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

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NEWS Industry News

Technology News

Innovative Commercial and Technical Solutions for CSG Produced Water Treatment Project - Hiep Le, Osmoflo Water Management Pty Ltd

WSSC Achieves Over 60% Reduction in Hydraulic Plan Review for Water and Wastewater Systems - Perrine Parrod, Bentley

CASE STUDY

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4 • April 2017

FEATURE 46

MARKETING INITIATIVE New Marine Breakway Coupling Reverse Osmosis and Ion Exchange – Unique Process Steps to Minimize the Liquid Discharge

55 56

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INTERVIEW “We have embarked around ` 1500 crores for the next phase of growth.” - Rajendra Gogri, CMD, Aarti Industries

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Chemical Engineering World

CEW Industry News Nestle India Reduced Its Water Consumption by 53% New Delhi, India: On the occasion of World Water Day on March 22, Nestle India has reduced its water consumption by 53% and waste water discharge by 55% for every ton of production, thus keeping its commitment towards responsible water stewardship. Nestle India is continuously working on conservation and optimal utilisation of water. To accomplish this, various initiatives have been launched to reduce, re-use and re-cycle water, across the value chain and with communities, for a sustainable future. "We work closely with communities to create awareness on water conservation and preservation and at the same time use technology to reduce water usage in our manufacturing locations. We are working in schools around our factories to provide clean drinking water to thousands of students. We also have a water stewardship initiative with AgSRI at the Kabini river basin in Karnataka. The project sets up demonstration farms and trains farmers in ecologically sustainable practices to reduce the agricultural water withdrawal from the catchment area, while improving agricultural productivity" said Sanjay Khajuria, Senior Vice President Corporate Affairs, Nestle India.

C l a r i a n t O p e n s N ew Wa t e r- B a s e d P i g m e n t Preparations Production Plant in Mexico Mexico City, Mexico: Clariant Chemicals has started the operation of its new production plant for water-based pigment preparations at Santa Clara, Mexico. The new facility has increased Clariant's annual production capacity for water-based pigment preparations in the country and improves access to growth markets in North, Central and South America. Clariant will be able to supply to the regions' current and emerging market segments, including decorative coatings, non-impact and flexo printing, industrial coatings, and specialties like home care, personal care and stationery. This method compromises faster and cost-efficient production with better flexibility and dispersibility as compared to powder pigments. The company is planning to open a new plant for solventbased pigment preparations by the end of 2017 to produce high milling demand products for specialties market in the US.

AkzoNobel set to Divest its Chemicals Business Amsterdam, Netherlands: Dutch chemicals company AkzoNobel denied the takeover offer from PPG Industries and plans to divest its chemicals business as a part of its growth strategy. The company has formed project teams to detach its specialty chemicals business within 12 months. The move will result in more returns to the shareholders and the divestment is expected to create chemicals business profit margin to reach up to USD 1 billion. 8 • April 2017

“The industry-leading performance and outlook of our specialty chemicals business gives us the confidence to return proceeds to shareholders in advance of the separation. In addition, we see extensive growth momentum in our paints and coatings business, which we expect to keep growing faster than market rates, allowing us to improve our long-term financial guidance. Now is the right time to create two focused, high-performing businesses. This strategy will create substantial value for shareholders with significant less risks and uncertainties compared to alternatives,” said Ton Buchner, CEO, AkzoNobel. The company is also planning investment in R&D to retain innovation and new product development. Fur thermore, the company announced to keep working on its commitment to sustainability by using 100 per cent renewable energy and becoming carbon neutral by 2050.

Aarti Industries to Invest ` 75 Crores in R&D Mumbai, India: Aarti Industries Ltd plans to invest ` 75 crore for establishing an R&D and innovation complex at Jhagadia (Gujarat), which will be spread over 50,000 sq. ft. and equipped with the stateof-the-art equipment and analytical tools. At present, Aarti Industries operates three R&D centres, two on pharmaceutical APIs, and one on speciality chemicals. The new R&D centre will comprise a scale-up facility consisting of a kilo-lab and a pilot plant, an innovation centre, dedicated labs for process safety, effluent treatment, etc. It plans to board more than 150 scientists and engineers for researching and developing revolutionary innovations, and for commercial scaling of numerous speciality chemicals. “The setting up of this R&D centre will enable us to enhance and expand our capabilities to develop high-end value added products and chemistries with niche market opportunities. The optimism for our new innovation centre is driven by a strong confidence in our R&D capabilities, process chemistries and customer relationships; and we clearly see a sizeable and sustainable opportunity. We have the levels to take advantage of the growth opportunities which are clearly identified and we continue to remain focused on them without any change,” said Rajendra Gogri, chairman & Managing Director, Aarti Industries.

BASF Invested in High Performance Silica Adsorbents Berlin, Germany: BASF invested significantly at its adsorbents production site in Nienburg, Germany. The investment shall result in increasing annual output and will reduce CO 2 emissions from operations. “This investment enhances our production technology and enables us to continue to meet our customers’ high demand for quality, consistency and performance,” said Rudolf Piehl, Site ManagerBASF adsorbents manufacturing unit, Nienburg. Chemical Engineering World

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CEW Technology News Graphene Sieve Turns Seawater into Drinking Water London, UK: Researchers, including one of Indian-origin, have developed a graphene-based sieve capable of removing salt from seawater, an advance that may provide clean drinking water for millions of people When immersed in water, graphene-oxide membranes become slightly swollen and smaller salts flow through the membrane along with water, but larger ions or molecules are blocked. Researchers from University of Manchester in the UK have now successfully developed graphene membranes and found a strategy to avoid the swelling of the membrane when exposed to water. The pore size in the membrane can be precisely controlled which can sieve common salts out of salty water and make it safe to drink, they said. When the common salts are dissolved in water, they always form a 'shell' of water molecules around the salt molecules. This allows the tiny capillaries of the graphene-oxide membranes to block the salt from flowing along with the water.Water molecules are able to pass through the membrane barrier and flow anomalously fast which is ideal for application of these membranes for desalination, researchers said. "Realisation of scalable membranes with uniform pore size down to atomic scale is a significant step forward and will open new possibilities for improving the efficiency of desalination technology," said Rahul Nair, professor at University of Manchester. "The membranes are not only useful for desalination, but the atomic scale tunability of the pore size also opens new opportunity to fabricate membranes with on-demand filtration capable of filtering out ions according to their sizes," said Jijo Abraham of University of Manchester.

To Reduce the Carbon Footprint Institute of Technology Recycles Waste To Generate Electricity Mumbai, India: Indian Institute of Technology (ICT) is taking giant leaps forward to convert its Matunga situated 16 acres campus into a green zone by recycling waste material such as waste water to generating its own electricity. To reduce the institute’s carbon footprint , the institute is mixing traditional methods with modern methods to recycle waste some of it which the institute itself have developed. After separating various materials like metal, wood and plastic the institute aims to recycle and use it for constructional purposes. “Nothing is wasted. Everything is reutilised,” said Bhalchandra Bhanage, dean, infrastructure and campus development at ICT . The institute will also be installing solar panels to generate 750kW of electricity which in order will help the institute in saving ` 15 Lakh annually. Keeping the conservation of water in mind the institute has also installed ‘auto indicators’ on the 20water tanks in the building , the institute uses a borewell to water the plants pon the campus instead of using water given by Brihanmumbai Muncipal Corporation (BMC). 10 • April 2017

Currently the institute is also planning to install facilities to treat chemical laden ‘grey’ material from laboratories and sewage water to residential areas. the technology to recycle sewage water has been developed in-house by researchers at the institute’s DBT-ICT Centre for Energy Bioscience. Under this technology, various species of algae are used to treat sewage water. The algae treatment plant is expected to treat an estimated 20,000 litres of water daily. “We started this project in 2009 and have been improvising on it. It is a pilot project and will launch it on a larger scale in the next five to six months,” said Reena Pandit, a research scientist at the centre.

