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CEW Contents CHEMICAL ENGINEERING WORLD RNI REGISTRATION NO. 11403/66 Chairman Publisher & Printer Chief Executive Officer
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VOL. 49 | NO.4| APRIL 2014 | MUMBAI | ` 150 NEWS ɻ Industry News / 6 Technology News / 16
NEWS FEATURES ɻ Mailhem-Ikos to Tap Waste to Energy Market in India / 28
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Chemical Engineering World
CEW Industry News Ajay Shriram Elected as New CII President New Delhi, India: Managing Director of DCM Shriram Limited Ajay Shriram has been elected as the new President of CII. Shriram succeeds Infosys Executive Vice Chairman Kris Gopalakrishnan as the new President.
FACTÊs Ammonia Storag e at Kochi Por t to be Increased Kochi, India: Fertilisers and Chemicals Travancore (FACT), the public sector company, may expand its capacity of ammonia storage facility at Kochi Port to meet its increased production requirements, sources revealed.
Shriram obtained a Bachelors degree Ajay S Shriram, in Commerce from Sydenham College, President, CII & Chairman & Mumbai. He has attended various training Senior Managing Director, DCM & management development programmes Shriram Limited in India and overseas, including the Programme for Management Development at the Harvard Business School, USA. Shriram is the Chairman of the governing body of Shri Ram College of Commerce and a Trustee of SOS Children Villages of India.
The organisation is planning to set up additional storage tanks in the port area with a capacity of 20,000 tonnes so that it would be able to bring in bigger shipments. The port has also agreed to allot land adjacent to FACTÊs present storage facility in Willingdon Island. A total investment of ` 120 crore is projected. FACT, a Government of India Enter prise, has business interests in manufacturing and marketing of fertilisers, caprolactam, engineer ing consultancy and fabr ication of equipment. Ammonia production is one of the core activities in fertiliser productions.
Government to Cut Potash Fertiliser Subsidy
Benchmark Price for Ethanol to be Revised
New Delhi, India: Government has reduced potash subsidy by ` 3.33/kg for 2014-15 financial year resulting in saving of ` 900 crore to the exchequer, but said that the move would not lead to increase in retail prices. The Cabinet Committee on Economic Affairs (CCEA) has approved subsidy of P&K (Phosphatic and Potassic) fer tilisers for next fiscal wherein it has recommended constant subsidy rates for all the complex fer tilisers, barring potash.
Delhi, India: The Inter-ministerial Group has agreed to revise the formula to fix the benchmark price for selling ethanol; however, as the sugar firms expect, it may not be up by 5 ` a litre. The current benchmark price for ethanol at ` 44 a litre and it is expected to be increased by ` 1 ă 2 a litre.
„Cabinet has decided to reduce subsidy on potash taking into consideration the fall in international prices. Consequently, this will not put additional burden on farmers. Subsidy on potash will come down to ` 15.50/kg from ` 18.83/kg earlier,‰ Fertiliser Secretary Shaktikanta Das told PTI. The Fertiliser Ministry had taken approval from the Election Commission to move this proposal before the Cabinet.
Anand Sharma Appeal to Use Natural Resources Judiciously New Delhi, India: In a recent gathering organised by C o n fe d e r a t i o n o f I n d i a n I n d u s t r y ( C I I ) , A n a n d S h a r m a , Commerce and Industr y Minister, asked to use the natural resources judiciously. Sharma further added that maximisation of profit cannot be the philosophy of a welfare state. Sharma also spoke about FDI and said that foreign direct investment (FDI) flow into the country had gone up 15 times over the last decade while expenditure on education and health has increased eight times and six times, respectively.
Imports of non-urea fertilisers expected to grow by 15% - 20% in 2014-15: ICRA
6 • April 2014
The public sector oil marketing companies have been procuring ethanol from the sugar mills to implement the mandatory five per cent blending programme. The current price is derived from the lowest Refinery Transfer Price (RTP) or the cost of petrol to the oil marketing companies.
Fertilisers Want 5-Year-Agreement with RIL New Delhi, India: Instead of an annual contract, Fer tiliser Industry in India wants Reliance Industries Limited (RIL) to extend the KG-D6 gas supply agreement up to five years. The existing D6 gas price as well as supply agreements with the buyers expired on March 31 this year. Reliance had earlier threatened to stop the gas supply from April 1 as Fertiliser Association of India had refused to sign the pact for the gas supply at new price. However, following the deferment of new price announcement b y t h e g o ve r n m e n t b a s e d o n t h e E l e c t i o n C o m m i s s i o n directive, RIL and its foreign par tners in the block have been asked to continue to sell the fuel at the prevailing rates of USD 4.2/mmBtu from April 1. But now, while RIL is in favour of an annual contract in the absence of any clarity on new gas price, fertiliser companies are seeking a five-year agreement. Chemical Engineering World
CEW Industry News D e e p a k F e r t i l i z e r M ay E x p a n d P ro d u c t i o n Capacities Navi Mumbai, India: Deepak Fertilizers and Petrochemicals Corporation Limited (DFPCL), which specialises in manufacturing Technical Ammonium Nitrate (TAN), is planning to expand its production capacities to meet the growing demand for the chemical in domestic market, the organisation revealed in a media briefing organised at its Technical Ammonium Nitrate (TAN) manufacturing facility at Taloja on April 9, 2014. Carl Lindgren, President, TAN, who addressed the meeting, said that the company is now fully compliant with ammonium nitrate rules under the new explosives act. The chemical is mostly used for explosives in coal mining and infrastructure usage. Earlier, India used to import ammonium n i t ra t e, bu t l a t e r, i t wa s i d e n t i f i e d a s a s e c u r i t y t h r e a t . Contamination of ammonium nitrate makes it dangerous and can be used by anti-social elements. The company is also mulling to set up a new facility at Paradip in Odisha, and the plant may be commissioned in the next 24-36 months after all necessary approvals. With this, its TAN production capacity will go up to 8.50 lakh tonnes by 2016-17. DFPCL has a total installed manufacturing capacity of 4,69,000 MTPA across its plants at Taloja in Maharashtra and Srikakulam in Andhra Pradesh.
UPL Sells Stake in Brazilian Firm New Delhi, India: Agrochemicals firm UPL has sold its entire 50 per cent stake in its Brazilian subsidiary Sipcam UPL Brasil SA for USD 58.50 million to an Italian firm, PTI reported. Sipcam UPL Brasil SA, a joint venture between UPL (formerly known as United Phosphorus Ltd) and Italian company Sipcam with both companies have equal stake of 50 per cent each. „UPL has entered into an agreement with an Italian company Sipcam to sell its entire stake of 50 per cent in Brazilian agrochemicals company Sipcam UPL Brasil SA subject to fulfilment of certain conditions and approvals «The divestment will release the funds to the company which will be available for new opportunities and meet growing business requirements. It will also help UPL have more focused approach for Brazilian a gr o c h e m i c a l s m a r ke t ‰ t h e I n d i a n c o m p a ny U P L s a i d i n a statement. The gross consideration amount of the transaction is USD 58.50 million (approximately ` 3.51 billion). This will be the first major divestment by UPL and the entire process is expected to be completed by June this year, the statement read. The company is planning to use the cash released from the sale of stake for its business requirements. 8 • April 2014
Quality of Solar Cell in County Not Satisfactory Chennai, India: Solar power developers, in a letter to the government, had stated that the India-made solar cells are of poor quality, less efficient and more expensive than imported cells, and the production of solar cell is also not sufficient to meet the growing demand. Although cell manufacturers claim they have the capacity to produce more than 800 MW of cells, in reality, only about 150 MW is available. Many units are shut either due to financial constraints or because of outdated equipment, the letter read. The letter was sent by The National Solar Energy Federation of India to the Ministry of New and Renewable Energy and Solar Energy Corporation of India (SECI). According to Research and Markets, the leading source for international market research and market data, the Indian solar energy sector has been growing rapidly, in the past few years, majorly due to governmentÊs initiatives such as tax exemptions and subsidies. Due to technical potential of 5,000 trillion kWh per year and minimum operating cost, solar power is considered the best suited energy source for India. Today, the solar power has an installed capacity of 9.84 MW which is about less than 0.1 per cent of the total installed renewable energy in the country. IndiaÊs currently total installed renewable energy stands at 13,242.41 MW as per MNRE.
ABB to Promote Solar Pumps in Rural Market Mumbai, India: ABB India, the leading power and automation technology provider, is planning to penetrate into rural market with its range of solar pumps. The organisation revealed that „its solar pumps can replace the conventional water pumps run by diesel or electricity, thereby, cutting farmersÊ power expenses.‰ Company officials revealed that the pump will make irrigation cheaper for farmers in the dry-land areas. The company has installed 200 such pumps in states such as Gujarat, Rajasthan, Madhya Pradesh and Tamil Nadu. According to Tobias Engelmeier, Managing Director, BRIDGE TO INDIA, „Solar irrigation pumps in India could be a very attractive market. They could replace diesel powered pumps in many parts of IndiaÊs agricultural heartlands, especially in the under-electrified Gangetic plains. They could even increase agricultural output by making more irrigation water available to farmers. However, at the moment, neither the products nor the distribution chains are anywhere near maturity.‰
C o u n t r i e s w i t h t h e l a rg e s t i r r i g a t e d areas - India - 39 million hectares (mh), China - 19 mh, US - 17 mh: UN
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CEW Industry News Praxair Starts Up Air Separation Plant for SAIL
Celanese to Build Methanol Production Unit
M u m b a i , I n d i a : P r a x a i r, I n c . h a s announced the star t-up of the first of two 1,250 metric tonnes per day air separation units at Steel Authority of IndiaÊs (SAIL) Bhilai, India facility. The plant will provide a reliable and energy efficient supply of gaseous oxygen, nitrogen and argon under a long term John Panikar, contract to suppor t SAILÊs expansion President, Praxair Asia activities. This is PraxairÊs first large project in the state of Chhattisgarh and central India. The facility will also produce liquid oxygen, nitrogen and argon to further support growing industrial and medical gases needs in the states of Chhattisgarh, Madhya Pradesh and parts of Maharashtra. „Praxair has worked with Steel Authority of India since 2006, when we first signed our contract to supply industrial gases to their Durgapur facility,‰ said John Panikar, President, Praxair Asia. „We are proud to further strengthen our relationship with SAIL and we thank them for their confidence in us,‰ he added. „This plant will also expand PraxairÊs merchant capabilities in central India and consolidate our presence in this growing market,‰ said Anuj Sharma, Managing Director of Praxair India. „Further, PraxairÊs innovative applications technologies will help customers optimise costs and productivity, improves quality, as well as enables them to meet increasingly stringent environmental regulations,‰ he added.
Texas, US: Celanese, a speciality material company has declared plans to set up a methanol production unit at its facility i n B i s h o p, Tex a s. T h e m e t h a n o l u n i t is anticipates to utilise abundant and l ow c o s t n a t u r a l g a s i n t h e U S G u l f Coast region as a feedstock which will eventually own an annual capacity of Mark Rohr, Chairman & CEO, Celanese 1.3 million tonnes. Mark Rohr, Chairman & CEO, Celanese said, „The strategic upstream production of methanol and the attractive economics of natural gas in the US Gulf Coast region, combined with the infrastructure at our Bishop facility, make this a unique opportunity for Celanese.‰ The company is also looking for joint venture for the particular project and waiting for environmental approvals.
CRI Pumps Aquires FIPS Coimbatore, India: C.R.I. Pumps IndiaÊs leading pump manufacturer has recently completed a Share Purchase Agreement with the shareholders of Fabbrica Italiana Pompe Sommergibili Srl (FIPS), Milan, Italy for acquisition of 100 per cent of the share capital of the company. This acquisition will enable CRI to scale new heights in embracing innovative technologies in Sewage, Effluent, Drainage and Waste Water handling Solutions for municipal, industrial, residential & building applications. This is the second acquisition after its recent acquisition of Pumps & Process Systems Ltd ă UK for Industrial pump range. FIPS is a Milan Italy-based company founded in 1978 and has an established track record of performance in waste & sewage water pumps, across the globe. FIPS products has its presence in Italy, Western Europe, Eastern Europe, Middle East, South Africa, China and several other countries. Speaking on the acquisition, Soundararajan, Vice Chairman, CRI Pumps Pvt Ltd, said, „CRI has been strategically focusing on different applications through organic as well as inorganic path. With the acquisition of FIPS Italy, CRI will be launching the complete range of sewage and waste water pump solutions in India using the technology transfer advantage from FIPS. CRI with its strong manufacturing and R&D capability, will be able to offer world-class technology to meet the growing industry demands‰. C.R.I. estimates the market size of sewage & waste water pumps in India to be around ` 500 crore and growing at the rate of 15 to 20 per cent annually, as waste water treatment sector have huge opportunity. 10 • April 2014
Solar policies in India not Cost-effective Mohali, India: Current wind and solar policies in India are not as cost-effective as they could be, says a new study from Climate Policy Initiative (CPI) and the Bharti Institute of Public Policy at the Indian School of Business (ISB). Given India targets to double renewable energy capacity to 55,000 MW by 2017, the cost of policy support is an important issue. The CPI-ISB report, „Solving IndiaÊs Renewable Energy Financing Challenge: Which Federal Policies can be Most Effective?‰, which compared a range of policy alternatives, found that a policy that both reduces the cost of debt and extends its tenor is the most cost-effective. For wind energy, reducing debt cost to 5.9 per cent and extending tenor by 10 years can cut the cost of total federal and state support by up to 78 per cent. For solar energy, which is more capital-intensive, reducing debt cost to 1.2 per cent and extending tenor by 10 years can cut the cost of support by 28 per cent.
GAIL, ONGC Sign Pact for Natural Gas New Delhi, India: Gail India has signed an agreement to buy all natural gas produced by Oil and Natural Gas Corp (ONGC) from its existing and new fields. In a statement released by the company, the state-run gas utility said that it would hold the exclusive marketing right of all gas produced by ONGC for a three-year period, which can be extended on mutual consent, and also market some of the chemicals to be produced from the Dahej petrochemical complex being set up by ONGC Petro-additions Ltd, a subsidiary of ONGC. The two companies have agreed to enhance the availability and effective utilisation of natural gas from new and upcoming fields of ONGC for supply of gas to customers through GAILÊs infrastructure. GAIL would supply imported LNG to ONGCÊs C2+ extraction plant at Dahej. In return, ONGC will supply an equivalent quantity of domestic gas. „This will pave the way for commissioning of C2+ extraction plant by ONGC. Pursuant to extraction, the C2+ components shall be supplied to OPaL for manufacturing petrochemicals at Dahej SEZ,‰ the statement read. Chemical Engineering World
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CEW Industry News Oxea to Upsurge DOTP Capacity Berlin, Germany: Oxea, a specialty chemical company, is planning to increase its European production capacity of dioctyl terephthalate (DOTP) by 50,000 tonne by the fourth quarter of 2015. The company has recently signed a memorandum of understanding with an undisclosed third party to set up a joint production plant in Germany, citing increasing demand for Oxsoft GPO DOPT. DOTP is a general-pur pose plasticiser used in a range of applications, such as construction, automotives and flooring. Jacco de Haas, Global Marketing Manager- Specialty Esters, Oxea, said, „This backward integration allows us to reliably meet the high level of demand and accommodate the needs of our customers.‰
S o l vay t o D o u b l e C o p o ly m e rs P ro d u c t i o n Capacity at Freiburg Facility Brussels, Belgium: Solvay Polyamide & Intermediates (P&I) has declared plans to double production of copolymers at its manufacturing site in Freiburg, Germany. The move is believed to be the part of the companyÊs effort to supply the consumer demand for added value polyamide solutions. Yannick Adnot, Director ă Europe Business, Solvay P&I, said, „As a leader in the global market of polyamides, we continue to invest in the quality and customer benefits of our material and service offering on a regular basis. The expansion project is subject to the receipt of regulatory approval, and is expected to be completed by the end of this year.‰
Cabot to Sell Security Materials Business to SICPA Boston, US: A US-based speciality chemical firm, Cabot has decided to sell its Security Materials business, (CSMI) to Switzerland-based SICPA for nearly USD 20 mn. The acquisition is estimated to be completed by the end of 2014. SICPA has formed a new company called STA Technologies, and after closure of the deal all the CSMI employees will continue to work at the current Albuquerque worksite. Cabot officials mentioned that the Security Materials business, which generated revenue of USD 7 mn in fiscal 2013, practises patented spray pyrolysis technology for brand protection activities and advanced nanotechnology for covert taggant applications. SICPA supplies security inks, authentication and traceability solutions for use in banknotes, security documents and consumer products. Cabot provides rubber and specialty carbons, activated carbon, inkjet colorants, cesiumformate drilling fluids, fumedsilica, aerogel and elastomer composites. 12 • April 2014
Waste Management & Partners to Yield Renewable Chemicals Tex a s , U S : L o c a t e d i n U S, Wa s t e M a n a g e m e n t , Ve n t e c h E n g i n e e r s International, NRG Energy and Velocys have teamed up to establish a joint-venture (JV) to produce renewable fuels and chemicals from biogas and natural gas using gas-to-liquids (GTL) Joe Vaillancourt, technology. Waste Management said it is Venturing Vice-President, Waste exploring new ways to extract value from Management Corporate the biogas at its landfills. In line with this effort, the company established a demonstration unit at East Oak landfill, which has accumulated more than 10,000 hours of operation. Joe Vaillancourt, Venturing Vice-President, Waste Management Corporate, said, „VelocysÊ leading smaller-scale GTL technology, VentechÊs engineering capabilities and NRGÊs clean energy development expertise will complement Waste ManagementÊs strengths in the JV.‰ Velocys will deliver the Fischer-Tropsch reactor and reagent to the JV, while Ventech will design and engineer the proposed facility. NRG will contribute its proficiency in developing renewable capital projects, as well as procurement and transportation of natural gas in bulk quantities.
Russian Chemical Industry to Face Crisis Moscow, Russia: The Russian chemical industr y will face serious crisis, as the countryÊs flagship chemical producer, K h i m p r o m , fa c e s l i q u i d a t i o n . T h e c l o s u r e c o u l d h ave a knock-on effect on other Russian producers. Rostec, a Russian state corporation and the majority shareholder of Khimprom, said that the enterprise will completely cease its operations by March 2015 and will be liquidated by May 2016. Of the 5000 workers Khimprom currently employs, about 4000 will be laid off. Khimprom is being closed down because it is no longer profitable. The company declared bankruptcy in November 2012, as its debts exceeded RUB10 billion. According to an official Rostec representative, the company was hampered by high energy prices; outdated technology; depreciation of equipment, which reached 95 per cent; as well as ineffective competition with foreign rivals.
Sika Acquires Manufacturing Facility in Gunsan Bern, Switzerland: Switzerland-based specialty chemical firm Sika has acquired a manufacturing facility in Gunsan, South Korea. The acquired facility, which employs 28 people, manufactures and distributes flooring and coating products based on epoxy resins, acrylic emulsions and polyurethane. The additional production capacity will allow Sika Korea to strengthen its local flooring and coating products range, as well as expand the production of its complete range of products, the company claims.Sika said it will leverage the distribution channels of the acquired facility with its product range and further expand the sales outlets network with the improved product portfolio. Chemical Engineering World
Steam Tube Bundle Rotary Dryer
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CEW Industry News
Industry News CEW
INEOS Charges Sinopec for Chemical Patent Violations
Mairetecnimont, Archirodon Backs Tahrir Petrochemical
Canton of Vaud, Switzerland: A lawsuit has been filed by the Switzerland-based INEOS against Chinese state-owned oil and petrochemical giant Sinopec for allegedly misusing p a t e n t s r e l a t e d t o t h e i n d u s t r i a l c h e m i c a l a c r y l o n i t r i l e. The company alleged that Sinopec Ningbo Engineering, a subsidiary of Sinopec, has broken a technology agreement, which along with trade secret misuse by other Sinopec units, enabled development of new acr ylontir ile plants without its consent.
Cairo, Egypt: A consortium of MaireTecnimont and Archirodon has secured a contract to develop facilities for the Tahrir petrochemical complex, located at the entry of the Suez Channel in Egypt. The project is estimated to value between USD 1.7 bn and USD 1.95 bn, of which 50 per cent is related to Maire Tecnimont. According to the agreement Carbon Holdings, both companies will construct utilities and offsite facilities for the Tahrir complex, which is anticipated to increase EgyptÊs annual exports by more than 25 per cent. Drake & Scull International is also expected to become a member of the consortium, while the Italian export credit company SACE is currently evaluating its financial support for the project.
INEOS is initiating proceedings in the Beijing High Court, as well as negotiation proceedings in Sweden. The Swiss firm claims that the incident could heavily impact its acrylonitrile business that generates up to USD 500 m in annual earnings. On the other hand, Sinopec officials said that it has full proprietary intellectual property rights over such technology. They added that there is no ground for the breach alleged by INEOS.
Solvay Purchases Plextronics Brussels, Belgium: Solvay has completed the acquisition of US-based Plextronics Inc. to bolster its Organic Light Emitting Diodes (OLED) electronic display technology and launch a new development platform with a strong Asian foothold. W i t h P l ex t r o n i c s , S o l vay i s ex p a n d i n g i t s k n o w - h o w i n emerging applications such as OLED TV screens, OLED lighting and in lithium-ion batteries. OLED technology uses stacked layers of organic compounds that emit light when submitted to an electric current. It boosts luminance efficiency and ultimately enables bendable displays as it reduces their thickness and weight.
