollutes the production cycle.

For details contact: Ultrafilter (India) Pvt Ltd Plot No: 70, Bomasandra Indl Area Bengaluru, Karnataka 560 099 Tel: 080-41429900 Fax: 91-080-41419903 E-mail: info@ultrafilterindia.com or Circle Readers’ Service Card 15

Chemical Engineering World

April 2019 • 73

CEW

NATIONAL Expo Paint &Coatings

ENGIMACH

Dates: 10-12 July 2019 Venue: Pragati Maidan, New Delhi Event: This event provides a platform to the needs of every facade of

Dates: 04-08 December 2019 Venue: The Exhibition Centre, Gandhinagar, Gujarat Event: ENGIMACH is a leading engineering and machine tools show and

the coating industry right from raw materials, formulation, application, technology, finishing, quality assurance, recycling and disposal.

The exhibition will feature a wide range of products, raw materials, application systems, machines, tools, current trends, development and innovations shaping the future of coating industry. This expo will bring together leading local and international manufacturers, formulators, buyers, industry professionals, consultants, enthusiasts and prospective entrants from the paint and coatings, surface finishing and allied industry presenting unrivaled opportunities to network, exchange best practices, do business, unveil new products and source cutting-edge product and technologies.

For details contact: Toredo Fairs India Pvt Ltd 16/1, 1st Floor, 2nd Cross Mission Rd Srinivasa Colony Bengaluru Karnataka 560 027 Machine Tool Expo

Dates: 8-11 August 2019 Venue: India Exposition Mart, Greater Noida Event: This event is a address the manufacturing requirements

of the OEMs of various industry sectors in Tier II and Tier III cities of India. It will cover the entire gamut of metal working machine tools for both metal cutting and metal forming including automation and robotics, tooling systems, CAD/CAM and other technologies essential for today’s manufacturing.

For details contact: Indian Machine Tool Manufacturers’ Assn Bangalore International Exhibition Centre 10th Mile, Tumkur Road, Madavara Post Bengaluru, Karnataka 562 123 Tel: 080-66246600, E-mail: imtma@imtma.in Pharma Tech Expo

Dates: 20-22 August 2019 Venue: Gujarat University Convention and Exhibition Centre (GUCEC), Ahmedabad

Event: PharmaTech Expo 2018 & LabTech Expo 2018 is an

International Exhibition on pharma machinery, lab, analytical, pharma formulations, nutraceutical and packaging equipment.

This will give oppor tunities to suppliers, manufacturers, industrialists, entrepreneurs, buyers and consultants to assemble at this common platform. The focus will be on the Pharmaceutical Formulations, Nutraceuticals, API’s, Cosmetic and Ayurveda sector.

For details contact: PharmaTechnologyIndex.com Pvt Ltd 701-702 Corporate House Nr Dinesh Hall, Income Tax Ashram Rd Ahmedabad, Gujarat 74 • April 2019

showcase engineering products and services, heavy and light machines, machinery equipment and accessories, tools and parts, technological devices and products, engineering tools and allied products and services.

It is the most trusted machines and tools show that exhibits latest products and services, latest innovations and technologies. It is an ideal event that witnesses the best buyer and seller partnership and is a dynamic platform.

For details contact: K And D Communications Ltd Kailash-A Sumangalam Society, 3rd Floor Above HDFC Bank, Opp: Drive-In Cinema, Bodakdev Ahmedabad, Gujarat

INTERNATIONAL ACHEMA

Dates: 14-18 June 2021 Venue: Frankfurt Fair, Frankfurt, Germany Event: This five day event showcases products like engineering products, abrasives, chemicals and compounds, chemical machineries, equipment, manufacturing technologies, chemical engineering compounds, laboratory compounds and other similar range of products and services.

For details contact: Messe Frankfurt Exhibition GmbH Ludwig-Erhard-Anlage 1 Frankfurt, Germany International Exhibition of Chemical Industry and Science

Dates: 16-19 September 2019 Venue: Expocentre, Moscow, Russia Event: This event will display products like raw materials for the chemical and petrochemical industry, and inorganic chemistry, refining and petrochemicals, fuels, lubricants, organic synthesis, small volume chemicals, chemical fibers and yarns, composite materials, fiberglass, household chemicals, perfumes and cosmetics, reagents, catalysts, film photographic, magnetic media, design of chemical plants, warehouses, terminals, personal protective equipment, tools fire and explosion, chemical production management, transportation of chemicals and petrochemicals, logistics solutions, containers and packaging, chemical technology, research and more For details contact: Expocentre Krasnopresnenskaya nab 14 Moscow, Russia, 123100 Chemical Engineering World

Book Shelf CEW Practical Plant Failure Analysis Author: Neville W Sachs Price: $103.81 No of pages: 288 pages (Hardcover) Publisher: CRC Press (1st Edition About the book: Component failures result from a combination of factors involving materials science, mechanics, thermodynamics, corrosion and tribology.

With the right guidance, you don’t have to be an authority in all of these areas to become skilled at diagnosing and preventing failures. Based on the author’s more than thirty years of experience, Practical Plant Failure Analysis is a down-to-earth guide to improving machinery maintenance and reliability.

Illustrated with hundreds of diagrams and photographs, this book examines when and how to conduct a physical failure analysis; basic material properties including heat treating mechanisms, work hardening, and the effects of temperature changes on material properties; the differences in appearance between ductile overload, brittle overload, and fatigue failures; high cycle fatigue and how to differentiate between high stress concentrations and high operating stresses; low cycle fatigue and unusual fatigue situations; lubrication and its influence on the three basic bearing designs; and ball and roller bearings, gears, fasteners, V-belts, and synchronous belts Taking a detailed and systematic approach, Practical Plant Failure Analysis thoroughly explains the four major failure mechanisms―wear, corrosion, overload, and fatigue―as well as how to identify them. The author clearly identifies how these mechanisms appear in various components and supplies convenient charts that demonstrate how to identify the specific causes of failure.