Merck Launches Advanced Lab Water Purification Technology Named Milli-Q Iq 7000 Darmstadt, Germany: Merck, a leading science and technology company has launched a seventh generation water purification technology named Milli-Q IQ 7000 marking 50 years of providing ultrapure water to scientists in laboratories all over the world. “While there have been tremendous advancements in the lab, today’s scientists continue to seek ways to improve reproducibility and reliability of data. Our customers are looking for compact, ergonomic systems and software so that they can advance science, further faster. Our new lab water system addresses these pain points, allowing scientists to focus on problem solving, without worrying about the purity of their water. This new system reflects our legacy of pioneering innovations in lab water purification,” said Udit Batra, member of the Merck Executive Board and CEO, Life Science. Merck has been the partner of choice for water purification systems and services for lab scientists who need to ensure their water is free of water containments for half a century. To meet the customers’ evolving needs the company combined the customer feedback with its engineering and technical expertise to develop the Milli-Q IQ 7000 system which is an even a smaller, easier to use device. It is designed with ech2o mercury-free UV lamps for the photoxidation of organic contaminants; purification cartridges that are 33 percent smaller than previous versions and high-definition digital touchscreen similar to a mobile phone display for simple operation. It can be easily connected to lab networks through an integrated data management system that allows quick, easy access to information, which includes custom reporting and global system data archive for traceability and paperless environment for generating reports. It also comes with hibernation mode to maintain system water quality with reduced energy consumption; ergonomic, precise dispensing wheel with a wider range of ultrapure water dispensing options - from drop-by-drop up to 2 liters per minute; and smaller footprint, free of tubing / cables for a smaller, clutter-free workspace. Merck’s leading brand, Milli-Q water, has become synonymous with ultrapure lab water, and is the most cited brand in peer-reviewed publications. Milli-Q systems have purification media that are tested and designed exclusively for Merck, allowing the company to provide the best water quality to labs across the world. Chemical Engineering World

CEW Press Release Grauer & Weil (India) Ltd Wins CFBP Jamnalal Bajaj Award for Fair Business Practices

federal state of North Rhine-Westphalia. The rest will be used to expand the facilities in Brunsbüttel (Federal State of Schleswig-Holstein), and Antwerp (Belgium). The expansion project is scheduled for completion by 2020. “Organic growth is a key success factor as new LANXESS heads forward. This investment program accompanies the dynamic development of our customers and their sectors. A high proportion of the planned new capacities is already backed by customers’ orders. At the same time, we are also strengthening our sites,” said Hubert Fink, member of the Board of Management of LANXESS AG.

(1st from Left) Vinod Haritwal, CEO & Director Grauer & Weil (I) Ltd receiving the Award.

Mumbai, India: Grauer & Weil (India) Ltd recently won the Jamnalal Bajaj Uchit Vyavahar Puraskar 2016 awarded by the Council For Fair Business Practices (CFBP) under the category of Manufacturing Enterprises-SME. The award was presented to Grauer & Weil (India) Ltd by Shri Suresh Prabhu, Hon’ble Minister for Railways at a glittering function at the Indian Merchants’ Chamber in Mumbai. The CFBP Jamnalal Bajaj Awards were instituted in 1988 as a tribute to the late Jamnalal Bajaj - a lifelong proponent of fair business practices. Each year, the awards are conferred upon the most deserving applicants from the Manufacturing Trade and Service Enterprises as well as Charitable Associations with an outstanding record of promoting fair business practices. The awards have been initiated to encourage and motivate ethics at every level and to persuade businesses to proactively pursue opportunities to fulfil their social responsibilities. The awards also aim at publicly felicitating commitment to fair business practices and safeguarding of consumer interests. The function was graced by Mr Suresh Prabhu, Minister for Railways, as the Chief Guest and Mr Girish Bapat, Minister for Food, Civil Supplies and Consumer Protection, Food and Drugs Administration, Parliamentary Affairs as the Guest of Honour. Expressing happiness on receiving the award, Mr Vinod Haritwal, CEO & Director, Grauer & Weil (India) Ltd, “We are extremely thrilled and honoured to have received this award. At Grauer & Weil, we have always believed in conducting our business using only the best of business practices and transparency in processes. These intrinsic values have helped us to be recognized as one of the most credible manufacturing companies in India. This award has further strengthened our goals, mission and beliefs.”

LANXESS Invests EUR 100 million in its Intermediates Production Network Cologne: Specialty Chemicals Company LANXESS continues to target growth. During the next three years, its business unit Advanced Industrial Intermediates will be investing some EUR 100 million in expanding production facilities for chemical intermediates. Around EUR 40 million each will be invested in the Leverkusen and Krefeld-Uerdingen sites in the 12 • April 2017

At the Krefeld-Uerdingen site, the plan is to expand production facilities for trimethylolpropane, hexanediol, benzylalcohol and menthols to accommodate growing demand on global markets. Trimethylolpropane and hexanediol are important for products in the automotive, furniture and construction industries, for example. Benzylalcohol is used in a broad range of applications, eg, construction, soap, coatings, seals and adhesives, agro and pharma. Besides KrefeldUerdingen, Lanxess manufactures Benzylalcohol at its Nagda site in India. “Benzylalcohol is one of the key products in the business unit Advanced Industrial Intermediates’ portfolio where LANXESS holds global market leadership positions. We service customer demands around the world from our production sites at Krefeld-Uerdingen in Germany and Nagda in Madhya Pradesh, India”, said Mr Neelanjan Banerjee, Senior Executive Director, LANXESS India Pvt Ltd and Senior Vice President, Business Unit-Advanced Industrial Intermediates (AII). Synthetic menthol is a key component of many aromas and pharmaceutical products. LANXESS had already started gradually increasing the capacities for these products in recent years. Now the company is planning new expansion measures. Construction work is set to commence during the coming year. At the Leverkusen site capacity expansion for special amines is scheduled to start this year. Special amines are mainly used as intermediates for further processing and ultimately in the automotive sector. LANXESS will considerably increase the capacity of the MEA plant at Brunsbüttel in the course of the year and will invest up to EUR 15 million for this purpose. The abbreviation MEA stands for 2-methyl-6-ethylaniline, which is required mainly as a precursor for crop protection herbicides. At the Kallo/Antwerp site in Belgium, LANXESS will be investing a midsingle digit euro million figure to expand its production capacities for rubber chemicals. Aromatics network hallmark The Advanced Industrial Intermediates business unit employs around 2,100 workers and is one of the world’s leading manufacturers of high-quality industrial chemicals. Aromatic compounds play a prominent role in the product range. The aromatics network forms the core of production and is regarded as the largest of its kind worldwide. LANXESS’s high-quality intermediates are primarily used in the manufacture of agrochemicals, polymers, paints, coatings and pigments. Further important applications include cosmetics, flavorings, fragrances, fuel additives, lubricants, tires, technical rubber goods and construction Chemical Engineering World

CHEMICAL & PHARMA INDUSTRY

CEW Press Release Pushing the Boundaries of Possibility With Innovative Coating Raw Material Developments Europe: Covestro, formerly Bayer MaterialScience is appearing at the European Coatings Show under its new name for the first time. The focus is on innovative and sustainable coating raw material developments and their use in near-series projects. More than just examples of concrete applications, they also document the great interest of key industrial segments. “For 80 years innovations have been the engine of progress for our company,” said Board Member for Innovation and Chief Commercial Officer Dr Markus Steilemann while speaking to journalists. “We don’t rely solely on our own research efforts here, but also collaborate intensively with partners along the value chains. This enables us to push existing boundaries and offer added value for our customers.” Sustainability targets met “But all of our developments must also meet our sustainability goals,” said Steilemann. “They should drive energy efficiency and improve people’s lives, but also reduce our own use of fossil raw materials. At the European Coatings Show we are using concrete projects to illustrate how they can also meet the sustainability goals of our customers.” Covestro therefore wants to bring more bio-based products to the market, provided that they are cost-effective, have a small ecological footprint and their technical properties are at least as good as, if not better than, those of existing petrochemical-based products. Renewable coating raw materials trending The use of bio-based coating raw materials is becoming increasingly important. One of the driving forces here is growing market interest in sustainable products. Covestro is committed to raw materials from biomass and has now expanded its portfolio once again. The latest product is the hardener Bayhydur eco 7190. It is the first polyurethane hardener for waterborne, two-component polyurethane coatings and is well-suited for coating furniture more sustainably, for example. The raw material is the perfect complement to the hardener Desmodur eco N 7300 and the dispersion Impranil eco. All three products are made from up to 70 per cent biomass and do not compete with food production.