BASF -TOTAL Petrochemicals Starts 10 Furnace th
L u dw i g s h a f e n , G e r m a ny : B A S F - TOTA L Pe t r o c h e m i c a l s has star ted operations of a tenth furnace at its steam c r a c k e r f a c i l i t y i n Po r t A r t h u r, Te x a s , U S . T h e n e w l y commissioned fur nace is expected to improve feedstock flexibility, enhance plant reliability and increase ethylene annual production capacity to more than one million metric tonnes (more than 85 per cent of its ethylene) based on cost advantaged feedstock. Heidi Alderman, Senior Vice-President, BASF Petrochemicals said, „The safe and successful start-up of the tenth furnace, along with other optimisation measures taken at the steam cracker facility, enhances the JVÊs competitive position within the petrochemicals industry.‰ BASF TOTAL Petrochemicals is a joint-venture (JV) partnership wherein BASF owns a 60 per cent stake, and Total Petrochemicals & Refining USA, holds 40 per cent ownership. 14 • April 2014
Pierroberto Folgiero, CEO, MaireTecnimont, said, „We are very excited to join Carbon Holdings and other very reputable industrial players in this venture, a project that is going to reshape the petrochemical market dynamics in the region.‰
Nufarm to Shut Down Manufacturing Facility Bern, Switzerland: Agricultural chemical firm Nufarm will shut down its manufacturing facility in Otahuhu, Auckland, New Zealand, a move which will affect 59 jobs. The move comes after the companyÊs plan to close its facilities in Welshpool and Brisbane, as part of the restructuring of its Australian operations, to improve profitability of sales, lower expenses and reduce working capital, as well as the fixed cost base. The rationalisation of manufacturing activities in Australia and New Zealand is expected to provide the company with annual cost savings of up to $16m, with one-off restructuring costs of up to $50m this year. Nufarm plans to consolidate production activities at the Otahuhu site to its existing Laverton facilities in Victoria, a process which will be carried out over a two-year period. The transfer of activities from New Zealand to Laverton will increase the efficiency of those facilities, while reducing unit costs, maintenance related capital expenditure and working capital requirements, the company said.
CB&I to Provide Dehydrogenation Technology for Shandong Chengtai Beijing, China: Shandong Chengtai Chemical Industry has awarded a contract to CB&I for the license and engineering design of a grassroots iso-butane dehydrogenation unit in China. To be built in Changyi, Shandong Province, the unit will use the Catofin dehydrogenation technology offered by CB&I and ClariantÊs Catofin catalyst to process iso-butane feed for the production of 114,000mt per year of isobutylene. To produce MTBE and other downstream products, isobutylene will be used as a building block, claimed CB&I. CB&I technology operating Group President Daniel McCarthy said, „The Catofin technology has been selected for 20 projects in the last five years. Chemical Engineering World
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Technology News Genetically Modified Tobacco Plants as an Alternative for Producing Bioethanol
Novel Way to Make Ethanol without Corn or Other Plants
Usurbil, Basque Country: Researchers at the NUP/UPNA-Public University of Navarre and the IdAB-Institute of Agrobiotechnology have conducted a study into genetically modified tobacco plants from which it is possible to produce between 20 and 40 per cent more ethanol; this would increase their viability as a raw material for producing biofuels. Tobacco, a high-density crop, which is mown several times throughout its cycle, can produce as much as 160 tonnes of fresh matter per hectare and become a source of biomass suitable for producing bioethanol. As Jon Veramendi, head of the plant Agrobiotechnology Research Group, explained, „Tobacco plants as a source of biomass for producing bioethanol could be an alternative to traditional tobacco growing which is in decline in the USA and in Europe because it cannot compete with emerging countries like China‰.
Stanford, USA: Stanford University scientists have found a new and highly efficient way to produce liquid ethanol from carbon monoxide gas. This promising discovery could provide an eco-friendly alternative to conventional ethanol production from corn and other crops, say the scientists. Their results are published in the April 9 advanced online edition of the journal ÂNature.Ê
In the course of the research, which has been echoed by the jour nal Molecular Breeding, tobacco plants of the Virginia Gold and Havana commercial cultivars have been grown. The plants were genetically modified to increase their production of starch and sugars, which contributes to the increase in ethanol production. The complete press release can be read at www.basqueresearch.com.
Research Finds „Tunable‰ Semiconductors, Will Allow Better Detectors, Solar Cells Atlanta, USA: One of the great problems in physics is the detection of electromagnetic radiation ă that is, light ă which lies outside the small range of wavelengths that the human eye can see. Think X-rays, for example, or radio waves. ApNow, researchers have discovered a way to use existing semiconductors to detect a far wider range of light than is now possible, well into the infrared range. The team hopes to use the technology in detectors, but also in improved solar cells that could absorb infrared light as well as the sunÊs visible rays. „This technology will also allow dual or multiband detectors to be developed, which could be used to reduce false positives in identifying, for example, toxic gases,‰ said Unil Perera, a RegentsÊ Professor of Physics at Georgia State University. Perera leads the Optoelectronics Research Laboratory, where fellow author and postdoctoral fellow Yan-Feng Lao is also a member. The research team also included scientists from the University of Leeds in England and Shanghai Jiao Tong University in China. To understand the teamÊs breakthrough, itÊs important to understand how semiconductors wor k. Basically, a semiconductor is exactly what its name implies ă a material that will conduct a n e l e c t r o m a g n e t i c c u r r e n t , bu t n o t a l way s. A n ex t e r n a l energy source must be used to get those electrons moving. The press release can be read at official website of the organisation. 16 • April 2014
„We have discovered the first metal catalyst that can produce appreciable amounts of ethanol from carbon monoxide at r o o m t e m p e ra t u r e a n d p r e s s u r e ă a n o t o r i o u s l y d i f f i c u l t e l e c t r o c h e m i c a l r e a c t i o n ,‰ s a i d M a t t h e w K a n a n , a n Assistant Professor of Chemistry at Stanford and co-author of the Nature study. Most ethanol, today, is produced at high-temperature fermentation facilities that chemically convert corn, sugarcane and other plants into liquid fuel. But growing crops for biofuel requires thousands of acres of land and vast quantities of fertiliser and water. In some parts of the United States, it takes more than 800 gallons of water to grow a bushel of corn, which, in turn, yields about 3 gallons of ethanol. The new technique developed by Kanan and Stanford graduate student Christina Li requires no fermentation and, if scaled up, could help address many of the land- and water-use issues surrounding ethanol production today. The complete article, written by Mark Shwartz, can be read at universityÊs website.
Application Note to Detect PPCPs in Water F r e m o n t , U S : Br uker has released an application note detailing a simple and convenient method for the quantification of trace Pharmaceutical and Personal Care Products (PPCPs) in clean water, using BrukerÊs EVOQ triple quadrupole Liquid Chromatography Mass Spectrometer (LC-MS/MS). PPCPs are products used for personal health or cosmetic reasons. PPCPs in environmental and potable water are potentially harmful for both humans and the environment, so are strictly regulated by environmental bodies such as the United States Environmental Protection Agency (US EPA). BrukerÊs technique proved simpler than traditional solid phase extraction (SPE) based methods and the EVOQ showed excellent sensitivity and robustness throughout. PPCPs include a very broad group of chemical substances such as human and veterinary medicines, cosmetics and housecleaning products. PPCPs may prove harmful to the environment due to their unpredictability when mixed with other chemicals. They also are highly soluble and some degrade slowly over a long period of time, and as a result some PPCPs are also detected in soil and higher up the food chain. For this reason the US EPA stringently monitors trace concentrations of PPCPs. Liquid chromatography with mass spectrometry delivers the sensitivity and selectivity to detect PPCPs at trace levels required by legislation. The application note is available to download at http://bit.ly/BCA582. Chemical Engineering World
CEW
Technology News Big Data Keeps Complex Production Running Smoothly
P r o c e s s Tu r n s C e l l u l o s e i n t o E n e r g y Storage Devices
Munich, Germany: Large amounts of data are produced when industrial companies monitor their facilities. Sensors check temperature, pressure, power, or energy use data. „If youÊre scanning to the nearest second, itÊs easy to rack up several terabytes of information in under a week,‰ said Dr Olaf Sauer from the automation business unit at the IOSB. But often there is a lack of suitable methods to evaluate the information. „TodayÊs operators use only about seven percent of this data for maintenance or protection from breakdowns,‰ added Sauer. At the Hannover Messe Digital Factory, IOSB developers from Karlsruhe and Lemgo would present ways to leverage this untapped potential. Their systems can process the collected data in a way that increases plant availability significantly while reducing energy consumption.
Corvallis, USA; Based on a fundamental chemical discovery by scientists at Oregon State University, it appears that trees may soon play a major role in making high-tech energy storage devices. OSU chemists have found that cellulose ă the most abundant organic polymer on Earth and a key component of trees ă can be heated in a furnace in the presence of ammonia, and turned into the building blocks for supercapacitors.
T h e s c i e n t i s t s f r o m K a r l s r u h e fo c u s e d o n c o n t i n u o u s processes in the chemical or pharmaceutical industries. „At the Fraunhofer Application Centre Industr ial Automation IOSB-INA in Lemgo, we have developed solutions, we can use to easily monitor complex manufacturing technology and hybrid systems,‰ explained Prof Oliver Niggemann, Deputy Head of IOSB INA in Lemgo. Together, the methods are suitable for all kinds of capital-intensive industrial facilities that need to run for long periods of time. „Even wind farms could be monitored this way,‰ said Sauer. The press release can be read at instituteÊs website.
Cement from Ceramic Waste London, UK: Researchers of the Universitat Politècnica de València, the Universitat Jaume I de Castellón, the Imperial College of London and the Universidade Estadual Paulista of Sao Paulo (Brasil) have created a new type of cement from ceramic waste in the laboratory. It is a more sustainable cement and it also opens business possibilities for the ceramics industry. The first results of this study were released the last year in Construction and Building Materials magazine. To date, the researchers have worked with brick, sanitary ware (washbasins and toilets) and porcelain stoneware waste, resulting in an end product that is stronger than the mortars used today. The entire story can be read at organisationÊs website.
Thermal-Imaging Lens From Waste Sulfur Tucson, US: Sulfur left over from refining fossil fuels can be transfor med into cheap, lightweight, plastic lenses for infrared devices, including night-vision goggles, a University of Arizona-led international team has found.The team successfully took thermal images of a person through a piece of the new plastic. By contrast, taking a picture taken through the plastic often used for ordinary lenses does not show a personÊs body heat.„We have for the first time a polymer material that can be used for quality thermal imaging ă and thatÊs a big deal,‰ said senior co-author Jeffrey Pyun, whose lab at the UA developed the plastic. „The industry has wanted this for decades.‰ Read complete PR on universityÊs website. 18 • April 2014
These supercapacitors are extraordinary, high-power energy devices with a wide range of industrial applications, in everything from electronics to automobiles and aviation. But widespread use of them has been held back primarily by cost and the difficulty of producing high-quality carbon electrodes. The new approach just discovered at Oregon State can produce nitrogen-doped, nanoporous carbon membranes ă the electrodes of a supercapacitor ă at low cost, quickly, in an environmentally benign process. The only byproduct is methane, which could be used immediately as a fuel or for other purposes. „The ease, speed and potential of this process is really exciting,‰ said Xiulei (David) Ji, an Assistant Professor of Chemistry in the OSU College of Science, and lead author on a study announcing the discovery in Nano Letters, a journal of the American Chemical Society. The research was funded by OSU. „For the first, time weÊve proven that you can react cellulose with ammonia and create these N-doped nanoporous carbon membranes,‰ Ji said. „ItÊs surprising that such a basic reaction was not reported before. Not only are there industrial applications, but this opens a whole new scientific area, studying reducing gas agents for carbon activation. Read the complete story on official website of the Oregon State University.
New Self-healing Plastics Developed Karlsruhe, Germany: The KIT group headed by Christopher Barner-Kowollik uses the possibility of crosslinking functionalised fibres or small molecules by a reversible chemical reaction for the production of self-healing materials. These so-called switchable networ ks can be decomposed into their initial constituents and reassembled again after the damage. The advantage is that the self-healing mechanism can be initiated any time by heat, light or by the addition of a chemical substance. „Our method does not need any catalyst, and no additive is required,‰ Professor Barner-Kowollik said. The holder of the Chair for Preparative Macromolecular Chemistry at KIT studies s y n t h e s e s o f m a c r o m o l e c u l a r c h e m i c a l c o m p o u n d s. T h e complete News can be read at KITÊs website. Chemical Engineering World
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CEW Marketing Initiative Anguil, MOJJ Team Up
Honeywell Brings Engineering Initiative to India
Pune, India: Anguil Environmental Systems, Inc. (Anguil) and MOJJ Engineering Systems Ltd (MOJJ) have teamed up to offer turnkey abatement solutions for toxic vapours and harmful fumes from industry.
Ve l l o r e , I n d i a : H o n ey w e l l i n t r o d u c e d P r o fe s s o r C l a u d e Cohen-Tannoudji, Nobel laureate in Physics, to the students and faculty of Vellore Institute of Technology (VIT), India, a s p a r t o f i t s g l o b a l H o n ey we l l I n i t i a t i ve fo r S c i e n c e & Engineering (HISE).
Anguil, a United States-based provider of industrial air pollution control, emission abatement and energy recovery systems, has been serving the global marketplace since 1978. The Anguil combustion technologies destroy Volatile Organic Compounds (VOC) and Hazardous Air Pollutant (HAP) from industrial sources. When released in to the atmosphere, these pollutants contribute to smog as well as the destruction of agriculture and forests. In humans they can cause birth defects, nervous system damage, respiratory ailments, heart conditions or even death during massive accidental releases. When compared to conventional air pollution control methods, Anguil thermal and catalytic oxidisers offer higher destruction efficiency and lower operating costs. All Anguil systems are guaranteed to meet or exceed regulatory requirements and capable of greater than 99 per cent destruction efficiency with minimal greenhouse gas output. India-based MOJJ, is a supplier of turnkey solutions, systems and equipment in the field of drying, evaporation, distillation and zero discharge systems for the pharmaceutical, food, chemical, ceramic, dyes and alcohol industries. Headquartered in Pune since 1986, MOJJ owns and operates three fabrication facilities conforming to international standards that meet the same quality control standards guaranteed with Anguil products. Having Indian fabrication capability allows Anguil oxidation equipment to be manufactured utilising local resources while avoiding substantial international freight costs and duties. Through this partnership, customers in India can expect a single source provider for their specific emission control needs. Anguil and MOJJ pride themselves on understanding and meeting the specific needs of their clientele. By combining complimentary product lines, both capital equipment companies are confident customers will be provided with tested and dependable turnkey solutions for their industrial applications.
Launch of „Singing‰ Paint Mumbai, India: Paint pioneer AkzoNobel has developed new technology which is set to pump up the volume for 21st century lifestyles and revolutionise the way people listen to music. The companyÊs scientists have created an ultrasonic coating - or singing paint - which can turn surfaces into surround sound speakers. Known as LiquidSoundz, the breakthrough paint ÂnÊ play technology uses embedded nanobots to convert signals from audio devices, which are transmitted via a downloadable app known as the Wall of Soundz. The key to the new technology lies in the funky nanotechnology embedded in the pigments, which is capable of receiving audio signals and then generating the sound waves that make those signals audible. Launch colours will include, Red Zeppellin, Teal Diamond, Fleetwood Black, Run DM Sepia, Depeche Mauve and Chris de Burgundy. Both the LiquidSoundz paint range and the Wall of Soundz app will be available soon. 22 • April 2014
Professor Cohen-Tannoudji is among 23 Nobel laureates t h a t H o n ey we l l h a s s p o n s o r e d a t u n i ve r s i t i e s wo r l d w i d e since 2006. The event marks the eleventh time Honeywell Hometown Solutions, HoneywellÊs corporate social responsibility organisation, has delivered HISE to a university in India, and the first time the programme is taking place at VIT University. H I S E h a s b e n e f i t t e d t h o u s a n d s o f s c i e n c e, t e c h n o l o g y, engineering and math (STEM) students and teachers across the country. Cohen-Tannoudji was awarded the 1997 Nobel Prize in Physics for the development of methods to cool and trap atoms with laser light to near Absolute Zero. This discovery has given rise to a number of recent developments in this field.
S i t t i n g L t o R : D r G V i s w a n a t h a n , F o u n d e r & C h a n c e l l o r, V I T U n i v e r s i t y, C l a u d e C o h e n - Ta n n o u d j i , 1 9 9 7 N o b e l L a u r e a t e i n P h y s i c s a n d S u r e s h Venkatarayalu President, HPS
SensoTech Honoured Barleben, Germany: In front of numerous guests from industry and commerce, politics and economy, the investor of the year 2013 was voted at the ball of industry and commerce on March 29, 2014. T h e w i n n e r i s t h e S e n s o Te c h G m b H p r o u d l y a c c e p t i n g the award. Managing Director Dr Ingo Benecke and Mathias Bode thanked war mly for honour ing at the ball gala.
Erratum In the March Issue 2014, CEW has carr ied „Slurr y Phase Hydrocracking: Bottoms Upgrading for TodayÊs Mar ket‰ ar ticle by KBR Technology on page number 5 2 . I n t h i s a r t i c l e o n p a g e nu m b e r 5 4 , F i g u r e 4 i s i n c o r p o r a t e d t w i c e. T h e c o r r e c t F i g u r e 4 i s a t t h e b o t t o m w i t h t h e t i t l e ă M a r i n e B u n ke r F u e l S u l f u r Limit (wt %).
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CEW Marketing Initiative Verder Opens New Office in India
Schneider Electric Partners with Ramco Systems
Pune, India: Verder International has opened its latest office, Verder India Pumps Pvt Ltd in Pune. The building of 250 square metres is situated in Chinchwad in the North East of the city and will showcase the groupÊs extensive range of positive displacement pumps, offer sales support and have capacity Verder’s India office for storage and service. Rajnesh Kalia, at Pune Sales Manager at Verder India, has been responsible for the sales, service, marketing and business development of Verderflex Products in India ă direct as well as through channel partners. After the initial market entry with the Verderflex peristaltic pumps, Verder IndiaÊs product portfolio now also includes the VerderAir, VerderMix and VerderHus pump range.
Chennai, India: Schneider Electric, a global specialist in energy management has entered into a strategic par tnership with Ramco Systems, an enterprise software product company. The partnership will see RamcoÊs Advanced Process Optimisation software, OPTIMA, become an impor tant par t of Schneider ElectricÊs solutions for the cement industry and strategically help explore business opportunities.
VerderÊs first exhibition in India, Chemtech World Expo, Mumbai, 2013, proved to be as successful as anticipated, generating large interest in both its Peristaltic Pumps and Air Diaphragm Pumps. The par ticipation in the exhibition, combined with a distributor meeting, helped cement the groupÊs presence in the Indian market and assisted in forming local distributor agreements with TechnoFlo, Anuvintech, Searock and Garnet Power tech. With a central representative office in India, Verder looks forward to continuing its worldwide growth in this exciting and growing sub-continent by thinking globally while at the same time serving locally to the needs of every Indian customer.
3 rd Edition of Watertech India Delhi, India: Messe Frankfurt India has announced that the third edition of Watertech India, IndiaÊs leading international trade fair for water & wastewater treatment & management, will take place at Pragati Maidan from 10 ă 12 September 2014. The trade fair will present business opportunities for companies providing solutions for water & wastewater treatment and management. Re-locating from Gandhinagar in Gujrat to IndiaÊs largest exhibition centre - Pragati Maidan in New Delhi, the show is set to attract key public and private sector professionals, gover nment officials and decision makers keen to source wastewater management technologies and equipment. R a j M a n e k , M a n a g i n g D i r e c t o r, M e s s e Fr a n k f u r t I n d i a , said, „The event has received suppor t from major industr y associations and government authorities for the third edition of Water tech India. Their strong backing has strengthened o u r c o m m i t m e n t t o p r ov i d e a p l a t fo r m t o i d e n t i f y gr e e n solutions that can be implemented at institutional and municipal levels.‰ 24 • April 2014
With cement manufacturers focusing their efforts on reducing energy and emissions, improving overall perfor mance and managing consistent product quality grade, plant operators are looking for solutions that stabilise the production process and maintain the optimal operation point for minimal effect on the environment. Schneider ElectricÊs strategic partnership with Ramco will deliver this much required solution, with a specific focus on optimisation of kiln and mill operations, to its cement customers. The solution will support increased production volumes, promote the ease and uptake of alternative fuels and support human operators to make the best decisions for changing operating conditions.
Diego Areces, Mining, Minerals and Metals Solution President, Schneider Electric and Virender Aggarwal, CEO, Ramco Systems signing the partnership agreement in Beijing.
Research Centre to Develop Advanced Chemical Products Leeds, UK: A new 7 million British Pound centre at the University of Leeds will lead UK research in manufacturing advanced chemical products. The Centre for Doctoral Training (CDT) in Complex Particulate Products and Processes will fund 50 new research students in a field that has been targeted by the government as a key growth area for the UK economy. The new facility is one of 22 new CDTs announced by the Chancellor of the Exchequer, the Rt. Hon George Osborne MP, in Manchester. Government money, allocated by the Engineering and Physical Science Research Council (EPSRC), will provide more than half of the centreÊs funding, with the remainder coming from the University and industrial partners. Companies backing the CDT include the multinational consumer goods company Procter & Gamble (P&G), agrochemical developer Syngenta, petroleum additives manufacturer Infineum and major drug companies including GlaxoSmithKline, Pfizer and AstraZeneca. Chemical Engineering World
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CEW Marketing Initiative Romaco Group Sells FrymaKoruma Rheinfelden, Switzerland: The Romaco Group is selling its stake in FrymaKoruma AG and FrymaKoruma GmbH to a new umbrella corporation within the Deutsche Beteiligungs AG. Paulo Alexandre, CEO of the Romaco Group said that during more than ten years in affiliation with the Romaco Group, FrymaKoruma developed very well. „We are pleased to offer a further growth spurt to the company in a group that specialises in process technology. Through this transaction, Romaco will focus even more on the development of its competences, especially in the pharmaceuticals market‰, he said. The companies Stephan Machinery (Hameln) and FrymaKoruma will cooperate under the new umbrella corporation ProXES. Both companies have strong brands in the area of food, pharmaceutical and health care technology, and they also see an excellent complement to their previous applications and their market presence in their common future. A clear focus on process technology will ensure a stronger market position under the common umbrella corporation. Therefore, the DBAG por tfolio company ProXES is acquiring the entire stake in FrymaKoruma (AG and GmbH) from the Romaco Group.