Industrial Machinery Repair Authors: Ricky Smith and R Keith Mobley Price: $44.95 No of pages: 544 pages (Paperback) Publisher: Butterworth-Heinemann (1st Edition) About the book: Industrial Machinery Repair provides a practical reference for practicing plant engineers, maintenance supervisors, physical plant supervisors and mechanical maintenance technicians. It focuses on the skills needed to select, install and maintain electro-mechanical equipment in a typical industrial plant or facility.

The authors focuses on Best Maintenance Repair Practices necessary for maintenance personnel to keep equipment operating at peak reliability and companies functioning more profitably through reduced maintenance costs and increased productivity and capacity.

A number of surveys conducted in industries throughout the United States have found that 70 per cent of equipment failures are self-induced. If the principles and techniques in this book are followed, it will result in a serious reduction in self-induced failures.

In the pocketbook format, this reference material can be directly used on the plant floor to aid in effectively performing day-to-day duties. Data is presented in a concise, easily understandable format to facilitate use in the adverse conditions associated with the plant floor. Each subject is reduced to its simplest terms so that it will be suitable for the broadest range of users. Since this book is not specific to any one type of industrial plant and is useful in any type of facility.

Chemical Engineering World

Machinery Failure Analysis and Troubleshooting Authors: Heinz P Bloch and Fred K Geitner Price: $125.17 No of pages: 760 pages (Hardcover) Publisher: Butterworth-Heinemann (4th Edition)

About the book: Failures of machinery in a plant setting can have wide-ranging consequences and in order to stay competitive, corporations across all industries must optimize the efficiency and reliability of their machinery.

Machinery Failure Analysis and Troubleshooting is a trusted, established reference in the field, authored by two well-known authorities on failure and reliability.

Structured to teach failure identification and analysis methods that can be applied to almost all problem situations, this eagerly awaited update takes in the wealth of technological advances and changes in approach seen since the last edition published more than a decade ago.

Covering both the engineering detail and management theory, this book provides a robust go-to reference and training resource for all engineers and managers working in manufacturing and process plants.

Provides detailed, complete and accurate information on anticipating risk of component failure and avoiding equipment downtime; presents documented failure case studies and analyses the procedures employed to define events that led to component or systems failure; and includes numerous photographs of failed parts to ensure readers are familiar with the visual evidence they need to recognize.

April 2019 • 75

CEW Ad Index Sr.

No.

Client’s Name

1

Aeron Composite

2

Atomic Vacuum Company (Exports)

3

Page No

Sr.

No.

Client’s Name

Page No

25

15

KSB Pumps Ltd

31

Inside Cover I

16

Mist Ressonance Engg Pvt Ltd

33

Avcon Control

55

17

Munsch Chemie Pumpen Gmbh

13

4

Chemept Solutions

53

18

Paharpur Cooling Towers Ltd

57

5

Chetan Kotak

53

19

Prochem Trunkey Projects Pvt Ltd

11

6

Desmi India LLP

41

20

Ravindra Heraeus Pvt Ltd

39

7 Grundfos

19

21

ReistoTech Industries Pvt Ltd

8

Hindalco

29

22

Ross Process Equipment Pvt Ltd

45

9

Hi-tech Applicator

5

23

Suraj Ltd

61

10

Horizon Polymer Engineering Pvt Ltd

8&9

24

Suryamani Glassed Steel Equipment Pvt Ltd

11

HRS Process Systems Ltd

7

25

TMVT Industries Pvt Ltd

61

12 IPCO

21

26

UNP Polyvlaves (India) Pvt Ltd

27

13

Jasubhai Engineering

43

27

Vacuum Drying Technology India LLP

37

14

Jay Water Management Pvt Ltd

49

28

Vega India Level & Pressure Measurement Pvt Ltd

Back Cover

Front Cover

15-18

ADVERTISE TO EXPAND

your reach through

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76 • March 2019

Chemical Engineering World

R.N.I. No. 11403/1966 Date of Publication: 29th of every month. Postal Registration No: MCS/095/2018-20 Posted at Patrika Channel Sorting Office, Mumbai 400001, on 30th of every month. Total Pages No.:78

Manufacturer of:

Lined piping systems, Columns, Vessel and Tanks for corrosive media applications

Lining Material: PTFE/PFA/FEP/PVDF/PP/HDPE

Why Resistotech: • Processing capacity of 50+ tonnes per month • Large diameters upto 2000 NB (80”) by paste extrusion • Liners thickness from 2 mm to 14 mm as per application • Seamless lining in Tanks, column and vessel – no weld joints • Liner lengths 6400 mm upto 400 NB and above all 3200 • All sizes 90 Deg Elbows in single piece • Minimizing joints by longer lengths -saves product and installation cost • Full vacuum upto 200 Deg C in any size • Testing as per ASTM F 1545 – 03 for 100% products • FDA certificate and compliance

Techno-commercial solutions provider with pre-engineering and case study of corrosion issues RESISTOTECH INDUSTRIES PRIVATE LIMITED

C-11, MIDC, SINNAR, DIST.: NASHIK, MAHARASHTRA, INDIA, PIN - 421 301.

M: 0091 9820429054 | T: 0091 2551 230540 | E: sales@resistotech.com | W: www.resistotech.com