It contains the coating hardener Desmodur eco N 7300, which helps to improve the customer’s eco-balance without compromising product quality. “The three partners were very pleased with the results obtained when coating the test bodies on existing equipment at Audi,” said Daniel Meyer. Debut in rail vehicle coating The bio-based hardener also recently made its debut in the coating of commercial vehicles. Polish rail vehicle manufacturer Newag SA used a coating formulated with Desmodur eco N to coat two diesel locomotives. Lankwitzer Lackfabrik of Berlin developed the coating in close collaboration with Covestro. The coating meets the specifications of the rail vehicle industry and offers 70 per cent better gloss stability and abrasion resistance than standard coatings. Milan-based furniture specialist RiFRA, coatings manufacturer Sirca and Covestro conducted a feasibility study to demonstrate that waterborne furniture coatings could be formulated even more sustainably by reducing the content of fossil resources. They succeeded in doing just that with the new bio-based hardener Bayhydur eco 7190, which can reduce the carbon footprint of coatings formulated with it by roughly 30 per cent. Coating furniture under extreme conditions RiFRA tested the first bio-based, waterborne, 2K polyurethane coating under extraordinary conditions. It exhibited very good mechanical and chemical resistance even in damp kitchen and bath environments. The company is currently presenting a line of designer furniture featuring the coating at the Salone del Mobile in Milan, Italy. The bio-based, waterborne polyurethane dispersion Impranil eco opens up a new dimension in the sustainable coating of textiles. The newest product in Covestro’s INSQIN lineup, it offers an improved eco-balance over the entire life cycle of coated textiles while also helping to conserve water. Covestro is thus helping brand owners and textiles manufacturers to achieve their sustainability goals. Unique design with DirectCoating Unique designs at competitive costs – this is Covestro’s aspiration for its DirectCoating technology. Carmakers want to meet customer demand for greater interior customization options even as they strive to increase productivity.

Covestro is presenting a number of visionary, and in some cases near-series, applications with these products at the European Coatings Show. “They are the results of close collaboration with partners along the entire value chain,” said Daniel Meyer, head of the Coatings, Adhesives, Specialties segment. “That underscores the strong industry interest in these developments.”

With the help of DirectCoating, coated plastic components can be produced in a single production step rather than the total of five forming and coating steps required by the conventional process. DirectCoating can also reduce costs by up to 40 per cent and energy consumption by as much as 75 per cent. Covestro offers a complete package of coatings and plastics expertise.

First automotive coating with bio-based hardener The highlight of the Covestro booth is an Audi Q2. It is one of a number of test bodies to which a clearcoat containing a bio-based hardener was applied for the first time under realistic production conditions. The two-component coating was developed by BASF’s Coatings division.

New dimension of design freedom A successful joint project with Votteler Lackfabrik suggests that a breakthrough is imminent for DirectCoating technology. It can be used to create parts with new and attractive designs combining different shades, surface structures and haptic properties even on a single component.

16 • April 2017

Chemical Engineering World

CEW Press Release Siemens Closes Mentor Graphics Acquisition Mumbai, India: With the recent closing of its acquisition of electronic design automation (EDA) software leader, Mentor Graphics Corporation (Mentor), Siemens sets out to underscore the significant customer value it envisions for both Electronic Systems and Integrated Circuit (IC) design tools. Mentor is now part of Siemens’ product lifecycle management (PLM) software business, making the combined organization the world’s leading supplier of industrial software used for product design, simulation, verification, testing and manufacturing. As today’s products – from smar t phones and household appliances, to automobiles, aircraft and machinery – continue to increase the use of sophisticated embedded electronics, Siemens has uniquely positioned itself to provide a seamless and comprehensive software solution to the companies that develop these products. “The entire suite of EDA offerings from Mentor are critically impor tant to our vision of growing our customer base and delivering the world’s most comprehensive portfolio of software solutions to build the Digital Enterprise,” said Tony Hemmelgarn, President and CEO, Siemens PLM Software. “Software tools such as Electrical & Wire Harness Design and Electronic Systems Design perfectly complement our existing solutions, while tools for IC Design, Verification, Test and Manufacturing expand our offerings and expertise into adjacent segments to bring value to a new set of clients. “Siemens is now the leading company providing a complete set of integrated software solutions across the entire value chain. We are proud to welcome the outstanding Mentor team and all of their excellent technology into our organization.” With approximately $10 billion in investments in multiple software companies since 2007, Siemens has made a significant push into the software space with acquisitions including UGS, LMS, Camstar, Polarion, and CD-adapco. Now, with the acquisition of Mentor, Siemens will continue its proven track record of effectively merging new organizations and technology into the industry’s leading Digital Enterprise Suite. This comprehensive suite helps customers create the industr y’s most holistic and precise digital twins of their products and production lines. “Joining the Siemens family presents tremendous opportunity, not only for the Mentor Graphics team, but also for existing, new and future customers,” said Walden C Rhines, CEO, Mentor Graphics. “Siemens’ desire to leverage all of Mentor’s technologies – from our IC offerings to our systems solutions – was an important part of this transaction. We are proud to become part of an organization with such an excellent reputation and successful track record over the years.” 18 • April 2017

Lubrizol, GF & Sangir Plastics sign Corzan Processor Agreement Cleveland & Mumbai, India: The Lubrizol Corporation, inventors and the largest manufacturers of CPVC (chlorinated polyvinyl chloride) compounds worldwide; Georg Fischer (abbreviated GF) global leader in industrial piping systems and Sangir Plastics Pvt Ltd, a quality Indian manufacturer of thermoplastics piping and sheet solutions announce the signing of Corzan Processor agreement for the manufacturing and sale of a complete Corzan CPVC Industrial solution that will provide increased corrosion resistance and greater peace of mind to industries throughout India. The comprehensive product package of Corzan Industrial Systems will be jointly launched and commercially made available in the Indian market and it will exclusively cater to industrial piping segment and fabricated corrosion-resistant industrial solutions. For more than a decade Lubrizol has been dedicated to supplying leading industrial organizations in India with the most consistent, highest quality CPVC Industrial systems with its world class Corzan product offering. The newest partnership with GF and Sangir Plastics strengthens the supply of a quality Corzan pipes, fittings and complete industrial system made from Lubrizol’s time tested industrial CPVC compounds. This will ensure continued supply of the only Corzan CPVC compound with 24448 Cell Class and 4120-06 rating providing 3X the impact strength and 25% higher pressure rating at elevated temperatures in India. Long lasting problem-free industrial products made from pioneering Corzan CPVC compounds along with the reliable advice and exclusive partnership will lower risk and ensure success of industrial organizations that need proven chemical resistance over decades. Mr Michael Fornes, Global Business Manager – Corzan Industrial Systems from Lubrizol’s Engineered Polymers Division says, ‘We are very pleased with this outstanding alliance which will provide a complete one stop Corzan Industrial solution along with best in class application expertise for the Industrial piping market in India. The combined strong reputations of Corzan with GF and Sangir will definitely strengthen our mutual commitment to delivering product reliability in India.’ He further adds, ‘this partnership will leverage our global expertise, GF’s global experience and Sangir Plastics’ local manufacturing and approach to drive optimized solutions within India and abroad. This will ultimately help the complex and niche Indian industrial market to grow and be more successful with our combined and cohesive technological support, innovation and wide product range. Mr Ketan Sapre - Head - Industry Sales, Georg Fischer Piping Systems Pvt Ltd – India talks about the partnership, says, this coalition would reinforce and focus on our joint commercial excellence and accelerated growth especially in industrial piping. We are looking forward to a long-term and successful partnership.’ Mr Sushil Mandhana, Director, Sangir Plastics Pvt Ltd expressed his thoughts on this occasion, saying, We feel proud to be associated with global brands (Corzan and Georg Fischer) and look forward to prove the ‘Power of 3’. Chemical Engineering World