Precision Polymer to Open New Manufacturing Site Brenham, USA: Precision Polymer Engineering (PPE), a leading manufacturer of advanced elastomer O-rings and components, has announced that it will open a new manufacturing site in Brenham, Texas later this year. The ground breaking ceremony, held on Wednesday, April 2, initiated the build of a 30,000 sq.ft. facility which will be up and running by October. The new factory will specialise in the manufacture of custom O-rings and other critical elastomer sealing components to the highest quality standards and with industry-leading delivery times. As well as high performance compression moulding of components for the oil & gas, food, drink & pharmaceutical and engine manufacturing industries, the capabilities will include advanced clean room facilities which will enable manufacture to the exacting standards needed for semiconductor applications. In keeping with PPEÊs operating model, the factory will have its own tool making, extrusion and inspection facilities.
The ground breaking ceremony, held on Wednesday, April 2, 2014
26 • April 2014
HRS Emphasises Role of Energy Efficiency in Chemical Industry Pune, 15 April, 2014: HRS Process Systems Ltd (HRS), part of HRS Group, UK, participated in the fifth ChemProTech Expo-2014 from 10 th ă 11 th April, 2014 at Bombay Exhibition Centre, Mumbai. HRS exhibited Ecoflux* Corrugated Tube Heat Exchangers, HRS Funke Plate Heat Exchangers and Hot Water System variants, with an emphasis on the role of energy efficiency in the chemical process industry. „In recent times the chemicals industry in India has seen reasonable traction; however, speciality chemicals & additives could present the next big growth opportunity in India where currently the consumption and awareness is low as compared to other countries. We are convinced that for this sector to continue to grow fast, energy efficiency will be a key differentiator. HRSÊ energy efficient technology coupled with our strong knowledge and understanding of Indian conditions over ten years, equips us to provide heat transfer products and solutions to meet these challenges comprehensively,‰ said V Gokuldas, Managing Director, HRS Process Systems Ltd. HRSÊ clients such as Jubilant, Atul, Bayer, Syngenta, and Zuari Agro were some of the well-known companies that visited this event. The exhibition offered a platform to reach wider gamut of chemical process companies.
Praj Renames NeelaSystems as Praj HiPurity Systems Pune, India: Praj Industries, global process solutions Company, announced that it has changed the name of its subsidiary Neela Systems as Praj HiPurity Systems Limited. Praj Industries had acquired majority stake in Mumbai headquartered Neela Systems in 2012. The change of identity is in line with the growth plan of Praj HiPurity to go beyond pure water solutions for Pharma Industry to end-to-end, integrated solutions for pharma, biotech and cosmetics industriesand the enhanced shareholding of Praj in the subsidiary.
Perma Pure Hires BDM Mumbai, India: Sanjeev Rai has joined Per ma Pure as India Business Development Manager. Rai adds to Per ma PureÊs investment in the strategically impor tant Indian market and will drive its sales and Sanjeev Rai m a r ke t i n g e f fo r t s i n t h e c o u n t r y. R a i c o m e s t o Pe r m a P u r e w i t h a d e g r e e i n C h e m i c a l Te c h n o l o g y f r o m H B T I K a n p u r a n d Po s t Graduate Diploma in Management from Indian Institute of M a n a g e m e n t , L u ck n o w. H e h a s a s t r o n g b a ck gr o u n d i n promoting wireless HART technology for process industry. Chemical Engineering World
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Mailhem-Ikos to Tap Waste to Energy Market in India Mailhem Engineers, an Indian waste management and renewable energy company, and Lhotellier Ikos, a France-based 200 million euro group specialising in infrastructure and renewable energy as well as water management and treatment, have formed a joint venture - Mailhem Ikos Environment Private Limited to provide waste to energy solution for India.
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energy solutions, and joining hands with Ikos will help us cater to this this growing market.‰
Furthermore, the solutions will enable close to 85 per cent of the waste to be reused in form of energy or recycled. Bringing together the domestic expertise of Mailhem and the technological prowess of Ikos, the JV will be able to establish large scale, up to 500 tonnes, waste management biogas plants in India.
Commenting on the potential of waste to energy solutions, Paul Lhotellier, President, Lhotellier Ikos Group, said, „Creation and execution of the waste to energy solutions are a win-win situation both economically through production of energy and environmentally through re-usage of waste. The dual advantages of these solutions truly make them an integral aspect of addressing the global issues relating to waste and energy consumption. It is an excitable time for us to be able to expand our presence into India by joining hands with Mailhem, and we are looking forward to some great work.‰
ith the growing concerns of energy and waste management in India, Mailhem Ikos will be able to provide centralised solutions for waste management, company officials informed in a media briefing organised in Mumbai earlier this month.
Lt. Col. Suresh Rege (Retd) Chairman Mailhem Engineers Private Ltd
Paul Lhotellier
President Lhotellier Ikos Group 28 • April 2014
The new JV will specialise in energy production from organic as well as household waste, turnkey biogas plant and recycling solutions including design, construction, & operations, and landfill restoration & degassing. Speaking on the occasion, Lt Col (Retd) Suresh Rege, Founder, Mailhem Engineers Pvt Ltd, said, „We have been working with Lhotellier Ikos Group on domestic projects over the last two years, and have found a strong synergy amongst the companies in terms of vision, approach and execution. After working for over 250 biogas projects since our inception, we are seeing a growing demand of our waste to
ItÊs High Time We Treated Leachate While interacting with CEW, Rege and Lhotellier spoke at lenght about the increasing dumping sites and leachate control. Sustainable Leachate Control and Management has always been a worrisome issue in India. About 90 per cent of the solid waste is disposed of by open dumping ă in landfill, and this has been identified as one of the major threats to groundwater resources. Landfill are already chocking, and as
The new JV will specialise in energy production from organic as well as household waste, turnkey biogas plant and recycling solutions including design, construction, & operations, and landfill restoration & degassing. Chemical Engineering World
CEW News Features Mailhem Ikos use Sequential Batch Reactor (SBR) process that combines biological treatment with filtration. The aerobic biological treatment lowers the Biochemical Oxygen Demand (BOD) and suspended solids thus reducing the risk of clogging the filters. Depending on the characteristics of the leachate, the filtration is done either by nanofiltration or by reverse osmosis. The filtration membranes are manufac tured and a v a ila b le in India.
Garbage piling is major issue in the country. Some of the recent news available in public domain suggests that authorities are finding it difficult to handle or treat waste piled up in the cities, and leachate originating from the site is posing a threat to ground water. The uncontrolled dumping of garbage in nullahs flowing through residential localities in the Nagpur was reported to clog up sewage water and cause filth to overflow. Further, Kolhapur Municipal Corporation (KMC) also found itself in a difficult situation when it failed to convince the farmers to use decomposed waste as fertiliser - without any cost. About three lakh tonnes of garbage are piling up at the Kasba Bawada site for the last three years, and when the municipality offered distribution of the decomposed garbage free of cost among the farmers, no one turned up. The KMC is now reportedly dumping the waste in the lagoon, an action that - some activists say - is environmentally hazardous as the leachate from the garbage may seep into the ground and pollute water resources.
some of the recent reports suggests, the amount of garbage in cities like Delhi that currently generates about 8,500 tonnes of solid waste daily, is likely to double by 2020. One can just not dare to visualise the situation that will worsen in near future if the issue is not addressed today. Mailhem Engineers and Lhotellier Ikos Group have the technology that can address the issue, say Lt Col (Retd) Suresh Rege, Founder, Mailhem, and Paul Lhotellier, President, Lhotellier-Ikos Group. When asked how severely leachate originating from the dumping site can contaminate the groundwater, Rege and Lhotellier replied that leachate can be defined as the percolation of liquids from 30 • April 2014
waste. It is the concentration of organic matter with heavy metals as well as that of hazardous microorganisms that contaminate water and can have an impact on human health. They further added, „Apart from organic matters from the kitchen, household, waste may also contain toxic items such as batteries, paints etc. Besides, leachate is also found in numerous industrial dumping sites which contain elements of high toxicity including heavy metals such as arsenic, cyanide and pyralen. Today, advanced water treatment technologies have made it possible for us to treat leachate ă whether from municipal landfill or industrial dumping sites - effectively in order to ensure that groundwater is safe for human consumption.‰
Highlighting the complexity involved in the entire process, Rege and Lhotellier explained that the difficulty in treating the leachate arises due to the lack of consistency in the quality of the Leachate. A volume of waste is similar to a living organism, subject to a large number of chemical reactions. „The quality and the quantity of the liquid (leachate) percolating vary according to the age and quality of waste and environmental conditions. To overcome this difficulty, one often plans for certain quantity of leachate to be stored in sealed pools, so that one can refine the quality of the ultimate Leachate to be treated,‰ Lhotellier added. Infrastructure for Leachate Treatment Facility To treat the leachate, one first needs to collect them. „Based on the volume of waste, we lay a cover with materials of low permeability in order to limit the quantity of leachate. Then e drill pumping wells units to pump the leachate and direct them to a dedicated pond,‰ Lhotellier revealed. The processing unit is generally of a small size. To undertake this process successfully one requires two to three biological tanks (diameter 2.5 meters, height 4 to 6 meters) and a filtration unit that fits in a shipping container of 20 or 40 feet (depending on the flow rate required). The system is modular and movable. The cost of treatment directly depends on the contaminants present in the leachate. - Harshal Y Desai Chemical Engineering World
CEW Features
'Management of Water Resources' That is where the challenges lie ahead...
With increasing urbanisation and industrialisation, the consumption of water is increasing dramatically, which has necessitated intelligent reuse and recycle of water and integrated and sustainable development of water resources. In an exclusive interview with Mittravinda Ranjan, A B Pandya, Chairman, Central Water Commission, Ministry of Water Resources and Chairman, CAB, WaterEX World Expo 2015, says that India has adequate water resource when viewed from the annual availability angle. However, the vagaries of distribution over space and time are the real challenges that have to be met with by planners and managers of water resources in the country with appropriate development policies. Pandya further comments on UN report which predicts grim picture for India and talks at length about several issues.
IEA report has forecasted that amount of fresh water consumed for world energy production is on track to double within the next 25 years. The report further elaborates that increase coal power along with the adoption of coal-based technologies and increasing biofuel capacity will drive the largest share of water consumption for energy through 2035. How do you view this in Indian context, and how does CWC plan moving along the mission of promoting integrated and sustainable development and management of IndiaÊs water resources by using stateăofătheăart technology and competency, and coordinating with all stakeholders? The quantum of fresh water consumed for world energy production especially for thermal, nuclear and solar-thermal cycle 34 • April 2014
is directly proportional to the capacity installed. Even biofuel preparation also consumes water for its processes. Thus, there is a strong dependence of all means of energy production on availability of water. In case of thermal power, 3-4 cu m water is required per hour per MW capacity of generation. Even gas-based power plants require about 2 cu m water per hour per MW. We will need to add about 15000 MW coal-based thermal generation capacity per year. This will require additional 335 MCM of water per year out of which 87 per cent water will be lost in evaporation and consumption. Thus, there will be an ever-growing need of water for power generation. In case of nuclear and solar-thermal cycles also the requirement will not go down significantly in terms of water consumption. It is no wonder that about 87.8 per cent of industrial demand Chemical Engineering World
We already have very little consumptive use of water out of Brahmputra and Barak basins in the north east and hardly 10 per cent of the annual available water is being utilised productively. We will need to increase the same for meeting the demands elsewhere in the country. is out of thermal power generation alone. However, hydro power provides for a non-consumptive energy generating platform and as the improvement of hydro versus thermal capacity ratio in all the developed countries - wherever local conditions allow, form a key corner stone of the water management policy and should be preferred. In Indian context, we have a preferential emphasis on coal-based generation due to relatively easy implementation. The areas rich in coal are not rich in terms of water availability, and vice a versa. This puts us in a difficult situation as either the water or the coal will have to be transported over long distances for such thermal generation. CEA have already worked out a plan for installing 50000 MW of hydro power in continuance with the rest of power development in an integrated way. This has a potential of correcting the adverse hydrothermal ratio, and also to improve the conservation of water for other usages. Special emphasis is being laid on the improving the efficiency of power generation and also on the use of lower quality water for consumption in the power generation. The progress improving the technology and competency are being taken up by CEA and CWC in collaboration with various industry bodies and also through development of guidelines and standards to this effect to channelise the development.
What are your views on recent UN report which predicts grim picture for India? As far as the impact of climate changes are concerned, India being a predominantly monsoon fed country, the impact will increase variability of rain fall in different areas in terms of time and aerial spread of the rainfall events. We will have to contend with very large water availability in very short durations and scarcity in longer periods between such events. With the growth in economy and improvement in our life styles, the water demand will become more and more uniform over the cycles of surplus and scarce rainfall. The conservation of fresh rainwater by all means at our disposal is the only solution. By creating adequate strategic storage, well distributed in topographically and connected with the various demand centres can meet the requirement. Matching the supply and demand for water with annual and carry over storages is a must for an economically well secured Indian society. We are also working very hard on managing the consumption through improvement of water usage, efficiency and optimising the reuse of water for generating more productivity per drop.
Economic pundits predicts that India will be the Rising Economic Powerhouse by 2030, and international reports have also forecasted India leaping ahead of China by 2050. How realistic is this from your point of view given the fact that water resources are one of the cornerstones of economic and industrial development of any economy? It is a fact that water as a resource plays a very significant role in the economic and social development of the country. India has adequate water resource when viewed from the annual availability angle. However, the vagaries of distribution over space and time are the real challenges that have to be met with by planners and managers of water resources in the country with appropriate development policies which encourage conservation of water, its efficient use and equitable distribution of water across the country. The constraints of water availability can be kept under control and can provide restoration of a dream of economic powerhouse for the world. In order to become an economic power house, the country will surely need interventions at all levels starting from local water conservation and extending upto Inter Basin transfers.
India faces natural challenge of unequal water distribution in the country which is one of the prime reasons for water stress in the country. How do you plan addressing this for the future keeping the quantum of growing urbanisation and increasing industrialisation? Unequal water distribution in the country is a challenge as well as an opportunity for the country like India. We receive 75-80 per cent of rainfall in about 100 days spread over the 6 months of the monsoon and that too with a spatially uneven spread. Enabled with the unequal water distribution, we are also endowed with equally varied agro climatic set up which generates differing demands for water throughout the year. The problem has to be addressed from the supply as well as the demand angle. We need to manage the water demand in a given area by promoting appropriate agricultural production policies which are suited to the local climatic set up. Accordingly, the challenges are faced during the lean season when the rain fall is minimum and problems of flooding are faced when there is good rainfall. This has to be addressed by promoting as much local conservation as practicable, to make communities less vulnerable during dry parts of the year.
We already have very little consumptive use of water out of Brahmputra and Barak basins in the North East and hardly 10 per cent of the annual available water is being utilised productively. We will need to increase the same for meeting the demands elsewhere in the country.
Also, changes in the life style by consumption of less water incentive food groups can be encouraged so that the demand is managed. For increasing industrialisation and urbanisation, large scale recycle and reuse policies will have to be aggressively put in place so that the demand for such usage
36 â&#x20AC;˘ April 2014
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We need to recognise that almost 80 per cent of available water resources are consumed by irrigation and more than 80 per cent of the industrial demand is consumed by power generation. Recognising the large quantum of water needed for food and energy security of the country, Ministry of Water Resources and CWC are front runners in the conservation of existing fresh water resources through their ƀagship programmes oriented towards coordinated irrigation beneſts, protection, repair, renovation and restoration of water bodies etc. ` 1,05,200 crores have been earmarked for AIBP coupled with CADWM programme and ` 30,000 crores have been earmarked or RRR of water bodies during XII plan. Programmes have been made comprehensive to cover the conservation, conveyance and equitable distribution through most efſcient and optimum means for a project and ensuring subsequent participation of user community in managing created resources with a sustainable revenue model. The management of pollutants of major rivers streams like Ganga is attempted through State and Central Pollution Control Boards and various action programmes taken up by the State Governments as well as Ministry of Environment & Forests. It is considered very important to manage and remove pollution from water at the sources where the waste water is generated. Reserving the maximum availability of water for ƀow in the lean season for ƀushing of the pollutants downstream, though appear simple, is not a solution. Desalination projects can be taken up to improve geo-genic poor quality water for local improvement in fresh water availability, and can be used to supplement the generating water resources in such areas, where either there are no sources or an emergency situation has arisen due to failure of existing sources of water. Desalination plants have performed well in such contexts at Chennai and in Lakshadweep islands. Many factors enter into the capital and operating costs for desalination such as capacity and type of plants, plant location, feed water quality, labour cost, energy cost, ſnancing cost, ease of concentrate disposal, level of instrumentation/automation and plant reliability. The production cost of a brackish water desalination plant is estimated to be ` 10 to 15 per m3. The production cost for a sea water desalination plant varies between ` 40 to 50 per m3. Whereas the production cost of desalted water from efƀuent varies from ` 15 to 50 per m3 depending upon the TDS load in the efƀuent stream. However, reduction in cost of desalinated water by way of reduction in energy consumption and cost of input materials can be examined for wider usage. Desalination plants will also have to contend with their own waste water which will have extreme concentrations of removed salts.
A B Pandya, Chairman, CWC, Ministry of Water Resources and Chairman, CAB, WaterEX World Expo 2015
can be met by diverting maximum water from other major sources. In this context, improvement of water efficiency, coupled with efficient policies for improving quality of waste and poor quality water is the need of the hour. Along with the other resources, we share our major rivers across states and communities. Release of poor quality water which creates fresh water availability problems to the downstream communities has to be recognised as a national problem and holistic solutions have to be found. All the communities depending on a single river stream have to be considered as a chain link in terms of quality and welfare of all links has to be ensured to see that the chain does not break. We have not been successful in protecting our fresh water resources. Recent news of Sabarmati becoming highly polluted clearly indicates the failure of statutory bodies to control industries from polluting the depleting fresh water resources. What initiatives is CWC taking towards stopping any further damage to our water resources? CWC is not primarily mandated with management of water quality in various parts of the country. We do monitor the ambient water quality in the country and report the same from time to time. Quality management part is generally handled through State and Central Pollution Control Boards. However, managing the quality of ambient water is a challenge in which all the agencies have to participate. It is necessary to estimate the fresh water used in a basin and the amount of water storage required to meet such demand on an average basis also accounting for the growth patterns over time. In this context, CWC through various schemes of Ministry of Water Resources attempts to improve the storage and to promote higher efficiencies in water use. Recycle and reuse can then supplement the demand curve especially in the lean seasons of availability. The other inventions have to necessarily come from the community where in assuring release of used water back in the natural stream with a quality, which can be managed by the natural process before the same, is picked up again by a different community for its use. We need to put the necessary quality management regulatory structures and guidelines in place specific to individual river basins. Many developed countries like Singapore meet the water demand through recycle water using high-end technologies which even treat the municipal waste. Is it possible to set up such projects in India? What could
CWC through various schemes of Ministry of Water Resources attempts to improve the storage and to promote higher efficiencies in water use. Recycle and reuse can then supplement the demand curve especially in the lean seasons of availability. 38 • April 2014
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be the possible bottlenecks in your opinion in executing such projects? Recycling water using any type of technology has to address the issue of treatment costs and costs of providing fresh water to the consumer groups. The setting up of any high-end technology project will hinge upon commercially viability and also, the demand of the consumer group. The possible bottlenecks are managing multiple sources of pollution over a wide area, each generating limited quantity of poor quality water. The other bottleneck is the complex nature of effluents from the communities which have mixed land usage thereby mixing the industrial pollutants along with the pollution generated by the purely domestic and urban water users. It would be a good idea to segregate the sewage effluents in these two categories so that the domestic effluents, which are relatively easy to treat from harmful metallic ion content angle, can be managed at a lesser cost. May we have your comments on strategies industries must adopt to curb their water footprint? The industries have to adopt efficient technologies which can reduce their water demands, and need to modify the processes in such a way that poor quality water generated in the primary process cycle can be used for other industrial processes after recycle. The industry may also examine the sustainability of their water consumption needs with the demand of the adjoining communities which may also be dependent upon the same resources. By way of community participation, the industry can attempt overall water availability solution to the community without encroaching upon justified usage patterns. Before siting an industry, the local usage and availability of water should be examined by the industry themselves and appropriate means of generating extra resource from the conservation and recycle angle should be worked out to reduce the conflict in the society. Which are the key technologies that India needs to bridge the growing demand-supply gap of water? India needs to bring in technology for efficient conservation by reducing loss of water through evaporation and other storage efforts, conveyance of large quantum of water without affecting its quality and minimising the losses in the conveyance process. We also need to develop or bring technologies which will handle treatment of water and its reuse on a commercially viable proposition as against the present view of an obligation with no commercial viability angle. Individual industries can form a chain to serially consume the same quantity of water by reuse and recycle to reduce their water footprints on the other communities. For this, a cooperative location and management mechanism has to be in place amongst them. India also needs to develop a respect principle where the community or a large user has a responsibility to give back the water to the nature in the same form in which the user received that water from the nature. 40 â&#x20AC;˘ April 2014
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CEW Features Technical Article
O&M Practices for Sustainable WWTP Operations A report on Super ESPC suggests that 21 per cent of reported savings could be achieved by reductions in Operation and Maintenance (O&M) costs which can be achieved through sustainable design and good O&M practices. The authors, in this article, delve in depth over adopting efficient O&M practices for sustainable Wastewater Treatment Plant (WWTP) Operations across the functions of Operations, Maintenance, Engineering Support, and Training Administration to achieve significant cost reductions.