CEW Press Release ABB to Acquire B&R Zurich, Switzerland: ABB today announced the acquisition of B&R, the largest independent provider focused on product- and software-based, open-architecture solutions for machine and factory automation worldwide. B&R, founded in 1979 by Erwin Bernecker and Josef Rainer is headquartered in Eggelsberg, Austria, employs more than 3,000 people, including about 1,000 R&D and application engineers. It operates across 70 countries, generating sales of more than USD 600 million (2015/16) in the USD 20 billion machine and factory automation market segment. The combination will result in an unmatched, comprehensive offering for customers of industrial automation, by pairing B&R’s innovative products, software and solutions for modern machine and factory automation with ABB’s world-leading offering in robotics, process automation, digitalization and electrification. Through the acquisition, ABB expands its leadership in industrial automation and will be uniquely positioned to seize growth opportunities resulting from the Fourth Industrial Revolution. In addition, ABB takes a major step in expanding its digital offering by combining its industryleading portfolio of digital solutions, ABB Ability, with B&R’s strong application and software platforms, its large installed base, customer access and tailored automation solutions. “B&R is a gem in the world of machine and factory automation and this combination is a once-in-a-lifetime opportunity. This transaction marks a true milestone for ABB, as B&R will close the historic gap within ABB’s automation offering. This is a perfect fit and will make us the only industrial automation provider offering customers the entire spectrum of technology and software solutions around measurement, control, actuation, robotics, digitalization and electrification,” said ABB, CEO, Ulrich Spiesshofer. “This acquisition perfectly delivers on our Next Level strategy. With our unique digital offering and our installed base of more than 70 million connected devices, 70,000 control systems and now more than 3 million automated machines and 27,000 factory installations around the world, we enable our combined global customer base to seize the huge opportunities of the Fourth Industrial Revolution.” “This combination offers fantastic opportunities for B&R, its customers and employees. We are convinced that ABB offers the best platform for the next chapter of our growth story. ABB’s global presence, digital offering and complementary portfolio will be key for us to further accelerate our pace of innovation and growth,” said Josef Rainer, co-founder of B&R. “This is a strong signal for our employees as our operations in Eggelsberg will become ABB’s global center for machine and factory automation,” said Erwin Bernecker, Co-founder of B&R. “The most important thing to me is that the companies and their people fit so well together and that our founding location will play such a key role.” B&R has grown successfully with revenue CAGR of 11% over the last two decades. Revenues more than quintupled since 2000 to more than $600 million (2015/16). The company has a rapidly growing global customer base of more than 4,000 machine manufacturers, a proven track record in automation software and solutions and unrivaled application expertise for customers in the machine and factory automation market segment. 20 • April 2017

Both companies have complementary portfolios. ABB is a leading provider of solutions serving customers in utilities, industry and transport and infrastructure. B&R is a leading solution provider in the automation of machines and factories for industries such as plastics, packaging, food and beverage. The joint commitment to open architecture increases customer choice and flexibility facilitating connectivity in increasingly digitalized industries. Substantial investments in innovation Innovation is at the heart of both companies. B&R invests more than 10 per cent of its sales in R&D and employs more than 1,000 people in R&D and application engineering. ABB spends USD 1.5 billion annually on R&D and employs some 30,000 technologists and engineering specialists. Going forward, ABB and B&R will continue to invest considerably in R&D. Automation of machines and factories is a key driver of the Fourth Industrial Revolution and the IoT. ABB will continue B&R’s strong solutionbased business model and build on its deep domain expertise to develop new software-based services and solutions for end-to-end digitalization. ABB’s industry-leading digital offering, ABB Ability, will now capitalize on the large installed base, application and solution know-how, simulation software expertise and advanced engineering tools of B&R. Proven integration approach On closing of the transaction, B&R will become part of ABB’s Industrial Automation division as a new global business unit – Machine & Factory Automation – headed by the current Managing Director, Hans Wimmer. Both companies consider B&R’s management and employees as a key driver of future growth and the business integration together with their counterparts from ABB. The co-founders of B&R, Erwin Bernecker and Josef Rainer, will act as advisors during the integration phase to ensure continuity. The integration will be growth-focused and live by the “best-of-bothworlds” principle, with ABB adding its own PLC and servo drive activities to the offering of the new business unit in a phased approach. ABB underlines its clear commitment to continuing the B&R growth story by articulating a mid-term sales ambition to exceed $1 billion. ABB is committed to further investing in the expansion of B&R’s operations and to building on the company’s successful business model and brand. B&R’s headquarters in Eggelsberg will become ABB’s global center for machine and factory automation. Austria benefits as technology and business hub With this acquisition, ABB becomes the largest industrial automation player in Austria. ABB has operated in Austria for more than 100 years. With the strong future role, B&R and its headquarters in Austria will play as part of ABB, Austria, particularly Upper Austria, will benefit. The planned expansion of the R&D and production activities in Eggelsberg and Gilgenberg will strengthen Austria’s high-tech industrial landscape. Transaction financials The transaction multiple is in line with peer valuations. The parties agreed not to disclose the purchase price. ABB will finance the acquisition in cash. The transaction is expected to be operationally EPS accretive in the first year, and is expected to add significant synergies of about 8% of B&R’s stand-alone revenue in year four. The transaction is expected to close in summer 2017, subject to customary regulatory clearances. Chemical Engineering World

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CEW Press Release Global Push for Earth Observations Continues Geneva Switzerland: The Group on Earth Observations (GEO) has been working for more than a decade to open access to earth observation data and information, and increase awareness around their socioeconomic value. As GEO moves into the second decade four new global partners are announced to help support GEO’s vision. The GEO community has been building a Global Earth Observation System of Systems (GEOSS) that links ear th obser vation resources worldwide across multiple Societal Benefit Areas (SBAs). These SBAs range from Biodiversity and Ecosystem Sustainability, Disaster Resilience, Energy and Mineral Resources Management, Food Security, Infrastructure and Transportation Management to Public Health Surveillance, Sustainable Urban Development and Water Resources Management. The SBAs serve as lenses through which the Member governments and Participating Organizations (POs) that constitute GEO may focus their contributions to GEOSS, with a goal to make the open EO data resources available for informed decision-making. The four organizations include Conservation International (CI), Earthmind, Global Open Data for Agriculture and Nutrition (GODAN) and the United Nations Children’s Fund (UNICEF). Each organization has now joined GEO as a Participating Organization, taking the total number to 110 working internationally to advocate, engage and deliver on open EO data. “CI empowers societies across the globe to sustainably care for nature through science and partnerships. We are excited to join the GEO community, which has long recognized the power of collaboration in leveraging earth observation to benefit humanity.” Said Daniel Juhn, Senior Director, Integrated Assessment and Planning Program at Conservation International. “Though we face obstacles to achieve the SDGs, we are at a critical juncture where the science of valuing ecosystems, and understanding the full services nature provides to people expands our knowledge and options. We hope this partnership exemplifies bringing together that science, the right policies, necessary collaboration, and advanced technologies to generate the solutions we need to tackle global sustainability challenges.” “Earthmind supports positive efforts by private, public and non-profit stakeholders to conserve and responsibly manage nature. As one of our main programmes is to recognise conservation in the areas where people live and work, we are most honoured and indeed excited to join the GEO community. In so doing, we hope to further encourage voluntary efforts to observe how we managing our planet in order to take better care for it.” said Francis Vorhies, Founder and Executive Director of Earthmind. “GEO, its Members and the broad new set of tools provided by geodata constitute a fantastic step forward in the quest to help farmers from all corners of the world improve their yields and Governments to improve their policies to further stimulate agriculture in their respective countries. This is why GODAN is very glad to become part of GEO and to count the GEO partnership among the GODAN network. We believe that this collaboration will be most fruitful for 22 • April 2017

all parties involved” said André Laperrière, Executive Director of the GODAN Secretariat. “UNICEF has learned through experience that problems that go unmeasured often go unsolved,” said Toby Wicks, Data Strategist at UNICEF. “We will work with the GEO community to link the needs of the world’s most vulnerable populations to a rapidly expanding set of data informed solutions, including GEOSS. This partnership signals an effort to build a world in which a near real-time understanding of risks and global challenges, particularly water resources management and disaster resilience, allows us to work harder and faster, for children.” The key engagement priorities for GEO in the coming years involve using open earth observations to respond to a number of global policy issues. The priorities are tied to the Sendai Framework for Disaster Risk Reduction, the Paris Agreement on Climate Change and the United Nations 2030 Agenda for Sustainable Development. These new partnerships will complement existing ones and also help deliver in line with the GEO engagement priorities.

Vepica USA Selects Intergraph Software Solutions for Project with Meridian Energy Group Huntsville, USA: Vepica Group, a multi-national engineering, procurement and construction company co-headquartered in Houston, Texas, and Caracas, Venezuela, with offices in Canada, Colombia and China, has chosen the Intergraph solutions suite for the Davis Refinery project, a high-conversion crude oil refinery to be constructed in southwestern North Dakota to serve crude oil producers and local liquid fuels and chemicals markets. Meridian Energy Group, a refinery owner, selected Vepica based on its exceptional performance in engineering and permitting support for the Davis Refinery; the significant experience of Vepica personnel; and ability to simultaneously work the project from three of its main locations to provide efficient and cost competitive solution. For the Davis Refinery project, Vepica will use Intergraph Smart 3D work-sharing between its offices in Houston, Calgary and Caracas, as well as integration with design tools via SmartPlant Enterprise. Vepica will use Smar tPlant P&ID, Smar tPlant Electrical and SmartPlant Instrumentation for the detail design as well as SmartPlant Reference Data and Intergraph Smart Materials for its entire materials management process during the initial phase. Derek Blackwood, CEO of Vepica, said, “The Intergraph suite of software has allowed us to efficiently bring together the capabilities and experience of all of our locations to deliver high-quality, on-time project deliverables to our clients at a highly competitive price, helping bring their projects to life.” Mattias Stenberg, Intergraph Process, Power & Marine President, said, “Vepica has been a user of Intergraph technology for more than 15 years, during which time it has successfully executed projects for the oil and gas industry, industrial and renewable energy sectors. We are pleased to support Vepica’s expansion using our suite of solutions, which allows them to compete with high execution standards.” Chemical Engineering World

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18/11/2016 10:20

CEW Press Release ORLAS CREATOR wins Red Dot award for high Quality Design

Prime Minister Dedicates ONGC Petro Additions Ltd (Opal) Plant to the Nation

Germany: With an impressive and contemporary design, the ORLAS CREATOR is a contained additive manufacturing system. The actual build platform is original in design and functionality, utilising an innovative blade design that ensures smooth operation and increased build speeds that produce fully dense metal parts up to 30% faster than comparable systems. The system also utilizes a high quality 250-watt fibre laser, which provides exceptional beam quality and power stability and guarantees optimum and consistent processing conditions in order to produce the highest quality parts, with exceptional resolution.

Dahej, Gujarat: Prime Minister Narendra Modi today dedicated ONGC Petro additions Ltd (OPaL) plant to the Nation at a function in Bharuch. Prime Minister also visited OPaL and addressed an “Industry Meet”. He had a detailed presentation on OPaL.

Professor Dr Peter Zec, founder and CEO of the Red Dot Award: “The Red Dot winners are pursuing the right design strategy. They have recognised that good design and economic success go hand in hand. The award by the critical Red Dot jury documents their high design quality and is indicative of their successful design policy.” The significance of the international design competition, Red Dot Award: Product Design, with its headquarter in Essen, Germany is well established internationally. It was already more than 60 years ago that a jury convened for the first time to assess the best designs of the day. Since then, an expert team has been awarding the seal of quality for good design and innovation to the outstanding designs of the year. Manufacturers and designers around the globe were also invited to enter their products in the 2017 competition. The jury of around 40 independent designers, design professors and specialist journalists tested, discussed and assessed each individual product, awarding the Honourable Mention for a well-conceived detail solution, the Red Dot for high design quality and the Red Dot: Best of the Best for ground-breaking design. In total, the competition received more than 5,500 entries from 54 countries this year. The Red Dot Award: Product Design 2017 will culminate in Essen on 3 July 2017. This is when the Red Dot: Best of the Best laureates receive their trophies during the Red Dot Gala award ceremony. At the subsequent Designers’ Night after-show party, the award winners will celebrate in the midst of all the prizewinning products in the Red Dot Design Museum Essen, and the Red Dot winners will receive their well-earned certificates. For five weeks,

The plant was dedicated to the Nation by the Prime Minister in the august presence of Gujarat Chief Minister, Vijay Rupani, Union Minister for Road Transport and Highways, Nitin Gadkari, Minister of State for Chemicals and Fertilizers, Mansukh L Mandaviya, along with a host of other dignitaries. OPaL is a joint venture company promoted by ONGC, GAIL and GSPC, implementing a grass root integrated petrochemical complex located in Special Economic Zone (SEZ) under Petroleum, Chemical and Petrochemical Investment Region (PCPIR) at Dahej, Gujarat. The company was incorporated on 15th November, 2006. This is the single largest petrochemical plant in India and at full capacity, will annually produce 14 Lakh Metric Tonnes of Polymers, viz, Linear Low Density/High Density Polyethylene, Polypropylene and 5 Lakh Metric Tonnes of Chemicals like Benzene, Butadiene, Pyrolysis Gasoline, etc. The Product Warehouse is one of the largest in India with an area of 1,28,250 square metres. OPaL would use ONGC’s captive feed of C2+ streams (ie, Ethane, Propane and Butane) from C2-C3 Extraction plant, and Naphtha from Hazira and Uran to produce Polyethylene and Polypropylene. Set up with an investment of Rs 30,000 crore, the plant is strategically located in the petrochemicals and chemical hub of the country with excellent connectivity, creating an integrated ecosystem. It will generate direct employment for 3,500 personnel and indirect employment for around 10,500 people. The project will further result in the growth of new downstream plastic processing industries in the country, generating further investment of Rs 40,000 crore and over 20,000 indirect employment opportunities, giving major thrust to government’s Make in India programme.

the special exhibition “Design on Stage” will present the awarded products of the year as part of the world’s largest exhibition of contemporary design.

The increased use of polymers will also reduce burden on traditional materials like wood, paper, metal and will help in conserving natural resources like water and energy and promote food safety and food conservation. OPaL’s projected market share in the polymer sector will be 13% by 2018. The company would also contribute in encouraging polymer consumption in the country and its products will be used for important sectors like Infrastructure, Housing, Packaging, Irrigation, Automotive, Healthcare, etc. OPaL’s production of polymer will help country towards self-sufficiency. The average per capita consumption of Polymers in India is 10 kg, compared to a world average of 32 kg.

The Red Dot Design Yearbook 2017/2018 also comes out on 3 July. The international reference work for award-winning design presents all of the year’s winning products. They will also be presented on the Internet, in particular in the online presentation, the Red Dot App and on the design platform Red Dot 21.

There is tremendous potential for growth of the sector catalysed by growth drivers such as increasing middle class, higher disposable income and urbanization. The Petrochemical sector in the country has witnessed a robust growth of 10-12% per annum in the last decade and is expected to grow at a rate of 12-15% in the next decade.