W
astewater treatment projects would typically have a cost structure as shown in figure 1. It indicates that ÂO&M costsÊ form a significant portion of the total project cost and that ÂengineeringÊ - which form small portion of overall project cost - can bring down the entire project pyramid if not carried out efficiently. On dissecting the O&M costs, it is typically found that manpower, power and chemical costs account for about 80 per cent of the annual O&M costs. (The percentage for each cost element is expected to vary primarily because of technology adopted, project size, location & environmental regulations (for example: sludge disposal norms). Hence, the cost savings can be achieved by adopting good design and O&M practices.) O&M costs can constitute a substantial portion of a projectÊs savings. A report on Super ESPC (Energy Savings Performance Contracts, 2007) projects shows that 21 per cent of reported savings were due to the reductions in O&M costs. By adopting good and sustainable design and O&M practices, we can reduce manpower, power, chemical and residual disposal costs. The overall O&M programme in any organisation typically consists of five distinct functional groups that includes Operations, Maintenance, Engineering Support, Training, and Administration. For sustainable O&M management, each of the functions must put in their best efforts. However, the key to effective system lies not only in individual best
42 • April 2014
Ć 15 years O&M Cost (60-70%) Capital Cost (20-25%)
Engineering Cost (5-10%) Figure 1: Project Cost Pyramid
efforts but largely in coordination among them and integrating them all together. (Read the sample cases in the Fact Box on next page) Strategies to Improve O&M Processes Following are some uncommon points which should be considered while planning strategies for an effective O&M system. Data Usage Ć Data collected through laboratory analysis and other indicators for power consumption, flow, drive run time etc is generally not analysed and utilised for process optimisation after a project is completed. Inferences from the analysis of data can be used to operate the plant more efficiently, design a preventive maintenance schedule as well as energy and water conservation models. Ć Data acquisition systems can be installed along with remote monitoring systems. Ć A feedback loop from ground level operators to manger and expert level is crucial.
Constant O&M supervision designers and experts.
from
Smart Working and Task Rotation Ć There should be rotation of tasks among various operators so that monotony can be avoided and help operators keep interest in what they are doing and give them the opportunities for career growth. Ć Laboratory testing schedule should be planned with the focus on obtaining high quality data and analysing the same rather than too much data which is seldom analysed. For example, there is no need to conduct BOD examinations daily when a much simpler COD test gives faster and more accurate information about water quality and pollution. Ć Standardise processes and use a centralised database for all facility related data. Facility management software tools are now available that seamlessly integrate all facility data on a single platform. For example, Cloud-based Facility Management System applications are available in the market as Software-as-a-Service (SaaS) at nominal monthly subscription fees. Performance Level Benchmarking Ć Intra and inter-organisation benchmarks should be defined and put as target for the employees both internal as well as outsourced. For example, effluent produced per kg of produce, energy used per m3 of wastewater treated etc. Ć Target once achieved should be maintained and benchmarks should be upped regularly. Chemical Engineering World
CEW Features Following are some sample cases where lack of performance and the necessary coordination became apparent and led to loss of output and/or higher O&M costs.
Solution: This can be avoided and more optimum steps can be remotely initiated by a team of experts based on factual data by adopting a consolidated data management system.
1
4
Replacement of Diffusers: The WWTP operations team notices that diffusers in one of the aeration tanks say Aeration Tank No 1 (out of a total of 2 aeration tanks) are damaged and need to be replaced. They pass on the message to the engineering team who initiates a purchase and replacement order to an outsourced maintenance team. When the diffusers reached the site, it was found that the diffusers ordered were of a different type that were installed in Aeration Tank No 2 and thus had to be sent back and a new purchase order had to be initiated. Because of this there was not only loss of time during which the WWTP ran inefficiently, but also posed a significant risk of failure to meet the discharge parameters. Solutions: Diffusers installed in all aeration tanks must be of the same make and type. Hence, no confusion would be created during replacement.
2
Asset Life: The operator claims that he ran two blowers for the aeration tanks for more or less the same amount of time. However, in realty the night operator forgot to switch on the blowers and because of which one blower on average ran for 30 per cent more and hence has to be overhauled or replaced sooner. Solution: This could be avoided if the data acquisition of the blower run times was automated and/or the manager got accurate data from the operator.
3
Electricity and Chemical Consumption: A new WWTP operator has been dosing higher than required amount of chemicals at the WWTP and/or running a pump more than required (e.g. sludge re-circulation pumps) or running a very old pump which should have ben replaced than being operated. However, no action is taken as this information is seldom presented to the engineers in a timely manner or in the right format.
46 • April 2014
Design Improvements: WWTP at manufacturing plant in Delhi has adopted a particular type of pump which the plant operators find to be inefficient but there is no/little feedback given to the projects team who are setting up a new plant in Mumbai and as a result the Mumbai team again installs the same make and model of the pumps. Solution: Such events can be efficiently captured if operations and maintenance data is captured and stored from older plants and made available to the design and project teams who can use the data for improving designs of new plants.
5
Under qualified operators: Many WWTP operators are under qualified and do not have the necessary understanding and/ or expertise in operating WWTP, especially during changing inlet quality and other process parameters. On the other hand hiring experienced operators can increase the manpower costs. Most WWTP managers have to grapple with this problem and many a times the hiring decisions are sporadic in nature. Solution: It is necessary to invest in regular training of operators which can be provided using virtual classrooms, shadowing, regular rotation etc. Further, it is also critical to ensure a seamless interaction medium is provided between the operations staff and engineering staff to address any technical queries of the operators. The above cases are only some common examples of on-ground challenges that lead to inefficient operations of WWTPs. The common theme that typically emerges is accurate data unavailability, lack of factual data use for optimisation of the various O&M processes and the lack of a positive feedback loop between operators and designers.
Ć
Ć
Ć
Practices should be as per standard operating procedure or O&M literature provided by the manufacturer or designer. These documents should be readily available to all operators and not archived in a library. Performance can be monitored keeping the following criteria in mind: Ć Energy Efficiency Ć Water Recovery Ć Chemical Usage Ć Down time of any asset Ć Frequency of troubleshooting requirements per year Depleting water resources have created a necessity to deploy skilled operators to utilise assets efficiently. It is necessary to train operators and establish a grading and reward programme to ensure a competitive environment and continuously improving system.
Automation Alternatives for Performance Improvement Supervisory Control and Data Acquisition (SCADA) systems are utilised for remote data acquisition and real-time control, whereas Data Acquisition Systems (DAS) are simply for one purpose only, i.e. Data Acquisition. Most WWTPs employ a SCADA system to operate and monitor their process plants; however, the level of automation is restricted to more or less data acquisition. Any utility going for a SCADA system mainly for data acquisition makes significant compromises to use it for this purpose. These compromises include cost, data integrity, flexibility, convenience and control of the task. It is important to first understand that DAS and SCADA systems are architecturally different types of systems. SCADA is a real-time system requiring a continuous channel of communications between the host computer and each I/O device (Remote Terminal Unit (RTU)). In data acquisition applications, the RTU responds to requests for real-time measurements from the host computer. If monitoring a field parameter (e.g. level, flow or pressure) once every five seconds is important, the host computer sends a request for these parameters every five seconds. SCADA systems operate in this fashion because when performing their primary Chemical Engineering World
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CEW Features
Figure 2: Typical O&M cost structure of WWTPs
function, which is control, they make real-time decisions at the host-based on real-time data collected from all field sensors. However, when a SCADA system is used for data acquisition only, particularly for remote monitoring applications, this approach of real-time monitoring of parameters is not optimum or even practical because of system complexity, cost and data reliability exposure. A dedicated DAS, however, is optimised for remote monitoring and comes at a much lower cost. A DAS is typically independently configured to store both manually entered data (e.g. laboratory testing data) and also sample each field sensor or instrument at a practically optimum rate for that parameter.
Some Key Advantages of a Cloud-based DAS: Following are some of the key benefits of a cloud based DAS system that can be easily integrated to meet the specific requirements of any utility: Ć The cloud platform is customisable to meet each utilityÊs particular requirements Ć Data centre delinked to the control system significantly reducing plant operations risks due to network hackers Ć Complete consolidation of all water quality data and asset operations data Ć Simultaneous access to all current and historical data Ć Access to your data anytime, anywhere and from any web enabled device Ć Operators and consultants can use the platform for performance enhancements and troubleshooting. Ć Store all plant related information including As-Built Drawings, water quality reports, O&M Manuals etc at an easily accessible location. Ć Reduction in data errors Ć Easier and faster access to relevant monitoring data Ć Reduction of time and effort to verify compliance and produce reports Ć Fully customisable and automatic email alerts Ć Allow comparing data between various utility assets within an organisation and establish benchmarking systems
Ć
All data is stored on a secure encrypted database and has backup so that you will never lose any data
This methodology provides user the best of all data worlds: cost, versatility and reliability a cloud-based DAS system ă all their plant and field data a common platform.
the the of and on
Summary A major part of the life cycle cost of an asset is spent on periodic maintenance and proper operation which helps in increasing the life of the asset and thereby the project costs. We believe the 1 st step towards better O&M management is to know what to measure, then measure and subsequently use the data for optimisation. As more and more WWTPs are designed for wastewater reuse and/or as ZLD projects, the importance of energy, chemical and waste solids disposal cost optimisation would greatly increase. Secondly, it is critical to ensure full alignment of interests at all functional levels and individuals. Operators, managers and engineers must feel adequately motivated and incentivised to ensure that they continually work towards improving the O&M and also the design of new systems and their performance adds value towards their personal career development.
AuthorsÊ Details Nitin Verma Environmental & Clean Technologies Expert Spans Envirotech Pvt Ltd Email: nverma@spans.co.in
Figure 3: DAS system data review via web browser
48 • April 2014
Jahanvi Kulshreshtha Water/Wastewater Process Engineer Spans Envirotech Pvt Ltd Email: jahanvi@spans.co.in
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CEW Features Guest Column
Is Production Without Wastewater Possible? In Germany, only one third of the water used for the production of goods is used repeatedly. Two thirds is purified to such an extent that it meets legal limits for disposal into public sewer systems or into open waters. However, modern treatment processes allow profitable recycling of such wastewater to production processes. This would not only allow saving of valuable fresh water resources, but would also reduce contamination of rivers and open waters drastically. Frank Schlegel, Managing Partner, H2O GmbH, explains how an industrial production without wastewater can become reality.
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t is of greatest importance to achieve energy efficient treatment processes with focus on the quality of the purified water. In their application centre for zero liquid discharge production the processes are developed further, resulting in patents on technologies and processes. The main target is customer orientation. Be it automotive, aviation, medical, chemical or metal working industry, every wastewater requires individual treatment processes. Water Consumption in the Industry To produce one tonne of steel, nowadays 18.000 l of fresh water is consumed. For one tonne of paper 7 m 3 of fresh water is required. The production of one laptop computer uses
15 m 3 of fresh water. In the automotive industry water consumption has been reduced a lot already. Nowadays only 400.000 l of water is consumed for the production of one car. Globally, the industry is taking great efforts to reduce water consumption. In 2007 the German industry used 1.910 million m 3 fresh water. Until 2010 this value was reduced to 1.770 million m 3 ò, a reduction of 7.5 per cent within 3 years. This development was driven by cost, as fresh water and related wastewater disposal cost are relatively high in Germany. Fortunately more and more the ecological advantages of fresh water saving and reduced contamination of open waters become important for the industry.
Figure 1: Evaporator separate industrial wastewater from its water content. This purified water can be reused in the production.
50 â&#x20AC;˘ April 2014
In all times, there was a tendency to locate industries close to rivers as they are helping to secure supply of fresh water. In addition the rivers offer advantages regarding disposal of wastes. Nowadays it is only allowed to dispose of wastewater into rivers if they are purified properly and meet legal limits. For the treatment of such wastewater several conventional treatment processes are available on the market. However, even if treated properly, the purified water still contains residual contaminants, such as oil, fat or heavy metals which cannot be removed in public wastewater treatment plants and thus finally end up in open waters. On the example of the river Rhine it can be estimated how far European rivers are polluted still today. At the Dutch Ä&#x192; German border in Lobith a daily pollution of 200 tonnes of TOC (organic carbon compounds) is measured. Taking into account that this contaminants are only the pollutants which could not be removed in sophisticated wastewater treatment plants and which will not be decomposed in the open waters, this seems to be a rather lager amount. In addition to that about 50 tonnes of heavy metals are disposed of into the Rhine every year. Some of these pollutants will finally end up in the ground water and are a threat to our drinking water supplies. Laws and legislations tolerate disposal of wastewater into open waters if they meet legal limits, and thus contain heavy metals and other Chemical Engineering World
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CEW Features Energy Consumption Evaporation of water is a very energy intensive process, and seems to be not profitable for the treatment of industrial treatment on the first sight. Essential is, that the VACUDEST systems re-condenses the evaporated water, recovering the thermal energy. The recovered energy is used for the evaporation of the industrial wastewater. Thus 95 per cent of the required evaporation energy is recycled. Using vacuum distillation technology the energy consumption can be reduced by 95 per cent, creating a profitable process for the treatment of industrial wastewater, even in regions with high electricity prices. Figure 2: 95% energy recycling in the VACUDEST Process
residual contaminations. This is far away from being an ideal situation, which could easily be improved with not too many efforts. The vision of H2O includes the termination of disposal of wastewater either into public sewer systems or open waters. Such a wastewater free industry certainly does not have to abandon consumption of fresh water; however, they should recycle it back to the production process and use it repeatedly. Using the VACUDEST technology companies can create a zero liquid discharge production. How Does Zero Liquid Discharge Work? Industrial wastewater often contains only small amount of impurities, such as oil, fat, salt or heavy metals or other organic compounds. They often amount to about 2 per cent whereas 98 per cent of the wastewater is really water. The VACUDEST process separates this clean water from the impurities by distillation. The purified water is clean enough to be recycled to production processes, even to surface technology processes requiring very high process water qualities like for instance in the production of cars, windows or furniture. This saves valuable fresh water resources and makes sure that no contaminations get into the public sewer system or into open waters. The process can be explained using an example from the nature. The sun evaporates water from the ocean, containing salt and other impurities. It is condensed in the sky, forming clouds. From those clouds it rains back to the earth as clean and clear water not containing any salt or pollution. The VACUDEST copies this process. Under vacuum wastewater is evaporated leaving behind high boiling impurities like heavy metals, fat or oil.
Figure 3: Before and after: industrial wastewater and the purified clear distillate.
52 â&#x20AC;˘ April 2014
Where can the New Technology be Applied? For the time being the most important applications are metal working and surface technology processes. During metal working so called cooling lubricant emulsions are applied. During production of aixle parts, engine blocks and other vehicle components quality requirements for the surfaces increase. By applying grinding and other surface technology processes these requirements can be fulfilled; however, a big amount of industrial wastewater is created. The same happens when applying plating processes or preparing parts for painting. In the new gearbox production of Peugeot in Tremery, France, two large VACUDEST evaporators are installed. In the middle the wastewater buffer tanks can be seen. The wastewater treatment process is perfectly integrated in Peugeots production process. The system is operated round the clock, carefully supervised by a control system, ensuring that all requirements to the quality of the purified water a kept. Farewell to Wastewater? How to motivate industrial companies to invest in future proof, zero liquid discharge systems for the processing of their wastewater? Enforcing by laws, legal limits and regulations is not the best method. The most important reason for the investment in an innovative VACUDEST vacuum distillation system is profitability. Due to reduction of cost for the disposal of wastewater with waste management companies by about 95 per cent the return of investment is usually less than two years. The conventional method would be the disposal of the industrial wastewater using tank trucks. A medium sized metal working company produces about 3.000 tonnes of such wastewater. Waste management cost in this example amount to 160.000 euro per year. This is to be compared to the investment in a treatment system with a life cycle of more than 10 years. The VACUDEST produces cost of about 60.000 euro per year including depreciation, interest rates and operation cost, thus the system pays for itself in less than two years. These big savings are the main motivation for the investment in a modern evaporation system. Further reasons are the intention to create a zero liquid discharge production and save valuable fresh water resources. That helps to protect the environment and improves the company image. Together with the above mentioned savings this creates a pleasant win-win situation for the investing company. Chemical Engineering World
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CEW Features Technical Article
Small STPs: Applications and Advantages Small Sewage Treatment plants (STP) are fully automated self-operating electronically controlled treatment systems that can treat domestic sewage (black and grey water) from individual houses that are not connected to sewers, and achieve treatment quality higher than the threshold limits prescribed by regulation. The article highlights the signilcance of STP and shares insights into its applications and advantages.
R
apid urbanisation and industrialisation is happening in India, such quick growth also comes with its effect on the environment, especially with water and sewage treatment. Metropolitan and many other smaller cities are faced with acute to chronic water shortages. On one hand, there is high water pollution of ground and surface water due to discharge of untreated or improperly treated sewage and on the other hand, industries and dwelling complexes empty raw sewage into water bodies hampering governmentĂ&#x160;s initiatives in rehabilitating natural water bodies. Sewers systems are effective and efficient where water is supplied from a single source. The groundwater dependency is high and will remain the same, but peri-urban settlements are faced with chronic ground water shortage due to over exploitation. Rainwater harvesting schemes reduce the stress on ground water depletion, but scanty and higher runoff limit the effectiveness of rainwater harvesting. There is a need for rethinking to find more innovative approaches to improve and increase the groundwater recharge. Under Ground Sewerage System (UGSS) and sewerage schemes are already
54 â&#x20AC;˘ April 2014
Fully underground SMALL STP below and office entrance in Chennai
suffering in various proposed cities and towns due to lack of space, shortage of manpower, lack of primary data, etc. The situation is expected to worsen, when drainages will be burdened with silt, storm water surge, vector infestation, accidents, morbidity and mortality arising directly or indirectly from the ill effects of sewerage schemes. On top of the sewers, there is also a need for erection, operation and maintenance of centralised sewage treatment plants. There are only a hand full functioning sewer systems complemented by properly designed and operating sewage treatment plants. User fee collection for water and wastewater supply and treatment is interlinked. Water charges include wastewater collection and treatment. It will be practically impossible for municipalities to charge this when most of the water used is from bore wells at household level. Even with 24x 7 supply of water, people would resort to using bore wells to supplement non-potable water needs. User fee collection for such schemes will be further challenged by lack of willingness from public and lack of political will to burden the users, leading to failure of such schemes even before starting.
Government has successfully incorporated rainwater harvesting at each household and a similar approach could be enacted to treatment of sewage and waste water treatment starting from household to communities. Individual homes, with the floor space of 2000 square feet, should have treatment facilities for reuse of treated water and also to recharge ground water aquifer. Small STP - for single houses to communities, offices, factories, hotels and hospitals - will be something to look forward to. These plants will be fully automatic and work independently without any operator and they would be like any household appliance such as fridge and washing machine. The treated water quality will meet the prescribed regulations and the treated water can also be sent back to nature for ground water recharge, a better solution to compliment rainwater harvesting, recycled and reused. Such small sewage treatment plants will replace existing septic tanks that produce Ozone depleting methane gas and are hazardous to human health. These plants are taking us much closer to eradication of human scavenging as it is handled by professionals. Chemical Engineering World
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CEW Features FREQUENTLY ASKED QUESTIONS How can as SMALL STP be used in existing septic tanks? With minimal changes or even with no change, small STPs can be retroſtted into already existing tanks. This means no need for new tanks and civil work for homes. What is the difference between a septic tanks and small STP? What about the volume of water treated in STP? A septic-tank works in the absence of air and produces an efƀuent that is septic, devoid of oxygen and full of pathogens. As small STP uses air to generate natural microorganisms to consume and digest harmful elements in sewage, the resultant water is comparatively safer for reuse and has positive effect on environment. The entire water that comes into the treatment plant is treated and sent out in batches. This means there is no water wasted in the treatment process without recovery. Is there odour or gases produced? The treatment is aerobic and large volume of air is pumped into the sewage water for treatment. By this way odor is minimized. Aerobic treatment does not produce harmful gases like methane and hydrogen sulphide. Would there be a need for human/manual scavengers to enter the tanks for maintenance? There is absolutely no need for manual scavenging. The tanks are free from any need for humans to enter the tanks for cleaning. Moreover, the tanks do not have odor and discomfort that a septic tank creates. Professionals/ engineers (like servicing washing machine or an AC) can be engaged for regular maintenance and thus it will not be a manual scavenging activity. Will there be sludge produced? Any biological treatment produces sludge and so does the small STP. The sludge generated is already digested and stabilised to a high degree that is safe for disposal into the environment. Onsite sludge stabilisation through sludge drying beds is an option. Government and private parties can be engaged in emptying and disposal services where sludge can be sold as agricultural fertiliser. With small STP, there is more regularisation of the desludging due and high degree of professionalism can be brought into the disorganised and illegal tanker services available. The stabilised sludge with its high nutrient value can be mixed with compost and sold to farmers. How small STP ensure that the water is treated properly? Each plant comes with an inbuilt artiſcial intelligence which ensures that water treatment is the same and to a high degree at all times. Alarms are set to warn the customers on the need for maintenance and also when something goes wrong. By this way the customer can always get the plant attended to. There are also options of remote monitoring systems where there is a need for regular monitoring. Bigger plants can choose to have remote monitoring systems where many plants can be managed from a central location through internet. What about troubleshooting and malfunction? The plant has a recording system, where all errors are recorded when it happens. The service people can read the error directly from the plant or through remote monitoring and attend to the plant needs without physical inspection of the plant. 58 • April 2014
Application of Sewage Treatment Plants Ć Ć Ć Ć Ć Ć Ć Ć Ć
Where there are no sewers and sewerage systems are challenged Urbanisation and development beyond corporation and municipal capacities and limits to serve Small to mid sizes offices and industries Factories with more than 30 workers Hostels Schools and colleges Showrooms Hotels and restaurants Commercial establishments
Sizes Available: Single home - 0.5 KLD to communitiesÊ up to 300 KLD Plant operation: Fully automatic Space required: Underground - no smell or other aesthetical or vectoral problems associated with sewers schemes. It can be under playgrounds, parks, road or walkways Treated water usage: Recharge of Groundwater, Reuse, and Recycle, etc. Advantages of Sewage Treatment Plants Ć Rapid construction due to small sizes (single home to small communities) Ć Less burden on municipalities, EPC contractors, etc Ć Toally underground hence no social issues Ć Can be under road, walkway, and retrofitted into septic tanks Ć Cost and time saving in sewerage systems and centralised STPs Ć Easy approval from concerned authorities When each individual home is fitted with sewage treatment plants there is no waste water. The same become a resource and all the water can be utilised for gardening as the water has all the nutrients needed for plant growth. The treated water can be used for watering the plants and vegetation directly and also can be used to recharge groundwater. This means that groundwater table is recharged at the source of water and thus adding to the environmental sustainability. This is a better option than rain water harvesting, which is only seasonal. These plants are mandatory in Europe and will become mandatory in India too. These systems will compliment government initiatives and also where there are challenges faced to provide sewers systems. The Reliability of the System Quite reliable, the system works independently without any requirement for human intervention apart from periodical yearly maintenance. Small STPs could support smaller communities and independent houses and a sewer free environment. AuthorÊs Details Kannan Pasupathiraj Managing Director EcoTec Engineers and Consultants Email: kannan@klaro.in
Chemical Engineering World
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CEW Features Technical Article
Managing Pipeline Scaling Scaling is a common problem in the Minerals & Metallurgy, Oil & Gas, Power Plants, Pulp & Paper and Municipal Waste Water industries, where production rates can be adversely affected by the hardening of iron, salts and other minerals in pipes and valves. The article highlights the new technology Electrical Capacitance Tomography (ECT), which allows operators to see inside piping systems without stopping the process or opening up the pipeline, and enables 3D-imaging and measurement of non-conductive media inside process pipelines and tanks.