24 • April 2017

Chemical Engineering World

CEW Press Release Honeywell Generates High Demand for New Paper Tissue Measurement Technology New Delhi, India: Honeywell Process Solutions (HPS) today announced its award-winning Crepe Structure Measurement sensor has received overwhelming global acceptance from pulp and paper industry customers. The new technology, which is unique to Honeywell’s Experion MX integrated quality control and process knowledge system, provides users with a tool to optimize creping in real-time for improved production quality and efficiency. This substantial change in paper tissue and towel production has gained rapid acceptance in the industry, and HPS has seen significant orders from paper manufacturers around the world. Some customers have even replaced their entire quality control system to reap the benefits of this new measurement tool. Introduced less than two years ago, HPS’ technology has earned recognition within the pulp and paper industry, receiving two awards recently. In November 2016, the sensor won the bronze award for innovation at the annual conference of the French paper industry association (Association Technique de L’Industrie Papetière) in Grenoble, France. Previously, Markku Kellomäki, HPS Senior Scientist, was awarded the Jasper Mardon Memorial Prize by the Technical Association of the Pulp and Paper Industry at its 2015 PaperCon Conference in Atlanta. The international organization presents this award for a specific technical achievement that makes a significant contribution to advancing the science and technology of papermaking. “While it has been great to see the power of this innovation recognized with awards by leading paper industry associations, the best evidence of the sensor’s value is the demand we have seen and continue to see from producers,” said Marko Jämsén, leader of HPS’ pulp and paper business in Europe. The Crepe Structure Measurement sensor analyzes tissue quality by capturing high-resolution images of the moving sheet to identify important variables in the creping process. Real-time images offer unprecedented visibility of machine and cross direction values, bringing a wide-range of potential benefits: •

Longer blade life for fewer blade changes and increased uniformity

•

Quicker recovery to crepe targets after doctor blade change, sheet breaks, grade changes or other upsets

•

Optimization of complex crepe processes for better runnability

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Enhanced paper machine performance for improved converting and total efficiency

28 • April 2017

•

Quicker trial runs and trouble-shooting processes

•

Continuous monitoring of production and equipment conditions with snapshot images from configurable locations across the sheet

•

Reduction of raw material, energy and maintenance costs

Crepe Structure Measurement is available to all users of Honeywell’s Experion MX solution to achieve stable production, compliance with quality specifications and elimination of waste in the pulp and paper industry. Used by manufacturers worldwide, Experion MX provides superior visibility into the papermaking process while simplifying operational efforts as well as reducing maintenance and service costs.

Sandvik Launches Thermocut System Mumbai, India: Sandvik has announced the introduction of an innovative new hot air-based cutting device that integrates into its Rotoform pastillation system to deliver perfectly formed pastilles from high viscosity melts. The ThermoCut® system has been designed to overcome a problem commonly known as ‘angel hair’. This refers to the formation of threads during the pastillation of hot melt adhesives and resins, products that can have viscosities as high as 40,000 mPas. These threads or tails, created when the melt is deposited on the steel belt cooler by the Rotoform, can result in a less than perfect pastille shape with more dust pollution and increased c l e a n i n g r e q u i r e m e n t s. T h e d eve l o p m e n t o f t h e S a n d v i k ThermoCut system overcomes this to deliver a significantly better quality end product. The system works by blasting a narrow jet of high pressure, heated air at the precise place where the droplets are formed between the Rotoform and steel belt. This powerful blade of hot air cuts the threads before they have chance to develop further. As well as delivering a more stable production process with better quality pastilles, the use of ThermoCut equipment also eliminates dust pollution and reduces cleaning and maintenance requirements. The ThermoCut tool has been specifically designed to work with Sandvik’s flagship Rotoform, a system widely used across the chemical industry for the production of pastilles directly from the melt. The Rotoform system consists of a heated cylindrical stator which is supplied with molten product, and a perforated rotating shell that turns concentrically around the stator, depositing drops of the product across the whole operating width of the steel belt. The heat from the pastilles is transferred to cooling water sprayed against the underside of the belt, resulting in quick, controlled solidification and a consistent end product. Chemical Engineering World

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CEW Press Release PX Phase 2 Commissioned RIL to emerge as the second largest producer of Para-xylene (PX) in the world, Set to commission one of the largest and integrated Ethylene cracker in the world Gasification project to enhance energy self-sufficiency RIL Jamnagar Projects on Schedule Mumbai, India: Reliance is executing major projects in its energy and materials chain at Jamnagar covering Para-Xylene, Cracker complex along with downstream plants and Gasification. Jamnagar is one the largest contemporary project sites globally with some of the largest and most complex process units ever built anywhere in this industry. These projects will add significant value to Reliance’s Refining & Petrochemical business and enable Jamnagar complex to achieve energy self-sufficiency. The benefits of integration at the Jamnagar complex will set a new paradigm of scale and value addition in the Refining and Petrochemicals industry. Para-Xylene, Cracker and downstream projects (MEG, Linear Low density and Low density Polyethylene) as well as Gasification which is linked to RIL’s DTA refinery, have now been installed, mechanically complete and are in various stages of pre-commissioning and commissioning. Para-Xylene: Reliance is pleased to announce the successful and flawless commissioning of the second and final phase of Para-xylene (PX) comprising of PX Crystallizers trains, Trans-alkylation and Aromatic Extraction units at Jamnagar. Earlier in December 2016, RIL had announced successful commissioning of the first phase comprising Train 1 of PX plant. Train 2 as part of second phase has been commissioned earlier this month and the last Train 3, is at an advanced stage of commissioning and will begin production later this quarter. This plant is built with state-of-the-art crystallization technology from BP which is highly energy efficient. With the commissioning of this plant, RIL’s PX capacity will be more than double. Reliance will emerge as the world’s second largest producer of PX with about 11% of global production. Cracker and Downstream: The Cracker project has a unique configuration as this world scale plant is tightly integrated with RIL’s refineries and will use refinery off-gases as feedstock. The project comprises 1.5 MMTPA ethylene cracker along with downstream facilities for producing LDPE, LLDPE and MEG. This cracker will have one of the lowest cost positions globally. Additionally, flexibility to crack Propane will help optimize feed mix further in a volatile market environment. Reliance has completed installation of cracker and downstream projects at Jamnagar in the previous quarter and pre-commissioning and start-up activities are in full swing. 30 • April 2017

Gasification: Gasification is one of the largest clean-fuel initiatives in the world. Gasification will make Jamnagar complex highly energy efficient with the lowest energy cost for any integrated Refinery and Petrochemicals facility globally. The installation and mechanical completion for the Gasification project linked to DTA refinery has been completed in the previous quarter and the pre-commissioning and start-up activities are on in full swing. The installation and mechanical completion for the Gasification linked to RIL’s SEZ refinery has also been substantially achieved and pre-commissioning activities are expected to start in the next quarter.

WACKER and STC Silicones Agree on CoBranding of Silicone Compounds Munich / São Paulo: The Munich-based chemical group WACKER and the Brazilian silicone compounder STC Silicones have concluded an agreement on the co-branding of ready-touse silicone compounds. Under its terms, STC is allowed to promote silicone compounds made from WACKER raw materials with the quality seal “Based on ELASTOSIL”. ELASTOSIL has been synonymous with high-quality silicone rubber products over more than 60 years, and is now one of WACKER’s most successful brands. STC Silicones is based in Ribeirão Pires in the Brazilian state of São Paulo. WACKER has been supplying STC Silicones with high-quality silicone raw materials and additives since 2003. The family-owned business uses them to produce ready-to-process silicone compounds for the automotive, medical, electrical and household-product sectors. “STC Silicones has been operating in the Brazilian market for over a decade and is now one of the country’s most successful compounders,” said Christian Gimber, Vice President of the Engineering Silicones Business Unit. The cooperation will benefit both STC and WACKER, the WACKER Manager adds. “STC can now supply its Brazil-based customers with high-quality and tailored silicone compounds even more effectively. We will do all we can to support STC. Consequently, we will be able to further strengthen our competitive position in the region.” STC’s Managing Drector, Joaquim Carlos Lopes da Silva, called the agreement a major milestone in positioning the company in the market as a supplier of high-quality compounds. “ELASTOSIL represents absolute quality in Brazil. It is a great benefit that we can use the brand name for our compounds, too. This will open up a raft of new sales and marketing opportunities. Products made from original WACKER raw materials are identified by the ‘Based on ELASTOSIL’ label, continued da Silva. “The ELASTOSIL brand is a global quality seal for silicones. This fosters trust and makes it easier for us to convince customers of our silicone compounds’ high quality.” Chemical Engineering World

CEW Features CASE STUDY

Innovative Commercial and Technical Solutions for CSG Produced Water Treatment Project The coal seam gas (CSG) exploration and appraisal activities by Santos in Narrabri, New South Wales (NSW), Australia results in produced formation water (PFW) that is stored in specially constructed double lined ponds. Santos is seeking to treat this water for beneficial reuse in irrigation, dust suppression, construction and drilling, and emergency firefighting purposes. Santos have outsourced this requirement to Osmoflo under a hybridized build, own and operate model, which includes the design and delivery of a water and brine treatment plant (WBTP), and specialist operation and maintenance services for 3 yrs initially, with a possible extension to 5 yrs. The WBTP is containerized to allow demobilization and future possible re-deployment, and to find an appropriate balance between the often competing drivers of the projects technical objectives, and the commercial requirements of delayed and minimized capital expenditure. The PFW and legacy brine has a wide salinity range of 18,000 to 51,000 mg/L and algae counts up to 8.8 million cells/mL These need to be desalinated to produce irrigation quality treated water of salinity <600 mg/L. Osmoflo has selected disc filtration followed by a microfiltration (MF) system as pretreatment prior to desalination through reverse osmosis (RO). The RO system has been designed with a two stage configuration with an interstage booster pump to allow variable water recovery from 55 to 70% depending on the PFW salinity. The brine from the RO system is further concentrated through Osmoflo’s Brine Squeezer (OBS) process which is an innovative, cost effective, ultra-high recovery RO process. The Brine Squeezer process is designed to concentrate the brine to a salinity >90,000 mg/L in order to minimize the brine volumes

antos are developing the Narrabri Gas Project (NGP) in the Australian State of New South Wales (NSW), about 600 km from Sydney. The NGP has the potential to supply up to 50 per cent of NSW’s natural gas demands by domestic and industrial users. The NSW State Government has recently implemented a range of new policy and legislation, making the NSW CSG industry one of the most highly regulated in the world.

brine produced by the WBTP, as the other ponds are treated and emptied providing further storage for ongoing field activities. The water qualities are shown in Table 1.

The exploration and appraisal activities conducted to date have resulted in the extraction of PFW that is stored in two state-of-the-art storage ponds at Leewood. The ponds have a storage capacity of approximately 300 ML each, and are doublelined, with leak detection systems and remote monitoring capabilities. Each pond is divided in halve so that there are effectively four ponds - called Cell 1 to 4. Two cells are expected to be full of PFW, while Cell 1 is largely full of legacy brine. The remaining cell will be used to store the highly concentrated

•

32 • April 2017

Osmoflo has been contracted to safely provide four primary services under the agreement: • •

• •

Provide irrigation quality “treated water” at 1 ML/day from the facility; Process of all of the ”legacy brine” within 15 months; Meet a final brine concentration target of greater than 90,000 mg/L TDS; and Remove solids (algal, etc) from the process The plant design must take into account leakage/spillage mitigation measures and low audible and visual impact on the site.

PROJECT SOLUTION Full Performance Risk Contract The tailored commercial structure is a first

of its kind for the CSG industry. It has been centered around a fit-for-purpose WBTP, where the design, construction and operation must comply with all applicable Australian Standards, good water industry practice and any related project approvals from the Government. The payment structure has two principle components: • Operating Lease for the Facility (offbalance sheet as Osmoflo retains ownership and risk over the term). This payment has ‘fixed’ charges under the operational lease and for the O&M services, and a ‘variable’ charge based on actual throughput. • Lump-sum component for the Associated WTP Infrastructure – which is mainly the fixed or buried infrastructure. Osmoflo constructs and owns the Associated WTP Infrastructure until Practical Completion date and then transfers ownership to Santos on payment of the lump-sum fee. Chemical Engineering World

CEW Features Table 1 - Pond Water Quality Parameter

Units

Produced Water

Legacy Brine

Parameter

Units

Produced Water

Legacy Brine

7.5 - 8.75

9.59

Aluminium (Total)

mg/L

6.1

<0.12

Electrical Conductivity uS/cm

20,220

51800

Aluminium (Filtered)

mg/L

1.4

<0.10

Chloride

mg/L

2,300

5310

Boron (Total)

mg/L

1.3

3.38

Alkalinity (HCO3)#

mg/L CaCO3

12,600

7350

Boron (Filtered)

mg/L

0.97

2.87

Alkalinity (CO3)#

mg/L CaCO3

830

21800

Iodide

mg/L

0.2

<0.200

Alkalinity (Total)

mg/L CaCO3

12,700

29200

Iron (Total)

mg/L

39.5

0.34

Sodium (Total)

mg/L

6,800

25600

Iron (Filtered)

mg/L

0.52

0.28

Barium (Ba)

mg/L

15.4

11.6

Lithium (Total)

mg/L

3.3

9.5

Barium (Filtered)

mg/L

12.6

9.73

Lithium (Filtered)

mg/L

2.8

8.3

Calcium (Total)

mg/L

14.6

Manganese (Total)

mg/L

0.177

0.07

Calcium (Filtered)

mg/L

Manganese (Filtered) mg/L

0.67

0.038

Strontium (Total)

mg/L

4.6

3.1

Zinc (Total)

mg/L

0.15

<0.058

Strontium (Filtered)

mg/L

3.7

2.53

Zinc (Filtered)

mg/L

0.16

<0.050

Fluoride

mg/L

6.5

27.1

Solids (Suspended)

mg/L

Silica

mg/L

91.2

Total Organic Carbon mg/L

4980

Sulphate

mg/L

17.8

<20

Dissolved Org. Carbon mg/L

14.3

4420

Ammonia-N

mg/L

16.3

<0.01

COD

mg/L

2,300

N/A

Nitrate-N

mg/L

0.1

0.43

BOD (5day)

mg/L

Nitrite-N

mg/L

0.04

<0.01

Colour (True)

PCU

8.4

TKN

mg/L

39.5

8.3

Colour (Apparent)

PCU

250

Nitrogen (Total)

mg/L

39.8

7.9

Total Suspended Solids

mg/l

Phosphorus (Total)

mg/L

0.63

5.42

Turbidity

57.7

Phosphorus (Filtered)

mg/L

0.05

Algae

cells/mL

>600,000

>1,000,000

Magnesium (Total)

mg/L

9.2

Bromide

mg/L

Magnesium (Filtered)

mg/L

9.8

Oil & grease

mg/L

Potassium (Total)

mg/L

15 - 35

82.3 762 Temperature contd in the next column...

WATER AND BRINE TREATMENT PLANT Pond Transfer and Feedwater Each pond will have a containerized pump station to transfer the water from the pond to the WBTP. The container will be bunded internally so that any leakage or spillage from flanged connections and pumps will discharge back into the pond. The container also consists of the pond return pipework to allow discharge of washwater or final brine (via manual valve selection) to each cell from the WBTP. 34 â&#x20AC;˘ April 2017

The HDPE pump suction line extends to 2729 m into the cell from the pond embankment and is attached with polyethylene pipe floats to allow it to float with the pond water level. At the end of the suction pipe the intake strainer drops 1 m below the surface to minimize algae concentration in the raw water. Similarly, the return pipeline extends approximately 136 m into the cell and floats on the pond surface. The HDPE pipework from the pond to the WBTP bunded area will be PN16 (>6 times more than the maximum operating pressure) and there will be no flanged

connections or air release connections in order to mitigate risks of leakage to the environment. Site Facility The WBTP site (refer to Figure 1) will be located on a new earthworks pad and the treatment process areas will be fully bunded to contain any spillage or leakage of PFW, brine or chemicals and allow controlled discharge of rain water. The bunding is achieved with geosynthetic clay liners on top of compacted sandy clay and is at 800 mm height at the top level of the Chemical Engineering World

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CEW Features 400,000 cells/mL of algae at reasonable membrane fluxes. Arkal disc filters were selected to be coarse filtration for the MF as they had also had a track record. Pretreatment design was finalized to incorporate two trains of 100 µm disc filters operating at lower velocities (with ability to reduce the velocity by 25 per cent by installing more pods) followed by MF operating at <40 L/m 2 /h flux.