I
n process industry, it is usually beneficial to have comprehensive information on the state of a process. First of all, this information may be essential for process control in various situations, since it typically provides means for keeping the process running in its optimal operating range, and thus increasing the overall productivity of a plant. Accurate knowledge on the state of the process helps operators to predict possible problems, and on the other hand, makes it possible to plan maintenance operations in a cost-effective way. Secondly, process measurements are needed for acquiring a better understanding and a deeper insight into process behavior in general, which can open ways for developing new solutions in improving process efficiency. Process Measurements Process measurements can be categorised into point-like measurements and volume measurements. Point-like measurements give process information from a single point in a fixed location, and typically such quantities are temperature, salinity and pH. In many situations point-like measurements are sufficient for efficient process monitoring and control. However, in the presence of inhomogeneities and/or multiple material phases, pointlike measurements do not necessarily provide appropriate information for operators since spatial variations cannot be identified. In such cases, it would be useful to know how certain material or quantity is distributed over certain volume instead of getting information from a single point.
60 â&#x20AC;˘ April 2014
'Process tomography' is a general term for volume measurement techniques intended for cross sectional or 3D imaging of material properties and distributions in various industrial positions such as pipes, vessels and reactors. Process tomography covers several tomographic techniques, e.g. electrical, X-ray and ultrasound methods, and typical applications include monitoring of different mixing and sedimentation processes as well as determination of material concentrations and distributions in multiphase flows. An important feature of tomographic techniques is that the measurements are typically carried out from the periphery of the target using a specially designed sensor in order to avoid disturbing the process. Tomographic measurements enable noninvasive process monitoring, which can give comprehensive understanding on the behavior of the process system and provide valuable information for process optimisation and control. Electrical Capacitance Tomography (ECT) The fundamental principle in tomographic measurements is to expose the target of interest to an appropriate stimulus and then measure the response that depends on the material properties within the target volume. For instance, in X-ray tomography, the target is exposed to X-rays from multiple directions and the attenuation of intensity is measured
along the beam lines to obtain information on the distribution of the attenuation coefficient. In electrical tomographic techniques, excitation signals are applied to the volume of interest via a suitable measurement setup and the objective is to measure output signals that depend on the electrical properties of the material, such as conductivity or permittivity distribution. A special algorithm is then used to find an estimate for the actual material property distribution. ECT is an imaging technique that can be used for the determination of the permittivity distribution of dielectric medium within a region of interest. Several organizations have contributed to the development of different sectors of ECT technology. Important pioneering work in ECT was carried out at the US Department of Energy, Morgantown Energy Technology Center, USA, and at the University of Manchester Institute of Science and Technology, UK. ECT measurement is based on the use of an ECT sensor which consists of a set of electrodes mounted around the periphery of the target region. In fixed sensor geometry, the capacitance of each electrode pair depends on the permittivity distribution of the material in the sensor. The basic procedure for capacitance measurements is to apply an excitation
Important pioneering work in ECT was carried out at the US Department of Energy, Morgantown Energy Technology Center, USA, and at the University of Manchester Institute of Science and Technology, UK. Chemical Engineering World
Features CEW
Figure 1. Visualisation of the effect of a permittivity inhomogeneity on potential distribution.
voltage (AC) to one of the electrodes while other electrodes and other physical components are grounded. A potential distribution and thus an electric field are formed within the sensor, and the underlying permittivity distribution affects the shape of the field.
definition of capacitance C i=Q i/V, where Q i is the charge on the i th electrode and 'V' is the excitation voltage. A complete set of measurements is obtained by using each electrode as the excitation electrode in turn and the rest as the measurement electrodes.
This is because permittivity is a measure for a materialÊs ability to ÂresistÊ external electric fields. In other words, the higher the material permittivity the weaker the electric field within the material when placed in an external electric field. The effect of spatial permittivity changes on the potential distribution is visualised in figure 1. Due to the electric field, electric charges are attracted to the grounded electrodes, and they are measured indirectly from electric currents. The capacitance data is obtained from the fundamental
Capacitance data as such does not give a very clear view on the actual permittivity distribution, even though some qualitative interpretations can be made by experienced persons in certain situations. Therefore, for full utilisation of ECT measurements, it is important to determine an estimate for the permittivity distribution in question. This necessitates the availability of a realistic mathematical model that simulates capacitance measurements given a permittivity distribution. Such a model can be derived from the famous
MaxwellÊs equations that form the basis of electromagnetic field theory. The basic idea in image reconstruction is to find a permittivity distribution for which the observations predicted by the model are in good agreement with actual ECT measurement data. In general, such an image reconstruction problem is an illposed inverse problem since it has, due to the very limited number of capacitance measurements, an infinite number of solutions that produce exactly the same capacitances as the ECT measurements. In order to enable the determination of a stable solution for this problem, it is necessary to impose additional constraints for the solution. These constraints can be of qualitative and/or quantitative nature depending on how much is known about the permittivity distribution in advance. It is important to notice that different scaling conditions may require different types of additional constraints to obtain optimal results. All in all, ECT imaging leads to a nonlinear problem that is solved iteratively by starting from an appropriate initial guess for the permittivity distribution and by gradually proceeding in the direction where better agreement with model data and measurements is reached. This procedure is illustrated in figure 2. ECT is typically used for the imaging of electrically insulating materials. However, the ECT measurement technique can also be used in cases where the conductivity is
Figure 2. Illustration of the iterative solution of ECT imaging problem. Actual permittivity distribution and measured data are shown in the leftmost panel. Iteration is started from a homogeneous initial value for which the correspondence with the measured data is poor (in the lower figures the thick gray lines represent the measured data and the thin black lines are the modelled data corresponding the estimated permittivity distribution at each iteration step). As the iteration proceeds, the modeled data approaches the measured values, and at the same time the shape of the actual permittivity distribution becomes increasingly recognisable in the estimates.
Chemical Engineering World
April 2014 • 61
CEW Features not negligible. In such situations, material permittivity is a complexvalued quantity, and in the image reconstruction, it is essential to solve the distributions of real and imaginary parts of the permittivity distribution. For this purpose the measurement system must be capable of measuring the electrical charges on the electrodes, and in addition, the phase shift between the charges and excitation voltage. Scaling Watch System The formation of scaling in pipelines and tanks can be a major problem and inconvenience in the process industry. The formation of layers of unwanted substances on the surfaces of process equipment may restrict fluid flow, decrease process efficiency or limit heat transfer, and therefore cause adverse effects on profit earning capacity. Scaling Watch System are used for online monitoring of process pipes for identifying possible process scale issues. Having adequate information on the state of scaling in pipelines can help optimise cleansing operations, avoid unexpected shutdowns and optimise the use of antiscalant chemicals. The Scaling Watch system uses the ECT technique to measure pipe volume and to characterise scale condition in pipelines. The applicability of ECT measurements is based on the differences in the electrical properties between the process fluid and unwanted scale material. Materials of different electrical properties affect the ECT measurements, and therefore reconstructed ECT images reveal how materials are distributed within the Scaling Watch sensor. The estimated permittivity distribution provides information on scaling thickness and how it is distributed on the pipe walls. In addition, it is possible to determine estimates for scaling growth rate and free volume percentage. The components of the Scaling Watch system are the ECT sensor and electrical cabinet. The sensor consists of a tubular metallic body and typically 8 electrodes that are mounted on to the body so that they are in contact with the process fluid. Some measurement electronics are brought to the sensor, which affects the sensor dimensions. The electrical cabinet contains a power source, a computer for data processing and an equipment for enabling remote connections. In the installation of the scaling watch system, a segment of the process pipe is replaced by a sensor with an appropriate inner diameter and the electrical cabinet is connected to the sensor with a bus cable. After connecting the cabinet to the power grid the system starts automatically and is ready for use. The scale situation in the sensor can be monitored with a web-based application through which measurement settings can also be changed.
AuthorĂ&#x160;s Details Molly Bragg Marketing Associate Flowrox Inc. Email: molly.bragg@flowrox.com
62 â&#x20AC;˘ April 2014
Chemical Engineering World
Features CEW Technical Article
Grooved Advantage in Cross-country Pipework Unpredictable conditions can make the outdoor installation of pipework more difficult than on construction sites. Grooved piping systems offer advantages in laying pipework cross-country that can make them a superior choice to traditional joining techniques. The article explains why mechanical joints are increasingly being used in the transport of water.
“Due to flame-free assembly, the use of grooved mechanical piping systems reduces the risk of fire as well as other hazards during installation.”
I
nstalling pipework outdoors can create numerous difficulties for engineers. Many problems may be caused by harsh external conditions, including the weather, difficult terrain, ground swell and landslides. Access to basic amenities is also often an issue. It is not always easy to bring a generator to remote areas in tough climatic conditions, whilst ensuring maximum safety levels are maintained. Delays are a common outcome. Grooved systems help alleviate many of the problems associated with using traditional joining methods in the field. Mechanical joints are perfect for outdoor, remote use as they can be hand assembled with no need for power tools and can be mounted under any weather conditions, unlike welds which need dry pipe. Couplings provide visual confirmation of proper installation and there is no need for X-ray testing. With a union at every joint, they offer added flexibility and are more easily adjusted if alterations are needed. Another benefit of using grooved mechanical piping systems is that their
Chemical Engineering World
flame-free assembly reduces the risk of fire as well as other hazards during installation. This is very important in installations outdoors in the countryside where the risk of using hotworks in dry conditions is high. In addition, a trench carrying a flanged or welded pipe must be nearly twice the width of a trench carrying a grooved line, so using grooved technology lowers labor and time requirements, as well as the environmental impact. At a recent penstock line installation, the use of the grooved system successfully narrowed the piping trench from 13m to 6m in the Pacific Rim Rainforest. Speed and Flexibility Whether the project owner is a public agency or a private company, the speed of implementation is a very important factor. Grooved systems are dramatically faster than conventional solutions even in
perfect construction conditions, lowering costs and limiting exposure. With measurable time savings between 35 per cent and 50 per cent as compared to welding, grooved systems can contribute significantly to meeting tough deadlines. In harsh climatic conditions the difference is even more dramatic. Also, pipe misalignments during installation are easier to resolve as angles can be changed more easily. In addition, the use of flexible couplings in grooved systems has other major advantages. Over a number of years, land may be subject to ground movements and displacement, which can create stresses on pipes and even lead to underground breakages. This is very difficult for engineers to control, but flexible couplings offer additional security and can accommodate these potential misalignments without the need to install expensive and delicate specialised equipment.
With measurable time savings between 35 per cent and 50 per cent as compared to welding, grooved systems can contribute significantly to meeting tough deadlines. In harsh climatic conditions the difference is even more dramatic. April 2014 • 63
CEW Features bolts. The pipe groove is made by cold forming or machining a groove into the end of a pipe. The key section of the coupling housings engage the groove and the bolts and nuts are tightened with a socket wrench or impact wrench and hold the housings together. The coupling housings engage in the groove around the circumference of the pipe and encase the gasket. A pressure responsive gasket then creates a seal unified joint that is enhanced when the system is pressurised. For engineers, the benefits of the grooved system are many: the design versatility of the joint can allow both rigidity and flexibility, or a combination of the two, throughout a system when necessary; a mechanical joint provides noise and vibration attenuation, seismic relief, and accommodates for thermal expansion and contraction. Added to these benefits, the system provides a union at every joint for ease of system maintenance and expansion. “A mechanical joint is comprised of four elements: grooved pipe, a gasket, coupling housings, and a pair of nuts and bolts.”
Using flexible joints with a grooved system can also allow for contraction and expansion of pipes and associated potential movements with temperature as well as angular deflection. Maintenance is much easier with grooved joints, which are easily maintained and easily expandable. It can take all day to unbolt a flanged joint depending on the size. Compare this with only few minutes to unlock even a large diameter grooved coupling. Joint Benefits Grooved mechanical pipe joining is a no-flame joining technique of forming or cutting a groove in pipe ends and then joining them with bolted housings around a sealed gasket. It has become a preferred joining method on many piping applications when compared with welding, threading and flanging, and is commonly used in water systems technology projects. A mechanical joint is comprised of four elements: grooved pipe, a gasket, coupling housings, and a pair of nuts and
Conclusions Mechanical grooved pipe joining has been proven through research, testing and extensive evaluation. It has stood the test of time in some of the most impressive engineering feats of the last century, including the Hoover Dam, the Alexandria Library, and the Burj Khalifa. Moreover, mechanical joining has been a reliable and rugged component of mission critical applications such as data centres, flammable chemical cleaning applications and has met the rigorous system demands required for high pressure applications in desalination plants, as well as mines, power applications and tunnelling Summing up the benefits there is scope for significant financial savings by using mechanical grooved piping systems. Faster field installation, elimination of hotworks and reduced need for expansion joints all add up to advantages that are particularly important when choosing a system for a project in the current economic environment. Choosing a high quality and innovative mechanical grooved piping system can bring improvements in productivity. In a sector where margins are increasingly tight, this is an increasingly attractive option for consultants, engineers and system designers alike.
AuthorÊs Details Pankaj Soni Country Manager - India Victaulic Email: pankaj.soni@vicatulic.be
64 • April 2014
Chemical Engineering World
Features CEW Guest Column
Opportunities in ME’s Chemical Industry Abundant in energy resources and home to a large youth population, the Middle East (ME) boasts of some of the fastest growing economies in the world. It has reasonably high standards of living, although varied across countries, thanks to the region’s rich energy endowment. With the ongoing industrial development and social revival initiatives by local governments, the region is poised for brighter days ahead, albeit with its share of localised geo-political tensions and a challenging global economy, Vishnu Shankar, Associate Director & Head, Chemicals, Materials & Foods Practice, Frost & Sullivan, writes.
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he Middle East · comprising the Kingdom of Saudi Arabia (KSA), Qatar, United Arab Emirates (UAE), Oman, Bahrain, Kuwait, Yemen, Lebanon, Iran, Iraq, Jordan, and Syria · is known to account for close to half of the worldÊs known crude oil reserves and over one-third of natural gas reserves. This largely makes up for the harsh climate, limited water availability, and scarce arable land that characterise the region. Revenue from trade of oil and oil products represented close to half of the regional Gross Domestic Product (GDP) in 2011. In countries like Kuwait, Iraq, Qatar, and the KSA, oil revenue superseded the revenue from their non-oil sources.
However, most countries in the ME are actively pursuing policies and initiatives to diversify their industrial interests and lower the share of oilÊs contribution to their GDP. Within the ME, the Gulf Cooperation Council (GCC), comprising the KSA, the UAE, Kuwait, Qatar, Oman, and Bahrain, accounted for about 65 per cent of the regional GDP during the year. Driven by ongoing developmental activities in the GCC, its share is tipped to increase to about 68 per cent of overall ME GDP, projected to be USD 3,373 billion, by 2020.
Investments in excess of USD 770 billion have been planned in the ME during 2011 to 2020. About 53 per cent of the total investment is projected to be in the GCC member nations, while the rest is predominantly being shared by Iran and Iraq. Oil and gas production and allied industries including petrochemicals, refining, and midstream operations are estimated to account for over 65 per cent of the total outlay. Chemical Industry in the ME The global chemical industry was valued at USD 4.7 trillion (including pharmaceuticals) in 2011. It is projected
Middle East GDP Growth Outlook (2011-2020)
Source: International Monetary Fund (IMF), Frost & Sullivan
Chemical Engineering World
April 2014 • 65
CEW Features Planned Investments (2011-2020)
Source: MEED Projects, Zawya, Frost & Sullivan
to register a Compound Annual Growth Rate (CAGR) of 4.4 per cent from 2011 through 2020, and become USD 6.9 trillion by 2020. Asia Pacific (APAC) would lead the growth with an estimated CAGR of 5.8 per cent during the period. The ME, along with Africa, would trail APAC growth during the period and is estimated to reach USD 263 billion by 2020. In 2013, the chemical industry in the ME was valued at USD 160 billion. Petrochemicals and polymers, followed by fertilisers, were the largest segments, together accounting for over 60 per cent of the market. Other major segments included paints and coatings, water treatment chemicals, construction chemicals, etc. Despite significant regional consumption volumes, oilfield and drilling chemicals are mostly imported into the ME. The ME chemical industry is projected to grow at a faster pace than global growth from 2013 to 2020. Petrochemicals and fertilisers would be the fastest growing segments, with projected CAGRs of 8.3 per cent and 6.7 per cent, respectively. In addition, these two segments are estimated to account for over 75 per cent of the market in 2020. Paints and coatings, oilfield chemicals, and water treatment chemicals are also likely to witness CAGRs of 5.0-5.5 per cent from 2013 to 2020. The overall industry is estimated to grow at a CAGR of 4.7 per cent from 2013 through 2020.
Middle East Chemicals Market Forecast (2013-2020)
‘Other’ segments include water treatment chemicals, oilfields and drilling chemicals, industrial gases, mining chemicals, etc. Source: Frost & Sullivan
66 • April 2014
Industrial diversification initiatives being pursued by the local governments and expansions underway in regional manufacturing capabilities would be the key growth drivers for the chemical industry through 2020. World-scale plants and integrated chemical complexes are being set up at newly developed industrial cities, mostly in the KSA and Qatar. The feedstock advantages in the ME, in addition to its strategic location bridging the emerging eastern markets and developed western markets, are attracting key global participants to establish their manufacturing assets here. Dow Chemical Company, LyondellBasell, ExxonMobil, Chevron Phillips, Total, Shell, and Sinopec are some of the top global chemical companies who have established their presence in the region. Supporting this trend is an increase in collaboration efforts between local and international chemical companies. For instance, Saudi Aramco, the KSAÊs national oil company and one of the largest oil companies in the world, is collaborating with Dow, Total, and Sumitomo Chemical in individual projects to develop world-scale refining and petrochemical production facilities. Other notable partnerships in the regional chemical space are SABIC-ExxonMobil, SABIC-Sinopec, MaÊaden-ThyssenKrupp, Qatar Petroleum-Shell, and Qatar Petroleum-Air Liquide. However, major participants are increasingly viewing decreasing margins owing to rising manufacturing costs and competition in the international market as an important restraint. At the same time, declining availability of easily recoverable oil and natural gas resources (which serves as primary feedstock for the petrochemical / chemical industry) in the ME is likely to pose a formidable concern to be addressed by authorities as well as market participants over the medium to long term. Diversification Initiatives and Opportunities in the ME The ME, particularly the GCC, is diversifying into the production of value-added chemicals, extending beyond its traditional forte of bulk chemicals and petrochemicals. Current portfolio includes commodity polymers like polyethylene (PE) and polypropylene (PP), and basic petrochemicals and fertilisers. Large projects are underway for the production of value-added chemicals, including performance polymers, speciality chemicals, and intermediates. These projects are expected to be operational at different periods towards the end of this decade. The region is expected to move further ahead into the production of fine chemicals, including agro-chemicals and pharmaceutical ingredients, from 2020 onwards. Diversification efforts are largely focused on two segments: i) Value-added Petrochemicals and Products: The GCC is likely to command a share of over 35 percent of global petrochemical production by 2020, as indicated by the aggressive expansions being witnessed at the petrochemical production facilities in these countries. Large-scale petrochemicals and their derivative complexes are being set up in the GCC currently, with the upcoming Sadara Chemical Company (Saudi Chemical Engineering World
Features CEW Planned Investments (2011-2020)
Source: Frost & Sullivan
Aramco-Dow Chemical Company joint venture) being the most notable among them. ii) Plastic Conversion: Despite being one of the largest manufacturers of polymer resins in the world, the GCC currently accounts for only 2 per cent of the global plastics conversion market. However, with steady growth in demand from the local consumer goods market and easy access to key raw materials, it is expected to register annual growth in the range of 10 per cent and above in the medium to long term. This would make it one of the fastest growing regions in the global conversion industry. Mega Trends Impacting the Middle EastÊs Chemical Industry Civil and commercial construction, emergence of industrial cities, and the development of intra-regional transportation network are the three key
mega trends that are empowering the chemical industry. Jubail and Yanbu in the KSA, Mesaieed in Qatar, Al-Ruwais in the UAE, Asaluyeh in Iran, and Shuaiba in Kuwait are some of the prominent industrial cities that are attracting large investments from major chemical manufacturers. The GCC railway project designed to connect all the six member nations, King Abdullah and Jazan Economic Cities in the KSA, Lusail City in Qatar, Mohammed Bin Rashid City in the UAE, various international airports, etc are some of the other mega projects that are currently underway in the region. An Estimated USD 4.3 trillion is tipped to be spent in the Middle East and North Africa (MENA) up to 2020, across various mega projects. Driven by these projects, the demand growth for construction chemicals and materials, which include paints and coatings, concrete admixtures, flooring compounds, waterproofing compounds, and adhesives and sealants,
Industrial diversification initiatives being pursued by the local governments and expansions underway in regional manufacturing capabilities would be the key growth drivers for the chemical industry through 2020. Chemical Engineering World
etc is expected to be ahead of the regional GDP growth up to 2020. While the ME has access to most of the essential industrial resources like raw materials, utilities, and human resources, it falls short of the advanced technologies that are required to make manufacturing possible. Some of the key trends being observed in the ME technology sphere are: Ć Buying and Replicating: With acquisitions, companies can quickly gain both technology and production capacities Ć Incentivising Foreign Investors: Special incentives offered by states for foreign investors with leading edge technologies Ć Joint Ventures: Large joint ventures, structured to deliver specific benefits for each party Ć Technology Licensing: Companies have the option of licensing advanced technology from a foreign competitor Ć Innovation/Research and Development (R&D): Success in downstream areas requires continuous product development and improvement The Way Forward The Middle East GDP is likely to grow at a CAGR of about 4.7 per cent from 2011 to 2020, and is expected to reach USD 3,373 billion by 2020. Growth prospects remain bright for the regional chemicals industry as well. The industry revenue is likely to reach USD 220 billion by 2020, up from the USD 160 billion in 2013. Value-added petrochemicals and downstream plastic conversion sectors are likely to be the key growth drivers; both are positioned to benefit from large-scale investments and incentives from local governments. Also, global companies are moving eastwards towards the Asian growth markets, buoyed by rising consumer purchasing power. With Europe tipped to become the pressure point of plant closures, the ME is increasingly being seen as rightly positioned at a pivotal point to which chemical and petrochemical manufacturers can flock to and flourish over the coming years. April 2014 • 67
CEW Features Guest Column
Execution Challenges during Project Life Cycle In the first part published in the March issue of CEW, E Pramod, Senior General Manager -Construction, Aker Powergas Pvt Ltd, explained how project execution, especially the projects, where continuous modification of technology in terms of processes and equipment take place, is challenging and threw light on some of the execution challenges normally faced during the project life cycle. In this concluding part, the author focuses on the Residual Process Work and Detailed Process Engineering, and some of the critical elements for successful construction work.
e read about Modes of Project Execution, Focus Areas and Competence Base Lines in Project Management, etc in first the part. In this part we will learn some other significant elements necessary for successful construction or project delivery.
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for other projects, where even capacities could slightly differ) from licensors. In such cases, substantial work needs to be done during the detailed process design. This would call for cross checking of the PFDs and heat & mass balance data as well.
Residual Process Work and Detailed Process Engineering Though the licensor is expected to provide a process package in order to proceed with the detailed design, this will mostly depend upon the scope of work as agreed between the licensor and the owner. Of late, in order to decrease capital expenditure, the owners are transferring the bulk of the residual process work to the detailed engineering company. This includes the check for inconsistency, heat & mass balance within some of the packages, thermal design of equipment, finalisation of utility consumption figures of the whole plant, thermal radiation dispersion studies, sizing of the flare gas header lines & cooling water supply and return lines and early HAZOP study.
The accuracy and timelines of the process engineering work are critical success factors for any project. Unlike the other engineering disciplines, the process group will have to ramp up their strength to the maximum soon after the commencement of detailed engineering. Most of the critical activities like consistency check of the licensorÊs package, work on PFD, Heat & Mass balance, P&ID, line list, line sizing and process data sheets start at approximately the same time. They also need to prioritise and provide the required inputs for the requisitioning of the long lead items.
Therefore, it is imperative that the project task force should include experienced process engineers who can pre-empt such issues and resolve them proactively. This would involve constant interaction with the licensor and the PMC. The project team should always give a high priority to these important activities right from the initial stage of the project. The problem can be even more acute when owners buy off-the-shelf packages (used 68 • April 2014
availability of equipment and bulk materials at site as planned. In order to ensure a positive cash flow, project cost controllers often attempt to follow the „just in time‰ principle. However, a prudent project execution team will always build in sufficient buffer time to ensure that the equipment and other bulk materials reach the site punctually. Over the last decade, the cost of construction has skyrocketed. Moreover, qualified and experienced construction resources are always difficult to come by. Hence the project team will always try to avoid leaving construction contractors idle. Therefore, the engineering team will always be under pressure to complete their requisitioning work.
This early process work should be executed with a very high focus on both accuracy and timelines, as both of these factors have an extremely critical influence on the subsequent activities. It is prudent for the project team to have a dedicated project engineer to closely monitor and review this process work for the first few months. This will also help the project team capture, control and manage the likely changes that arise during this phase of the project.
These calculated risks taken by the procurement team can prove to be very costly at a later stage on EPC projects, where the PMCÊs approvals on requisitions are a must. However, the irony is that the EPC contractor rarely has the luxury of waiting for final approval of the requisition before the purchase order is placed on the supplier for the long lead items. Delay in ordering can expose the project to potential high idling charges from the construction contractor, while critical comments or errors in the requisition may lead to a price escalation claim from the equipment supplier.
Procurement One of the most critical elements for successful construction work is the
On one refinery EPC job, the EPC contractor and the equipment supplier had missed out one of the hidden requirements for the Chemical Engineering World
Features CEW waste heat boiler. This omission came to light only 6 months after the purchase order was placed. In its absence, the supplier had considered the boiler as conventional smoke tube type in place of water wall design. On another occasion, the EPC contractor and the supplier had wrongly interpreted the atmospheric pressure at site, which led to modification of the inlet vanes of the stator of the imported blower which was almost ready for shop testing. In both cases, the schedule and the cost were badly impacted. Though everyone is aware of the golden rules and the hidden perils, there are no straightforward and ready-made solutions available while finalising the order for critical long lead items. The gift of a good project execution resource lies in bringing the right talent, experience and the lessons learnt from earlier projects to the table during the requisitioning and ordering phase of the critical equipment. With these, the potential troubles of the construction phase may - to a large degree be prevented. Project Controls One expects no debate while discussing the importance of the project control functions. While a Level-3 schedule is available from the owner or the PMC, the project control function will generally involve Establishing the work breakdown structure (WBS), Planning, scheduling and progress control, Finalising the progress measurement norms, Progress measurement, Cost control and estimating, Scope and change control, Procedure for baseline correction, Quantity control (material & equipment), Forecasting, status, trend analysis of cost, schedule and quantities, Uncertainty management and Reporting. Even though the project controls cover the above listed functions, they are often not fully utilised. In most cases, both the owner and the project execution team are satisfied with monitoring the project through a baseline schedule and various reporting which in turn form a part of the management report. The sole project control engineer is normally busy with scheduling and progress measurement work, as well as the generation of the look-ahead schedules and weekly/monthly reports. Chemical Engineering World
The very fact that most projects employ only one planning engineer at the engineering and project office and one more at the construction site, irrespective of the size of the project, is proof of the under-utilisation of this function. To make project controls a critical success factor, all the functions need to be leveraged by the execution team. Another grey area, especially for EPC projects, is the treatment of the baseline schedule as sacrosanct. It is very important to adhere to this schedule throughout the duration of the project. However, if some of the critical path activities get delayed due to reasons beyond the control of the contractor, it is always prudent to have a catch up or mitigation plan with a realistic schedule. Sadly, the popular approach is generally to crash the project schedule by requesting the contractor to deploy more resources even when the delay is obviously unavoidable. On such occasions, the project execution team should try to influence the stakeholders to revise the baseline schedule. Here again, the general feeling is that by clinging on to the original baseline schedule, they will be successful in minimising the absolute delay period at the end of the project. However, in reality, the grip on project control loosens as the schedule remains unmet month after month, leading to a chaotic situation and larger delays than if the baseline schedule had been revised. Construction Construction has always been the toughest phase of project execution. It is the phase during which the correctness, accuracy and efficiency of the engineering and procurement teams are put to the test. On the other side, the construction team is always under pressure to minimise the delays which have occurred during engineering and procurement phase. They also have to deal with the quality issues which surface in the drawings issued for construction and in the equipment delivered to site for erection. One of the major advantages of the 3D engineering software like PDS and PDMS, which are being widely used by engineering companies, is to minimise the errors in the drawings issued for construction. In spite of this, the construction team still encounters numerous quality issues in these drawings
which they have to work around. However, the use of these software tools has brought down the occurrences of such cases drastically. For the last 10 years, the biggest challenge faced by the construction industry in India is shortage of manpower resources, an odd problem in a country with a population of one billion. One of the main reasons for this is that India has seen a tremendous growth in the service industry, and a large pool of engineering talent has moved towards the IT and IT enabled service sector. The construction labour force has also shrunk in size due to increased development at a state level, as well as a number of national work guarantee schemes. Hence in the present scenario, it is a herculean task for the construction companies to mobilise and retain the required labour force on projects. This human resource problem to some extent has been mitigated through technological advances in the construction industry, but India still has a long way to go in this respect. However, it is important to change the mind-set that construction resources are easily available in India. Various factors have also made conditions difficult for the contractors to set up their own office, fabrication yards and labour camps at sites. We need to give more focus and attention to minimising the work at site from the design stage itself. The aim should be to maximise the fabrication under controlled conditions (in fabrication shops and yards) and use more prefabricated structures and modular buildings at site. Conclusion This article covers the challenges of project execution and the reasons why it continues to produce high levels of interest among project execution teams. However, we have touched upon only a few key facets, to bring out the unique complexity that one may face from project to project. Though one may have a good project execution strategy and learning from past projects, there is no ready-made single solution available for the issues one encounters on each project. Lastly, the success of the project execution also depends on the ability of the project execution team in motivating all the stakeholders towards the achievement of the final goal. April 2014 â&#x20AC;˘ 69
CEW Market Insights
Demand for TAN to Increase in India: Lindgren
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echnical Ammonium Nitrate (TAN) is a key ingredient in pharmaceuticals, mining, explosives, power and steel industries; however, its highly explosive nature makes it very susceptible to its misuse for antisocial activities. Many countries have laid stringent rules to curb the malpractices in selling of ammonium nitrate to avoid its misuse against the society and India is now following the trend. Indian Government has recently come up with stringent rulings that would make each producer and supplier accountable for every bag of chemical. Its three pronged approach Identification, Traceability and Accountability - would mandate the producers and suppliers accountable for each bag of the chemical and also necessitate the need of valid license to deal with this product in whatsoever manner. Ammonium nitrate sales went up in the country immediately after the announcement of the new ruling. Current demand of TAN in India stands at 700 KMT against the total supply of 788 KMT which is met by the domestic production through indigenous manufacturing, and to a certain extent, through imports in loose bag form countries like Russia and Ukraine. It is extremely difficult to keep track of the quantities as well as trace them to the supplier and the final end user. India has been importing Fertiliser Grade Ammonium Nitrate (FGAN) from Russia and Ukraine which are the major exporters globally for this chemical. Many countries have imposed a ban on FGAN due to security concerns. India has been importing considerable amounts at Vizag; however, after the recent announcement import in loose form has been banned and allowed only in bag form. TAN: India Scenario During a recent media interaction, Carl Anders Lindgren, President & Technical Advisor Deepak Fertilisers & Petrochemicals, shared that the organisation has a current capacity to produce 48.4 KMT and accounts for 37 per cent of domestic market share and 3.4 per cent of global production which stands at 153000 KMT. Lindgren sees an indirect correlation between the healthy demand of TAN with the growth of economy.
TAN Domestic Production DFPCL
444 KMT
RCF
140 KMT
GNFC
140 KMT
STL
40 KMT
NFL
20 KMT
Source: DFPCL
70 • April 2014
Current demand of TAN in India stands at 700 KMT against the total supply of 788 KMT, Source: DFPCL
In domestic market, Deepak Fertilisers & Petrochemicals Ltd (DFPCL) competes with, Rashtriya Chemicals & Fertilizers Ltd (RCF), Gujarat Narmada Valley Fertilizers Corporation Ltd (GNFC) and National Fertilizers Ltd (NFL). DFPCL has continuously grown over the last 5 years to reach its current capacity of approximately 500 KMT. The company, however, is operating at 75 per cent capacity currently. DFPCL commissioned its first plant in 1991 based on Stamicarbon technology and added second plant based on GP technology and third plant in 2010 on Uhde technologies. Lindgren observes healthy demand for TAN in the domestic market that will be driven by almost 8 per cent projected growth of mining and infrastructure sectors and significant demand highly un-fragmented explosives sector. Delving further on his observation, he elucidates that macroeconomic factors like growing GDP and increasing per capita purchasing power parity, are already driving the demand of energy steel and infrastructure that will provide significant thrust to the mining sector which includes - coal, iron, limestone and other minerals, and the need to scale up the required infrastructure of rail road and ports will provide thrust to the demand of TAN in country. „In my view demand of TAN will grow at the same 8 per cent rate projected for the growth of mining and infrastructure sectors in the country,‰ he says. DFPCL is now looking at new capacity additions by increasing the total capacity to approximately 830 KMT to tap the increase in demand. The company is looking at enhancing upstream products in coming years.
- Mittravinda Ranjan Chemical Engineering World
Marketing Initiative
“DrM-Sophisticated Flexible Filtration Solutions” DrM, Dr. Müller AG, is a privately held enterprise with its headquarters in Männedorf, Switzerland where it develops, designs and fabricates filtration systems for solid/liquid separation in the processing industries. DrM currently have three manufacturing sites: Switzerland, Poland and China. The FUNDABAC® and CONTIBAC® Filters are the main products with more than 3000 filters in operation worldwide and approximately 130 new systems are put in place every year, says Martin Grantham, Managing Director- DrM Filter Technology Pvt Ltd.
Martin Grantham Managing Director DrM Filter Technology Pvt Ltd
Please apprise us of the manufacturing facility in Ankleshwar. How well the facility is equipped to develop and manufacture filtration and separation systems? At present, we have acquired 2 acres land in Ankleshwar. We have sales and administration office and ware house. We are importing filter internals like Filter candle and filter cloth from our head office at Switzerland. In India we have tie up with sub suppliers for manufacturing vessels. Our engineers do the rest job of installation, commissioning and servicing of filters. We also have well equipped laboratories with different size of Filters. We do trials on basis of customersÊ request. Are the products manufactured at this facility exported as well, or they cater to domestic requirements only? Also, please comment on your R&D operation in India. As said earlier, we are importing material from our Head office at Switzerland. We assemble it here and supply to the customers. We have our own R&D department at Switzerland. We are continuously improving our product for better performance. How does India figure in global business strategy of the company? India is very fast developing country with reference to industrialization. DrM is present in Indian market since 1987.
Chemical Engineering World
We have sold around 60 units to different client in all over India. So we are much helpful to serve Indian customers with our patented technology. What is the current market share? Will you please name some of your major clients? We have started our office in India 2011. Our client list includes Reliance, L&T, GNFC, Aditya Birla NUVO Ltd, Dr ReddyÊs Laboratories Ltd, Nirma Ltd, UHDE India, Dow Chemical and many more. What are your plans for future? Will you like to share any other information with us? As said earlier we have acquired land in Ankleshwar. Our plan is to build a manufacturing plant in near future so that we can serve Indian customer better.
Contact Detail: Ubaidqaiyoom Badi Technical Sales Engineer DrM Filter Technology Pvt Ltd Ankleshwar-393020, Gujarat, India Plot No.: 46 ă 1 & 2, Village Pungam Tel: +91 2646 652774 Mobile: +91 94088 68705 E-mail1: info-in@drm.ch E-mail 2: uabadi@fundabac.com April 2014 • 71
Marketing Initiative
Why Use Dura 5 & Dura 7 HPLV High Pressure Low Volume Dosing Pumps?
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he Dura 5 & Dura 7 HPLV (High Pressure Low Volume Dosing) delivers stable sublitre per hour flows at either 5 or 8 Bar in a rugged hose pump format.
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hose is totally contained inside the pump casing. This results in superior secondary containment, allows pre-spillage detection and may eliminate special spillage bunds. Ć
High Pressure Low Volume Dosing: The Dura 5 & Dura 7 deliver stable sub-litre per hour flows at either 5 or 8 Bar in a rugged hose pump format. Care Free Pumping of Off Gassing Liquids: Municipalities regularly use Sodium Hypochlorite („Hypo‰) to disinfect drinking water and the food industry uses Hypo to prevent bacterial contamination. When pumped, Hypo off gases, vapour locking a diaphragm pumpÊs chamber resulting in additional degassing valves. Often pumps are set to „over-dose‰ to compensate for the loss of performance leading to increased chemical usage. Hose pumps are a well proven solution and also address the associated crystallisation issues. Eliminate Abrasive Wear Costs: Lime or Kalkmilch is a very common pH adjustment chemical, used in water treatment, industrial waste remediation and process acidity control. LimeÊs fine particles are highly abrasive and cause severe stator and valve wear resulting in high pump ownership costs. Verderflex has many yearsÊ experience solving this pumping problem and peristaltic pumps are accepted as the proven valve free solution to pump lime, the Dura 5 & 7 now bring this proven performance to lower flow rates.
Ć Reduce Chemical Usage: Peristaltic pumps have a gentle, low shear pumping action that maintain particle size and reduce the flocculation chemical volumes. In contrast, traditional solutions often shear flocculent particles increasing chemical use and result in higher operating costs. The Dura 5 and 7 now bring these benefits to lower chemical low flow rates. Ć Kill Clogging Costs: Viscosity variations cause metering pumps to clog up requiring maintenance intervention. The Dura 5 & 7 use re-enforced hoses to generate powerful suction eliminating both the performance variability caused by minor viscosity fluctuations and the consequential clogging maintenance costs. Additionally, the truly reversible Dura 5 & 7 allow pumps to run backward and clear blockages unlike nonsymmetrical tube pumps where flow rates change with pumping direction. 72 • April 2014
The Dura peristaltic Hose Pump Family
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Crystallisation: Many reagents crystallise when the metered chemical flows are interrupted coating the seats result in a loss of performance whereas the abrasion resistant Dura 5 & 7 pumps maintain flow rates.
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No Tube Re-tensioning: Some peristaltic pumps use continuous lengths of non-reenforced tubes which require re-tensioning after initial installation. The long life heavy duty Dura 5 & 7 hoses are fit and forget.
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True Dry Priming: Dura 5 and Dura 7 dry prime to 9.5m of water compared to sub 5m wet-primed lifts associated with diaphragm pumps. The Dura 5 and 7 now eliminate the need for pre-wetting and priming in lower volume chemical feed systems.
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Halt Dry Running Problems: Progressing cavity pumps cannot tolerate any interruption in their liquid feed lines or the result is costly burnt stators and downtime. The Dura 5 & 7Ês hoses are lubricated from the outside and bring care-free, operator proof pumping to lower flow rates.
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No Ancillary Equipment: Conventional metering solutions need back pressure, foot & degassing valves. The Dura 5 and 7 fixed occlusion rotors simplify installations and eliminate additional parts by maintaining a separation between supply and discharge lines.
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Stable Liquid Delivery: Many metering pumps lose accuracy when flow rates or system pressures change, however, the powerful restitution of the Dura 5 & 7 hoses give consistent dosing accuracy even under varying operating conditions.
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Superior Secondary Containment: The pumped liquid is totally contained inside the Dura 5 & 7Ês high pressure hose and each
High Margin of Safety and Secure Clamping: The heart of the Dura 5 & 7 is the re-enforced hose with a burst pressure in excess of 80 Bar (1150 PSI) unlike non-re-enforced tubes that can easily burst and rely on crimped connections unlike the Dura 5 and 7Ês high compression taper fit clamping system.
Ć Superior Viscous Performance: Diaphragm dosing pumps require customers to use more complex special liquid ends for 200 CPS liquids and non-re-enforced tubingÊs recovery limits tube pumps operating speeds. The powerful restitution of the Dura 5 and Dura 7Âs re-enforced hoses give problem free pumping of 1000 CPS plus liquids and eliminate flow fluctuations without requiring additional parts. Ć Maintenance Simplicity: Only the easy to change hose is in contact with the pumped liquid. Downtime is minimised dramatically with infrequent servicing and hose lives in the thousands of hours. Simple on site changeovers can be made by semi-skilled staff, lowering the total metering solution ownership cost. Ć
Simple User Controls: Hose pumps need no complex local keypads. Dura 5 & 7 pumps can be remotely controlled by inverters eliminating operator confusion and maintaining control system simplicity. These inverters can be the familiar site standard brand further simplifying the control system support requirements.
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Scalable Performance: The Dura 5 and 7 have the same common casing and mounting frames as the Dura 10. Should system demands change, flow rates are easily scaled up on site or down by replacing the hose and a few standard components.
Contact Detail:
VERDERFLEX LTD 3 California Drive,Castleford West Yorkshire, WF10 5QH, United Kingdom TEL + 44 (0) 1924 221 020 FAX + 44 (0) 1132 465 649 MAIL info@verderflex.com WEB www.verderflex.com Chemical Engineering World
Products CEW Non-electric Water Purification Tata Swach offers non-electric water purification solution - Tata Swach Silver Boost. While chlorine provides protection from bacteria and virus, and does not protect from the harmful cyst ă Cryptosporidium, which causes health related issues such as substantial weight loss, nausea and even malnutrition - highly detrimental to growing children. Other non-electric purification technologies which use only membrane purification do not provide protection against virus, which may cause harmful diseases like Polio, Hepatitis A and Hepatitis E. The all-new Tata Swach Silver Boost combines the power of MF membrane with Silver nanotechnology to make water microbiologically safe from virus, bacteria and parasites/ cyst along with safety from algae, fungi, rust, metal particles and turbidity. It provides double protection from bacteria through Tata Swach Bulb and Tata Swach MF membrane For details contact: Tata Chemicals Bombay House, 24 Homi Mody Street, Fort, Mumbai 400 001 Tel: 022-6665 8282 E-mail: cjoshi@tatachemicals.com or Circle ReadersÊ Service Card 1
Pumps The LM range compliments the existing range of L-Series pumps. These pumps from Roto Pumps Limited, Uttar Pradesh, have been built on the robust field proven L-range platform retaining vital features such as CARDAN Universal joint and improved Rotor Stator geometry that ensures a lower life cycle cost, enhancing the flow rate capabilities. These pumps are available in single stage up to a maximum pressure of 6 bar. For details contact: Roto Pumps Ltd Roto House,13 Noida Special Economic Zone Noida , Uttar Pradesh 201305 Tel: 0120-3043901 | Fax: 91-0120-3043928 E-mail: contact@rotopumps.com or Circle ReadersÊ Service Card 2
Chemical Engineering World
• April 2014 • 73
CEW Products Multi-stream Controller for Loading Products H Honeywell Enraf offers the Fusion4 MSC-L, multi-stream controller for loading products from refineries and cchemical plants into transports. The controller can operate up to six loading arms simultaneously, providing ssafe, reliable control for road loading, as well as tank farm transfers and marine and rail terminal operations. Like tthe other devices in the Fusion4 portfolio covering blending and additive control. Based on mobile phone and ttablet computing „apps‰, on-screen icons make it uniquely intuitive, cutting training times and reducing the risk oof human error. Combined with the installed keyboard, it offers simple, secure and fully functional control of the lloading system from the unit itself. A modular design enables legacy Honeywell Enraf systems to upgrade cost effectively, while multiple protocol libraries and communication network capabilities offers seamless, cost effective integration with other industry standard terminal automation systems to avoid expensive alterations to existing equipment. The Fusion4 MSC-L completes the Fusion4 portfolio to provide a comprehensive solution for loading, blending and additive control that includes the Fusion4 MultiPak multistream additive controller, Fusion4 MiniPak single-stream additive controller, and Fusion4 BioBlend and Microblender blend controllers. For details contact: Honeywell Automation India Ltd 56 & 57 Hadapsar Indl Estate, Pune, Maharashtra 411 013 Tel: 020-66039400, Fax: 91-020-66039800 E-mail: hpsmarketing@honeywell.com or Circle ReadersÊ Service Card 3
Surfactant to Replace Solvents
Heat Exchanger Tube Cleaner
Stepan Co offers STEPOSOL MET-10U, a surfactant derived from natural oils that is targeted to displace solvents. This new cleaning solution is the first commercial product launched by Stepan as part of its joint development agreement with Elevance Renewable Sciences, Inc. This innovative solution utilizes a naturally derived, metathesized feedstock to form a next generation bio-based surfactant that achieves sustainability goals while improving cleaning performance. The applications for STEPOSOL MET 10U are broad, including adhesive removal, paint and coating removal systems, kitchen degreasers and all-purpose cleaners for both consumer and industrial uses. STEPOSOL MET-10U specific product attributes include its Kauri-butanol value greater than 1000; boiling point of 297ĈC; Biorenewable Carbon Index of 75%; and formulating pH range of 3-12. These parameters create a high-strength and non-volatile surfactant, which provides faster and more effective cleaning by fulfilling the role of both a low HLB surfactant and a strong solvent.
To f u n c t i o n e f f i c i e n t l y ev e r y tube of heat exchanger must be kept clean in order to maintain production efficiency and to p r ev e n t p e r m a n e n t d a m a g e s from overheating. As one of the pioneers in the development of tube cleaning equipment DBX Tool developed new heat exchanger tube cleaner. This heat exchanger tube cleaner consists of pneumatic or electric motor with water feeding attachment. The motor drive various cleaning tools by means of driven shafts, drive shaft, cutter, and brush. Water is supplied through shafting by a feed attachment on the motor and is used to flush away the deposit removed by the tool. Best for removing extremely hard scale from condensers and heat exchangers from 9 to 28 mm ID.
For details contact: Elevance Renewable Sciences, Inc 2501 Davey Road Woodridge, IL 60517, U.S.A. Tel: 866-625-7103 Fax: 630-633-7295 or Circle ReadersÊ Service Card 4
74 • April 2014
For details contact: DH Boiler Exchangers Tools Pvt Ltd 3101 Bhandup Indl Estate Pannalal Silk Mill Compound LBS Marg, Bhandup (W) Mumbai 400 078 Tel: 022-66711682, 25948419, 25948420 Fax: 91-022-25948419 E-mail: dh.boilertools@gmail.com / info@dbxtool.com or Circle ReadersÊ Service Card 5
Chemical Engineering World
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Chemical Engineering World
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$ 10 ` 150 April 2013 US
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VOL. 48 NO. 4
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VOL. 49 NO. 1
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CHEMICAL ENGINEERIN
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Chemical Engineering World
Products CEW Lifting Columns
High-speed Dispersers
The Lifting Columns consist of anodised extruded aluminium profiles, which slide into each other. Their robustness and performance is complemented by the ability to link multiple units together for flexibility in design configuration. Thomson Lifting Columns are available in three model variations, which provide different performance in extension to retraction ratio, load capacity, speed and cost to best match application needs. The lifting columns can also be customised to meet specific customer requirements. The innovative design and maintenance-free operation of the new Thomson LC Series Lifting Columns can truly help engineers optimise overall machine design, offering the potential for cost reduction and reduced manufacturing time. Strong, reliable and quiet, they deliver excellent performance and versatility to match design engineer application and budget requirements.
Mouvex offers its SLC Series eccentric disc pumps. that is ideal for demanding liquid-transfer applications found in the pulp-and-paper industry, including the handling of numerous chemical-based compounds. MouvexÊs new SLC4 and SLC8 models are ideal for pulp-and-paper applications because they feature major technological advancements that includes the incorporation of a double-wall bellows into the design, along with monitoring that is done by pressure switch. By mounting the pressure switch on the bellows flange, the bellows becomes an independent sub-assembly within the pump, making for safer and easier operation. Other improvements in the SLC4 and SLC8 pumps includes the ability to handle differential pressures up to 10 bar (145 psi) in the SLC4 and 6 bar (87 psi) in the SLC8, and high-quality sand castings that are integrated into the manifold flange and bracket, which are compatible with ISOPN16 and ANSI150 flanges.
For details contact: Thomson Sigma Blfg, 10th Flr, Hiranandani Business Park, Powai, Mumbai 400 076 Tel: 022 42270300, Fax: 91-022-4227 0338 E-mail: sales.india@thomsonlinear.com
For details contact: Fluidyme Process Flow Technologies E-2/4,Popular Prestige, Off Highway Bridge Warje, Pune, Maharashtra 411 058 E-mail: fluidyme@vsnl.net.
or Circle ReadersÊ Service Card 6
or Circle ReadersÊ Service Card 7
Portable Dew Point Meter CS Instruments GmbH, Germany, offers portable dew point meter Model DP500 with data logger and USB interface, meets the requirement for checking refrigeration, membrane and adsorption dryers and measure the dew point precisely down to (-) 800 Ctd with fast response and user-friendly for digital, graphical via touchscreen. It is ideal for service technicians and can calculate directly required parameter for compressed air and gases like g/m3, mg/m3, ppm V/V, g/kg, 0Ctdatm, %RH with measuring range for dew point (-) 80«+500Ctd, temperature (-) 20«+700C and RH 0«100%RH with basic accuracy +0.50Ctd along with precision calibration certificate at (-) 400C dew point with ISO certificate and measurement capacity up to 350 bar. Battery can withstand 12 hours continuous operation, product is with EMC norms DIN EN 61326 For details contact: AV Measurement & Control (India) Plot No: P46/1, 102 Sonata Comml Complex Opp: Unique Automobile, Nr ICICI Bank, MIDC Dombivli (E), Dist: Thane, Maharashtra 421203 Tel: 0251-2424418, 6458885 E-mail: vadnerkar@avmacindia.com / sheeja@avmacindia.com or Circle ReadersÊ Service Card 8
Chemical Engineering World
• April 2014 • 77
CEW Products Circulator Pump
Safety Valve
The Grundfos MAGNA3 pumps are designed for circulating liquids in heating systems, domestic hot-water systems and air-conditioning and cooling systems. MAGNA3 is an energy optimized, variable-speed wet rotor circulator that features a permanent magnet motor design. It cuts power consumption up to 85 per cent through its innovative AUTOADAPT function which automatically analyses the heating system, finds the optimum setting and then continuously adjust its operation to changes in demand. MAGNA3 is also equipped with the new FLOWADAPT control mode that reduces the need for pump throttling valves. In addition, MAGNA3 pumps are fitted with radio communication (15 mts from line of sight) and can offer external control and monitoring via expansion modules. Furthermore, wireless connectivity enables handheld pump control and monitoring capabilities by Grundfos GO, a mobile toolbox available on Apple and Android devices. The MAGNA3 range of pumps can also be used for solar-heating systems. Another important feature of MAGNA3 is its GENIair connection (wireless) which helps control the pump/s (up to two pumps connected in parallel). For details contact: Grundfos India Pvt Ltd 118 Old Mahabalipuram Road, Thoraipakkam, Chennai 600 097 Tel: 044-45966800, Fax: 91-044-45966969 E-mail: salesindia@grundfos.com or Circle ReadersÊ Service Card 9
Fainger LESER offers safety valve, Type FL 237, for industrial applications. Typical applications include thermal expansion, utility steam or compressors. The safety valve is suitable for pressures from 0.1 to 93 bar and temperatures from -273 to 280ĈC. It is supplied with threaded connection according to different standards, eg, BSP, NPT, BSPT. The material used, AISI 316 stainless steel, gives it a wide area of application. The safety valve can be used for steam, gas or liquid applications without any modifications to the internal components. This feature, known as single trim, reduces the number of spares and brings down costs for the customer. Fainger LESER has also designed the outlet body in such a way that no media residues remain in the valve after it has been activated. The safety valve has been successfully tested in accordance with the guidelines of DIN EN ISO 4126 and ASME Section VIII Div. 1. With complete opening within a 10 % pressure increase and closing within 10% or 20% for liquid applications, the valve complies with the requirements of the major international guidelines. It also has the IBR approval. For details contact: Fainger Leser Valves (P) Ltd 136/137, Sanjay Bldg No: 3, Mittal Estate, Marol Andheri Kurla Road, Andheri (E), Mumbai 400 059 Tel: 022-28501692, 28504277, Fax: 91-022-28504470, E-mail: info@faingerleser.com or Circle ReadersÊ Service Card 10
Eccentric Disc Pumps Mouvex offers its SLC Series eccentric disc pumps. that is ideal for demanding liquid-transfer applications found in the pulp-and-paper industr y, including the handling of numerous chemicalbased compounds. MouvexÊs new SLC4 and SLC8 models are ideal for pulp-and-paper applications because they feature major technological advancements that includes the incor poration of a doublewall bellows into the design, along with monitoring that is done by pressure switch. By mounting the pressure switch on the bellows flange, the bellows becomes an independent sub-assembly within the pump, making for safer and easier operation. Other improvements in the SLC4 and SLC8 pumps includes the ability to handle differential pressures up to 10 bar (145 psi) in the SLC4 and 6 bar (87 psi) in the SLC8, and high-quality sand castings that are integrated into the manifold flange and bracket, which are compatible with ISOPN16 and ANSI150 flanges. For details contact: Dover India Pvt Ltd ă PSG 40 Poonamallee By-pass Senneerkuppam Chennai 600 056 Tel: 044-26271020 E-mail: sales.psgindia@psgdover.com or Circle ReadersÊ Service Card 11
78 • April 2014
Chemical Engineering World
Products CEW Online Monitoring of Concentration and Contamination To measure the concentration of the cleaner and the degree of contamination in the bath continuously, accurately and quickly, the LiquiSonic analyzer of SensoTech will be directly integrated into the process. The automatic realtime measurements every second show immediately how much cleaner must be replenished to keep the cleaning result constant, eg, the analyzer Is used in cleaning and degreasing baths, in rinsing baths, pickling and etching baths, and coating and plating baths as well. Installing the LiquiSonic sensor into the plant is easy and suitable for every cleaning or surface processing plant. This eliminates time-consuming manual measurements, which provide delayed and often inaccurate results by titration analysis. LiquiSonic technology measures inline and accurately in various bath fluids, because the measuring method is independent of the turbidity and conductivity of the fluid and has a high tolerance of soiling. For details contact: SensoTech GmbH Steinfeldstr 1, D-39179 Magdeburg-Barleben Germany Tel: +49 39203 514 100 Fax: +49 39203 514 109 E-mail: info@sensotech.com or Circle ReadersÊ Service Card 12
UV-Vis Diode Array Spectrophotometer The Cary 8454 UV-Vis includes a new version of UV-Vis ChemStation software that integrates with OpenLAB Enterprise Content M a n a g e r ( E C M ) . To g e t h e r they provide the secure data management needed in pharma and other highly regulated industries. The system can collect a complete spectrum in less than one second. The Cary 8454 UV-Vis is the successor to AgilentÊs 8453 UV-Vis, which has long been the UV-Vis spectrophotometer of choice for laboratories conducting pharma quality assurance and quality control, and for academic and chemical lab conducting timebased kinetics analysis. The Cary 8454 UV-Vis spectrophotometer incorporates world-class PDA technology for life sciences and chemical analysis applications. It incorporates robust PDA detector technology used in AgilentÊs liquid chromatography instruments with pre-aligned light sources for easy maintenance and high levels of reliability required in QA/QC labs. Its compact design and open sampling area improve ergonomics for accessory installation and enable easy, error-free sample preparation and results. For details contact: Agilent Technologies India Pvt Ltd G01. Prime Corporate Park, 230/231 Sahar Road Opp: Blue Dart Centre, Andheri (E), Mumbai 400 099 Tel: 022-30648287, Fax: 91-022-30648250 E-mail: rajendra.jathar@agilent.com / cag_india@agilent.com or Circle ReadersÊ Service Card 13
Chemical Engineering World
Shoulder Mill Balances The Square T4-08Ês strong, reliable pocket seats combined with multi-edge inserts optimise cutting stability and allow for clean 90-degree walls. The inserts mount tangentially in the cutter so that the cutting forces impact the thickest parts of the inserts, allowing manufacturers to achieve the required levels of strength for increased depths of cut with small diameters. The Square T4-08 also provides a smooth cutting action via positive rake angles with a variable lead angle on the cutting edge. In addition to high metal removal rates, manufacturers will also benefit from the versatility of the Square T4-08. There is a wide variety of insert geometries and grades, and it is available in various mounting types that include Cylindrical, Weldon, Arbor and Combimaster. For details contact: Seco Tools India (P) Ltd Gat No: 582, Pune Nagar Road Koregaon Bhima, Tal: Shirur, Dist: Pune Maharashtra 412 216 Tel: 02137- 667300 Fax: 91-02137-667410 E-mail: seco.india@secotools.com or Circle ReadersÊ Service Card 14
• April 2014 • 79
Global Petroleum Show Dates: 10 - 12 June, 2014 Venue: Calgary, Alberta, Canada Details: Pe t r o l e u m show on production and transpor tation of oil gas technologies Organiser: DMG World Media Contact: +1 403 209 3555 Email: amystadel@dmgevents.com Website: www.globalpetroleumshow.com
exploration, and natural
Surface & Coatings Expo 2014
Global Petroleum Show
Dates: 4-6 July 2014 Venue: Chennai Trade Centre, Chennai Details: Exhibit technology for cleaning, preparation, coating, painting of surface Organiser: Confederation of Indian Industry Contact: +91 44 4244 4555 Email: b.jeikrishnan@cii.in; businessfairs@cii.in Website: www.cii.in
Dates: 10-12 June 2014 Venue: Big Four Building, Calgary, Canada Details: Global Petroleum Show presents a world throbbing with power - the world of oil & gas Organiser: DMG World Media Contact: +1 403 209 3555 (Toll-free: 888 799-2545) Email: paulaarnold@dmgevents.com Website: www.globalpetroleumshow.com
Watertech India 2014
Chemspec Europe
Dates: 10-12 September 2014 Venue: Pragati Maidan, New Delhi Details: Trade Fair for Water & Wastewater Treatment & Management Organiser: Messe Frankfurt Trade Fairs India Pvt Ltd Contact: +91 22 6144 5900 Email: rohit.rebello@india.messefrankfurt.com Website: www.watertechindia.com
Dates: 18-19 June 2014 Venue: HUNGEXPO Budapest Fair Center, Budapest, Hungary Details: Exhibition of fine and speciality chemicals Organiser: Quartz Business Media Limited Contact: +44 1737 855 076; +44 1737 855 000 Email: johnlane@quartzltd.com Website: www.chemspecevents.com
World PetroCoal Congress
13 th Clean Coal Forum 2014
Dates: 15-17 Feb, 2015 Venue: Convention Centre-NDCC, New Delhi Details: On sustainable usage of the non-renewable resources Organiser: Energy and Environment Foundation Contact: +91 11 2275 8149 Email: punit.nagi@ee-foundation.org Website: www.worldpetrocoal.com
Dates: 9-13 June 2014 Venue: Beijing, China Details: Key investment hotspots in AsiaĂ&#x160;s Coal Conversion and Utilisation Organiser: CDMC Contact: +86 21 6840 7631 Email: elvaq@cdmc.org.cn; ccf@cdmc.org.cn Website: www.cdmc.org.cn
India Chem
International Conference on Chemical Structures
Dates: 9-11 October 2014 Venue: Bombay Convention & Exhibition Centre (BCEC), Mumbai D e t a i l s : A n ex h i b i t i o n o n c h e m i c a l , p e t r o c h e m i c a l a n d pharmaceutical sector Organiser: Federation of Indian Chambers of Commerce & Industry Contact: +91 11 2373 8760; +91 11 2376 5081 Email: manoj.mehta@ficci.com Website: www.indiachem.in
Dates: 1-5 June 2014 Venue: NH Conference Centre Leeuwenhorst, Noordwijk, Netherlands Details: Conference to cover aspects of cheminformatics and molecular modeling Organiser: American Chemical Society, and other societies. Contact: +49 30 6128 8887 Email: iccs@mcc-pr.de Website: www.int-conf-chem-structures.org
80 â&#x20AC;˘ April 2014
Chemical Engineering World
Project Update CEW New Contracts/Expansions/Revamps The following list is a brief insight into the latest new projects by various companies in India. Ć CHEMICALS SK Solvochem Private Limited is planning a 1,500 TPA synthetic organic chemicals manufacturing project - dye and dye intermediates, bulk drug and intermediates excluding drug formulations, synthetic rubbers, basic organic chemicals, other synthetic organic chemicals and chemical intermediates at a cost of ` 20 million in village: Nimbua, district: Mohali, Punjab. The project is waiting for environmental clearance. Nuray Chemicals is implementing a ferric citrate-manufacturing project unit at the existing unit - SIDCO Industrial Estate Kakalur, in district: Tiruvallur, Tamil Nadu. Civil, mechanical and engineering work is in progress. The project is scheduled for completion in Q4 2014. Equipment is already available. Lion Tapes Private Limited, a sister concern of Stretch Bands, Gujarat, is planning a 100 TPM synthetic organic chemicals manufacturing project in GIDC, Chitra Estate, district: Bhavnagar, Gujarat. As of October 2013, the project is waiting for environmental clearance. Work on the project is expected to commence in 2014. According to the MoEF sources, the project includes products like 40 TPM of Fast Red B Base, 20 TPM of Fast Bordeaux GP Base, 10 TPM of Fast MNPT (Red G) Base, 5 TPM of Fast Red 3GL Base, 10 TPM of Fast Scarlet RC Base, 5 TPM of Fast Yellow GC Base, 5 TPM of Fast Orange GC Base and 5 TPM of Fast Red RC Base. The commercial waste generated from administration building would be disposed through sale to scrap vendors. The generated industrial wastewater will be treated in ETP and treated effluent will be discharged through common pipeline. N u m a l i g a r h R e f i n e r y L i m i t e d is implementing a wax manufacturing project at a cost of ` 5,770-million in Numaligarh Refinery, district: Golaghat, Assam. The project envisages production of high value low volume paraffin and micro-crystalline wax utilizing inherent properties of North East crude. Engineers India and Axens of France have been selected as the process licensors for solvent de-oiling and wax hydro-finishing units. Ascent Pharma is planning a synthetic organic chemical manufacturing project at village: Veraval,in district: Rajkot, Gujarat. As of September 2013, the capacity of the proposed unit is yet to be finalized. The project is waiting for environmental clearance. Work on the project is expected to commence soon. Vasudha Pharma Chem Limited is planning a chemical manufacturing project - 1-(2-Phenylethyl) piperidin-4-one unit in Parawada, district: Visakhapatnam, Andhra Pradesh. As of September 2013, the project is waiting for Government approval. 1-(2-Phenylethyl) piperidin-4-one is used as an intermediate in the manufacture of chemicals and pharmaceutical drugs. This is a new product line in the existing plant. The company also plans to produce Amitriptyline HCl in the same unit in future. Resil Chemicals Private Limited is planning a specialty Chemical Engineering World
chemicals manufacturing project in Malur, district: Kolar, Karnataka. As of July 2013, land has been partially acquired. The project is in conceptual stage. Other details are yet to be finalized. Macro Polymers Private Limited is planning a 15,000 TPM synthetic resin manufacturing project at a cost of ` 250-million in village: Chacharwadi, district: Ahmedabad, Gujarat. Land acquisition is in progress. The project is waiting for clearances and is planned for completion soon. Hindusthan Chemicals Company, formerly known as Cyanides & Chemicals Company, is planning an expansion of its sodium cyanide manufacturing project from 5,400-TPA to 12, 000-TPA in Olpad, district: Surat, Gujarat. As of May 2013, the project is waiting for environmental clearance. Work on the project will commence soon and is planned for completion in 2016. Ć MINING Sri Venkatesh Granites is planning a colour granite mining project in Kamanpur, district: Karimnagar, Andhra Pradesh. As of December 2012, environmental clearance has been received. The project will come up on 4.56 hectare of leased area. Global Enviro Labs is the environmental consultant. Western Coalfields is planning the Penganga opencast coal mining project (3-MTPA and peak capacity is 4.5-MTPA) on 781-hectare land in village: Wirur, district: Chandrapur, Maharashtra. As of November 2012, the project has been submitted in the 59 th EAC (Thermal & Coal Mining Projects) meeting held on 6 th November, 2012. Central Coal Fields is planning the Ray Bachra underground coal mining project (0.3-MTPA) in district: Ramgarh, Jharkhand on 1,215.45-hectare land. As of September 2012, the project has been submitted in the 57 th EAC (Thermal & Coal Mining Projects) meeting held on 17 th September, 2012. Rajasthan Rajya Vidyut Utpadan Nigam is planning the opencast 10-MTPA Parsa East and Kanta Basan coal mining project and a 10-MPTA coal washery in Udaipur, district: Surguja, Chhattisgarh. As of August 2012, the project has been submitted in the 55 th meeting of the EAC (Thermal & Coal Mining Projects) held on 28 th August 2012. O d i s h a Po w e r G e n e r a t i o n C o r p o r a t i o n i s p l a n n i n g the opencast Manoharpur coal mining project in district: Sundergarh, Odisha. As of July 2012, the company is waiting for environmental clearance. Chhattisgarh Mineral Development Corporation is planning open cast and underground coal mining project in district: Surguja Chhattisgarh. As of July 2012, the company is waiting for environmental and forest clearance. April 2014 • 81
CEW Project Update
::d Central Coalfields Limited plans expansion of its Churi Benti UGP coal mining capacity from 0.16-MTPA to 0.81-MTPA in district: Chatra, Jharkhand. As of June 2012, MoEF clearance has been received and the project is planned for completion in 2 years from zero date. Zain Coke & Energy India is planning a 150,000-TPA metallurgical coke manufacturing project at a cost of ` 450-million to ` 500-million in Chickanthapura, district: Bellary, Karnataka. As of May 2012, the project is waiting for revenue and statutory clearance and is planned for completion in 10 months from zero date. Calcom Cement India, belonging to the BK Group, is implementing the New Umrangshu limestone mining project in district: Dima Hasao, Assam. As of April 2012, the mining work commenced in 2013. Jaiprakash Associates is planning limestone mining project in village: Kothar, district: Satna, Madhya Pradesh. As of March 2012, the project is waiting for environmental clearance and the project completion date is yet to be finalized. Ć NON-CONVENTIONAL ENERGY Siddheshwari Paper Udyog is implementing a 6-MW rice huskbased captive power project in Kashipur, district: Udham Singh Nagar, Uttarakhand. The project is coming up with an expansion of its kraft paper-manufacturing unit. Civil work is nearing completion and machinery has been ordered. The Jeypore Sugar Company Limited is planning an expansion of its bagasse-based co-generation power plant from initial 0.5-MW to 8.5-MW in village: Chagallu, district: West Godavari. Andhra Pradesh. As of January 2014, the project will come up along with a new 120-KLD grain-based distillery. The project is waiting for environmental clearance. Savera Beverages is planning a 5-MW coal and bagasse-based captive power project in village Hiranwali, district: Fazilka, Punjab. The project is waiting for environmental clearance and is planned for completion in 6 months from zero date. 28 acres of land has been acquired. The project will come up along with a 100-KLD grain-based distillery to produce extra neutral alcohol. Arunodaya Techsolar Power Projects Private Limited, an SPV of BM Solar Systems LLP, is planning a solar independent power project in village: Kudluru, district: Anantapur, Andhra Pradesh. Work on the project commenced in November 2013. 26 acres of land has been acquired. DPR is yet to be prepared. Approval has been received from the Central Power Distribution Company of Andhra Pradesh. Azure Sun Energy Private Limited, a Group Company of Azure Power India, is planning a 2.5-MW solar rooftop power project at a cost of ` 250-million in district: Gandhinagar, Gujarat. As of 82 • April 2014
May 2013, the project is to be set under Gandhinagar Photovoltaic Rooftop Program (GPRP). The project is planned for completion in Q2 2014. Favorich Sugars, belonging to the Favor ich Group, is planning a 15-MW bagasse-based co-gen power project in Krishnarajpet, district: Mandya, Karnataka. As of January 2013, the company is waiting for land approval from Karnataka Industrial Areas Development Board. The project is waiting for financial closure and is planned for completion in 18 months from zero date. The State Government had allotted 250 acres of land for the sugar project, distillery and mega food park. Ć NON-CONVENTIONAL POWER IPL Sugars & Allied Industries, a group company of Indian Potash, is planning a 20-MW bagasse and rice husk-based IPP spread over 250 acres of land in village: Motipur, district: Muzaffarpur, Bihar. As of March 2012, the existing plant will be demolished and the new plant will be constructed. The project is planned for completion in 1-year from zero date. Tathagata Bio Energy Private Limited plans to set up 12-MW biomass power plant in Gaya, Bihar. As of May 2011, work on the project is under planning stage. Ć THERMAL POWER Jai Bhole Cement Combine, a group company of Zawar Sales, is planning a 72-MW coal and 10-MW WHR-based captive power project in Velabai, district: Yavatmal, Maharashtra. Equipment supplier is yet to be appointed. The project is waiting for final approval of environmental clearance. Work on the project commenced in March 2014 and is planned for completion in H1 2017. The project will come up as part of its ` 151-billion integrated cement project spread over 2,500 acres of acquired land. Aditya Birla Nuvo is planning an expansion of its coal and lignite-based captive power projis project from 34.5-MW to 54.5-MW at a cost of ` 8,500 million (Inclusive of viscose filament yarn project) at Indian Rayon unit at Veraval, district: Gir Somnath, Gujarat. The project is waiting for environmental c l e a r a n c e a n d i s p l a n n e d fo r c o m p l e t i o n i n 2 ye a r s from zero date. Cauvery Power Generation Chennai, an SPV promoted by the promoters of Kaveri Gas Power, is planning an expansion of its coal-based power project in village: Sirupuzhalpettai and Billakuppam, district: Tiruvallur, Tamil Nadu. The capacity will be augmented from 63-MW to 213-MW. The coal for the plant is imported from Indonesia and supplied by Coastal Energy. The project is in a conceptual stage. The 63-MW coal-based power project stands commissioned since 2012. Chemical Engineering World
Ad Index CEW Sr No
Clientâ&#x20AC;&#x2122;s Name
1
Atomic Vacuum Company (Exports)
2
Page No
Sr No
Clientâ&#x20AC;&#x2122;s Name
Page No
Inside Cover I
18
Kwality Process Equipment Pvt Ltd
17
Avcon Controls
51
19
Leister Technologies
59
3
BHS-Sonthofen (India) Pvt Ltd
73
20
Membrane Hitec
35
4
Busch Vacuum India Pvt Ltd
23
21
Paharpur Cooling Towers Ltd
55
5
Chempro Technovation Pvt Ltd
88
22
Raj Process Equipments & Systems Pvt Ltd
13
6
Chemtech World Expo 2015
41
23
Rasaii Flow Lines Pvt Ltd
29
7
Cole Parmar
49
24
Ross Process Equipment Pvt
31
8
De Dietrich
19
25
Super Industrial Lining Pvt Ltd
3
9
Dipflon Engineering & Co
9
26
Suraj Ltd
59
10
Emjay Engineers
49
27
Transflow Asia
27
11
Fluidyme Process Flow Technologies
51
28
Universal Forces Industries
37
12
Gopani Product Systems
Back Cover
29
Vega India Level & Pressure Measuremnet
13
Hitech Applicator
9
14
HRS Process Sysstems Ltd
5
15
Integral Process Controls India Pvt Ltd
16 17
Pvt Ltd
25
30
Verder India Pvt Ltd
11
15
31
Warade Automation Solutions Pvt Ltd
43
Kirloskar Brothers Ltd
Inside Cover II
32
Watertech
47
Kishor Pumps Pvt Ltd
53
33
Yashtec Instrumentation & Engineering Source
39
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April 2014 â&#x20AC;˘ 83
CEW Book Shelf Waste Energy Harvesting: Mechanical and Thermal Energies (Lecture Notes in Energy) Authors: Kong Ling Bing, Tao Li, Huey Hoon Hng, and others Price: ` 12,292 Pages: 592 (Hardcover) Publisher: Springer About the Book: Waste Energy Harvesting overviews the latest progress in waste energy harvesting technologies, with specific focusing on waste thermal mechanical energies. Thermal energy harvesting technologies include thermoelectric effect, storage through phase change materials and pyroelectric effect. Waste mechanical energy harvesting technologies include piezoelectric (ferroelectric) effect with ferroelectric materials and nanogenerators. The book aims to strengthen the syllabus in energy, materials and physics, and is well suitable for students and professionals in the fields.
Waste-to-Energy: Technologies and Project Implementation Authors: Francois Screve, Marc J Rogoff Price: ` 6,971.27 Pages: 178 (Hardcover) Publisher: Elsevier About the Book : This book covers in detail programs and technologies for converting traditionally landfilled solid wastes into energy through waste-to-energy projects. Modern Waste-to-Energy plants are being built around the world to reduce the levels of solid waste going into landfill sites and contribute to renewable energy and carbon reduction targets. The latest technologies have also reduced the pollution levels seen from early waste incineration plants by over 99 per cent. With case studies from around the world, Rogoff and Screve provide an insight into the different approaches taken to the planning and implementation of WTE. The second edition includes coverage of the latest technologies and practical engineering challenges as well as an exploration of the economic and regulatory context for the development of WTE.
D e s i g n o f M u n i c i p a l Wa s t e w a t e r Tr e a t m e n t Plants Author: Water Environment Federation Price: ` 16,084 Pages: 2600 Publisher: McGraw-Hill Professional About the Book : Fully revised and updated, this threevolume set from the Water Environment Federation and the Environmental and Water Resources Institute of the American Society of Civil Engineers presents the current plant planning, configuration, and design practices of wastewater engineering professionals, augmented by performance information from operating facilities. Design of Municipal Wastewater Treatment Plants, Fifth Edition, includes design approaches that reflect the experience of more than 300 authors and reviewers from around the world. 84 • April 2014
Wastewater Treatment: Concepts and Design Approach Authors: Karia G L, Christian R A Price: ` 383 Pages: 448 (Paperback) Publisher: PHI About the Book : This thoroughly revised second edition presents a comprehensive account of the principles of operation and design of wastewater treatment plants. Beginning with the basic concepts of treatment of wastewater and the design considerations required of an efficient treatment plant, the book moves on to spotlight the design criteria for domestic wastewater treatment units. In essence, the text gives the detailed procedures for design computations of all units of a wastewater treatment plant. It also describes the most common types of reactors used for physical operations and biological processes in wastewater treatment plants. Besides additional examples and exercises, this edition also includes a new chapter on „Disinfection of Wastewater‰. The book is intended for the undergraduate students of Civil and Environmental Engineering. It will also be useful to the practising professionals involved in the design of wastewater treatment plants. The Book provides several examples supported by graphs and sketches to highlight the various design concepts of wastewater treatment units and Encapsulates significant theoretical and computational information. Chemical Engineering World
Interview CEW
En route to a Greener Path
IGL holds the distinction of being the only green petrochemical company of its kind which has commercialised the production of ethylene oxide, its derivatives and glycols from renewable agricultural resources, says Rakesh Bhartia, Chief Executive Officer, India Glycols Ltd. In an exclusive interview with Mittravinda Ranjan, he further highlights the need for versatile bio-refinery model capable of offering a range of products, and talks about the early year of the company, bio-based product market in the country, challenges and the future – that will see adoption of plenty of new technologies in bio-refining industry.
How big is the share of green chemicals in the global industry and what are the current technologies and trends driving its growth? What are the major challenges? There are varying estimates available on the size of bio-based chemicals industry ranging from USD 5-10 billion. However, the cumulative
Chemical Engineering World
annual growth rate for bio-based chemicals seems to be unanimously acknowledged between 35 to 45 per cent which is substantially high and offers a big opportunity.
industry, and challenge lies in the availability of feedstock at competitive prices to ensure green products are economically viable when compared to fossil-based equivalent products.
Development in the field of sugar-based packaging material and plastics are the key drivers for the
India Glycols Limited (IGL) enjoys the distinction of being the Âonly green petrochemical companyÊ in India
April 2014 • 85
CEW Interview for deriving the feedstock from biomass, which has so far been unconventional in Indian context despite its availability in abundance in the country. Tell us about the early years of the company, challenges and major milestones in the journey. IGL was established in 1989 in the heart of sugarcane belt in north India (Uttarakhand). The promoters had a vision to use molasses, which did not have much commercial value at that time, for production of ethanol and EO-based products. Neighbouring sugar companies could supply large amount of molasses at throw away prices thus making the IGL business model viable. IGL used to market its product in the domestic market directly competing with petro-route products. The business model made good economic sense as molasses price was very low. Gradually, as the industry started realising the value of molasses and ethanol demand increased, the prices started shooting up. In the meantime - during the period 20072010 - crude prices were low so naphtha derived products were available at low prices. It was difficult for IGL to compete in domestic market with such products. So, IGL embarked upon an aggressive campaign for marketing its products in mature markets in the overseas (US, Europe, Japan), where the customer was environment conscious and was ready to pay the premium for the green product. The focus shifted to exports. Last year nearly 50 per cent of IGL sales was from Exports. India is playing a major role in global supply chains for petrochemicals and fuels with increasing petroleum refining capacity and value addition through integration of refineries with petrochemicals. What is the current overlap of products coming from petroleum refiners and IGL? All the products (in Chemical Division) that IGL makes are Ethylene Oxide-based products. They have a direct overlap with the similar petro-based products. However, there are other divisions within IGL which manufacture Guar Gum (which is a natural seed-based product) and nutraceuticals extracted from plants or herbs which is totally green product. These do not have any overlap with petro-based products. 86 â&#x20AC;˘ April 2014
Though India has a thriving production of bio-masses, the true potential in the field of chemical manufacturing is yet to be realised. May we have your comments on what could possibly have been the limiting factors for the industry to get into this space? India does have a thriving bio-mass and it is infact the second largest producer of sugarcane after Brazil. The number of sugar and ethanol producing companies is large, but to enter into the space of sugar-based green chemicals through vertical integration is costly. The cost of putting up a grass root plant capable of producing green chemicals is quite high which ultimately affects the finished product price. Indian market has not yet matured to be able to pay the additional cost for green product vis-ĂĄ-vis the functionally similar fossil-based product. IGL enjoys the advantage of having put up such a plant 25 years back, and now with its depreciated value the burden on final product is nominal. Many small petrochemical manufacturing organisations have vanished due to non-availability of feedstock from petroleum refineries as a result of thier expansion into petrochemical manufacturing. What kind of scope is available for the chemical manufacturers using bio feedstock in India? Small petrochemical manufacturing organisations stand a risk in terms of feedstock availability due to big capacity enhancements that refineries have undergone along with forward integration into petrochemical manufacturing. The big MNCâ&#x20AC;&#x2122;s are today controlling the global petrochemicals business, and in the last 2-3 years, we have seen consolidation through acquisitions and mergers leading to growth in size of the global players. This has rendered small business uncompetitive in terms of price structure, distribution set and difficulty in availability of feedstock. IGL relies on bio-based feedstock i.e. molasses or ethanol for its range of green products. The challenge faced by IGL is of different nature. Though the market for green products is growing, it is very price sensitive. Paying extra for green product is a big deterrent. On the other hand, for IGL, the feedstock prices (ethanol) are rising. The recent introduction of ethanol for fuel
blending programme has had a direct impact on procurement costs whereas the end market is not ready to absorb the increase. This has put severe pressure on the margins. India Glycols has a broad diversified basket of products across basic, specialty & performance chemicals. How do you stay cost-competitive in the market? As I said earlier, remaining cost competitive is a real challenge for IGL in current scenario. On one hand is the end market which is very price sensitive. The product essentially goes for green PET bottles and packaging films which have been launched in mature markets, where customer is concerned about environment, but there is a reluctance to pay extra cost. The additional cost is generally absorbed by the brand owner as an expenditure on CSR initiatives. Hence there is reluctance to accept any cost increase. On the other hand is the increasing feedstock costs which cannot be absorbed in totality and hence it is affecting the margins. IGL is adopting a flexible procurement approach. It is procuring molasses from the sugar companies and making ethanol in its own distilleries. It is buying ethanol from market wherever it is available at competitive prices. Also, it is importing some of its ethanol requirement from Brazil. IGL has also launched an ambitious project of making ethanol from waste bio-mass like wheat and rice straw, paper pith, wild/ napier grass, etc. Currently the project is in Pilot Plant stage. Once a full commercial size facility is operational, ethanol price is anticipated to be more economical. How do you compare maintaining the profit margins in the operations with the petroleum refiners who are constantly struggling for maintaining the Gross Refining Margins (GRM) amidst highly volatile crude prices? IGL pricing model is independent of crude prices. It is more connected to the ethanol price movement. Since the products from petro-route overlap with the green products offered by IGL, one does need to keep a close tab on crude Chemical Engineering World
Interview CEW prices because a downward trend in crude does put pressure on ultimate pricing of green product in order to bring it within acceptable range of end consumer. This is a challenge faced by IGL. What are the other issues apart from ÂPricingÊ? In addition to the pricing issues, the other main concerns faced in terms of marketability of the product are the ones related to sustainability aspects, social and ethical aspects, product traceability aspects and issues related to responsible care. Logistics cost form a substantial component of the pricing model. IGL is working hard to keep such costs in check. It plans to a have railway siding of its own at its facility which will help in keeping the cost competitive and would yield top line growth. According to recent studies on petroleum refining, around 70 refineries have already shut down due to inability to maintain profitability which has clearly pointed out the need to select right operational model, particularly ability to process different crude mixes. May we have your views on what would be right operational model for bio-refiners as a part of long term growth strategy? In today’s challenging scenario, the bio-refinery model needs to be very versatile and capable of offering a range of products. In our view, a workable model would be use of bio-mass leading to range of products from sugar platform i.e. ethanol on one hand finally being used in Bio-MEG and Green EOD’s and Chemicals on the other hand like HMF, FDCA, Furfurals and derivatives. The lignin produced as by-product can be used as liquid burner fuel. Global green solvents market was worth USD 4.0 billion in 2013 and expected to reach USD 6.3 billion by 2018. What kind of growth do you see for IGL and those in the same space and utilise bio-feedstock for chemical production? It would be difficult to hazard a guess on the segment-wise market size, but we feel that the biggest share of green chemicals as of now is in the PET bottle and packaging film segment, plastics, and to some extent , in fibres and car interiors. There are drop-in bio-plastics which have identical properties to the petro-based products and Chemical Engineering World
hence easy to integrate. Additionally, there are functional equivalents which have improved characteristics and higher value applications. IGL is more into the former segment and we see this segment growing at great pace as it does not require much process modification when shifting to use of green product. The price differential is also not very large. This segment may be growing at about 30 per cent pa. Any international model that could possibly be emulated in India to develop the biobased industry; and your thoughts on developing the bio-based chemical industry in India to create a globally competent market against petroleum rich Middle East, Gas rich USA & High-capacity country China; meeting the environmental goals and growing indigenous product demand. What measures do you propose at the industry and policy level to realise this? India needs to evolve its own unique model for bio-based chemical industry. The feed stock availability options in India and its strategic geographic location puts the country in advantageous position as major supplier of green chemicals. On the policy front, a major work on the ground needs to be done for improving logistics and infrastructure of speedy movement for material and reducing transaction costs. The issue of easy credit availability at internationally competitive rates needs to be addressed immediately in order to increase the investments in green chemicals sector. Quick single window clearance of new projects, ecological and environmental clearances need to be expedited and a strong positive signal needs to be sent across to revitalise the industry. The political and economic environment needs to be conducive for key domestic companies to undertake new projects as well as expansion plans for current capacities. There is a need to focus on environment, permissions and labour reforms. The constraints in the availability of petro-based feedstock and petro-based energy source is a grim reality Indian chemical industries is facing. Alternative bio-based technologies and bio-based feedstock need to be incentivised to promote growth of Green Chemicals. Adequate investments in R&D and new technology need to be made by industry
and supported by government. Issues related to better corporate governance, intellectual property protection, aggressive R&D, up-skilling local talent and sustainable raw materials, among others are a key to future growth. A focus on sustainability would certainly be one of the many expectations from Indian companies. What are your thoughts on future challenges, trends and technologies in this space? The main challenge for the future lies in availability of bio-mass at competitive prices. Newer technologies are being developed to generate ethanol from waste bio-mass. Research is being carried out to use diverse bio-mass for optimum yield of ethanol through recycling and reuse of enzymes and faster reaction times to bring down the cost. More versatile models on bio-refinery concept are being worked-out to offer a range of green products at competitive price. As the strain on non-renewable fossil-based resources increases over the next few years, the acceptability of green products will grow and more and more investments will be made in newer technologies and putting up new green chemical plants. Today, sustainability is recognised as both - a business driver and a business outcome. Sustainability is evolving simultaneously on operational footprints and product footprints. The issues of sustainability are revolving around air emissions, energy, GHG emissions, health and safety, water, waste or spills and innovation. IGL has implemented several green methodologies, including new solutions and products made via the green route, i.e. from raw materials that are renewable resources, novel technologies including super critical technology for nutraceuticals, super critical carbon dioxide as a green solvent during extraction processes, etc. There is a focus on improving sustainability, by looking at energy usage, carbon footprints and life cycle assessment of products. At IGL, we are working towards lowering our impact on the planet by reducing use of raw materials and non-renewable resources, product toxicity, wastes and emissions during manufacture, risk and hazards from manufacturing and environmental impact of products. April 2014 • 87
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