Figure 1: WBTP Layout

bund. The bund surface will have a rubble finish. The chemical storage and loading area on the southern side of the bund will be sealed with 40 mm asphalt surfacing with heavy duty binder. Gradient within the bund is towards closed sumps so that any overland flow, including rain water, can be tested and confirmed to be harmless before release. Water storage tanks within the bund will be heavy duty polyethylene tanks with multiple modes of tank level detection to minimize the risk of overflow. These include tank level transmitter with high level shutdown interlock, high level switch in the tank and a high level switch in a sealed (from rain) drum where the tank overflow is directed into. The majority of equipment is containerized, which will minimize on site construction. All containers will have drip drains where all drain and sample lines are directed into. The drip drains will be piped to sumps to prevent uncontrolled spillage into the bund. Other major infrastructure outside of the bund includes generators and a treated water storage tank that is a 5,000 kL bolted modular panel tank with plastic liner. Power generation is an important part of WBTP as power is a major part of the operating costs. It has been designed with three generators. The 1400 kW generator is a containerized reciprocating gas engine that supplies all the necessary 36 • April 2017

power with spare capacity. It uses fuel gas from Santos’ CSG operations to significantly reduce the operating costs of the WBTP. The 656 kW and 240 kW diesel generators are backup generators. Water Treatment Osmoflo’s extensive experience of membrane filtration and RO treatment of CSG produced water was a key to ensuring robust and flexible treatment design with high level of automation. The high algae counts in the pond water ensure the need for a robust pretreatment process and could be compared to the issues of dealing with algal blooms in seawater RO desalination. Laboratory analyses showed that the algae are of small particle size mostly <150 µm. The legacy brine had the highest counts (up to 8.8 million cells/ mL), the PFW in the pond has high counts (mostly <1 million cells/mL) and the PFW water in the pipeline feeding the ponds had the lowest counts (<20,000 cells/mL). Osmoflo wanted to keep the treatment processes simple including pretreatment and decided to reduce the algae counts of the feedwater by blending the sources of available water. This facilitated selection of membrane filtration as pretreatment without the need for more extensive pretreatment such as dissolved air flotation. Pall microfiltration (MF) equipment was selected as it had a track record in treating similar produced water and that it could treat up to

The high algae counts with the high organic levels combined with the fact that CSG produced water tended to have high biofouling potential meant the pretreatment design needed to include for disinfection. A provision for shock dosing of three different biocides has been included to mitigate biological fouling in the RO process. These include isothiazolinone, Kuriverter IK-110 (Kurita Industries) and DBNPA (2,2-dibromo3-nitrilopropionamide) and ensures that the ‘bugs’ do not become tolerant to one particular biocide. In addition, manual shock chlorination of the pond transfer pipelines to disinfection these pipeline has been provisioned. The feedwater blending also has the benefit of reducing the TDS variation between the PFW and legacy brine. The RO system, called Primary RO (PRO) is designed as a two stage concentrator with interstage booster to allow flexibility in treating the variable feed water TDS and temperature and ensure the highest recovery possible while distributing the membrane flux properly to minimize fouling. The PRO recovery will vary between 55 and 70 per cent for the blended feed water. The PRO system consists of two trains for some level of redundancy similar to the pretreatment. Treated water from the PRO (called PRO permeate), blended with the permeate from a polishing brackish water RO (BWRO) system that desalinates the Brine Squeezer permeate is dosed with calcium chloride. The calcium chloride Chemical Engineering World

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CEW Features

Figure 2: Schematic of the Brine Squeezer Process

increases the calcium in the blended permeate and ensures the sodium adsorption ratio (SAR) or sodicity is <5 and suitable for irrigation. Brine Treatment It is expected that the PRO will produce a brine TDS of 70,000 mg/L while contractual obligations require >90,000 mg/L for the final brine TDS. One of Osmoflo’s key strength in securing this contract was the use of the in-house developed and patented Brine Squeezer process to reduce the RO brine reject volumes cost effectively. It has been demonstrated in two applications to increase the overall plant recovery 9295 per cent from 70-75 per cent resulting in only 5-8 per cent brine to dispose of. The Brine Squeezer (OBS) process incorporates many existing and available equipment and learned techniques to manage and mitigate fouling and scaling of increasingly concentrated brine streams - with some innovative features and techniques including: • • •

Use of unique combination of membrane properties Use of sacrificial coating (when required) to manage fouling and scaling Use of innovative cleaning strategies to effectively clean foulants/scales.

40 • April 2017

Other simple features to manage fouling and scaling include operation at high crossflows, low fluxes and higher ionic strength. The OBS is expected to produce a brine concentrate 100,000-120,000 mg/L and in blending with the small amount of PFW or legacy brine remaining in the ponds the final brine TDS of >90,000 mg/L is able to be achieved. The higher final brine TDS allows for more costeffective further concentration and salt recovery as part of the CSG industry’s vision for beneficial reuse of salts and solids disposal offsite. The OBS system has the highest level of automation, intelligently adjusts operating parameters for the higher fouling and scaling conditions and automatically cleans the membrane. Frequent CIPs are expected and the membranes are used as a semi-consumable as they are operating outside the normal boundary of RO. The innovative hot water CIP technique on the OBS will easily remove biofouling, organic fouling and some of the scaling. The unique sacrificial coating will only be used to enhance scale removal and reduce CIP chemicals.

Solids Dewatering DAF and centrifuge were selected for solids dewatering due to proven tracking records in algae laden water and flexibility in handling variations in flows and solids concentration. The jar testing correlated that the use of filtered feedwater (same ionic species as the PFW or legacy brine) for backwashing the MF (which forms the majority of the solids to be dewatered) will cost >$200,000 per month in chemicals in the dewatering process. This was costly and a more cost-effective design of using the permeate from the OBS for MF backwashing was developed. The significant lower TDS and alkalinity of the OBS permeate are expected to significant reduce the chemical consumption from extensive field experience. The DAF design incorporates a conservative detention time of approximately 30 mins for coagulation to ensure adequate reaction time since experience indicated algae are one of the more difficult types of solids to coagulate. The hydraulic loading of the whole DAF has been sized conservatively so that there is a 40 per cent contingency over the normal feed flow. The centrifuge has also been sized conservatively to treat the DAF sludge under 16 hours and incorporates an automatic greasing which will reduce maintenance frequency and effort. It is designed to produce a sludge cake of 18-20 per cent dry solids that is suitable for disposal off site via trucking.

Author’s Details Hiep Le Technical Services Manager Osmoflo E-mail: hiep.le@osmoflo.com www.osmoflo.com Chemical Engineering World

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CEW Features CASE STUDY

WSSC Achieves Over 60% Reduction in Hydraulic Plan Review for Water and Wastewater Systems Helped complete hydraulic plan analyses more efficiently than WSSC’s in-house system Hydraulic Plan Review Scope Washington Suburban Sanitary Commission (WSSC) Development Services Group reviews hydraulic plans for approximately 160 proposed development plans per year. This includes water and sewer system extensions as well as approximately 172 small-site utility plans (commercial private systems) that connect to the existing water and sewer network in two large Maryland counties. Each system extension is hydraulically reviewed and mains are properly sized by WSSC hydraulic engineers during the hydraulic plan analysis (HPA) process. In this process, engineers use hydraulic-grade benchmarks developed by the planning group within the existing system to analyze the proposed extensions and connections.

These benchmarks are developed using system-wide modeling while considering the severest conditions in the system. The WSSC hydraulic engineers determine the appropriate sizes for the proposed mains while considering various scenarios that focus on the system integrity and future needs to provide adequate fire flow and pressure to new developments. When the creation of a new pressure zone is sometimes required to serve a new development, the hydraulic reviewer interacts with the planning group that models the system-wide network to help with zone creations. The project’s overall goal was to increase customer service levels by implementing a workflow process improvement. To meet

this goal the Development Services Group implemented Bentley’s WaterGEMS and SewerGEMS to increase the turnaround time on reviews and keep pace with one of the most rapidly developing areas in the United States. The reviews were critical to the success of the projects as they serve as the primary planning mechanism for growth. Increased Review Efficiency Prior to using WaterGEMS and SewerGEMS the Development Services Group completed the hydraulic plan analyses with small-scale software developed in-hozuse that was less advanced and less user-friendly. Using WaterGEMS and SewerGEMS, as well as group restructuring, the Development Services Group increased review efficiency through a standardized model between projects, improved quality assurance of

Figure 1: Plan review workflow improvement charts 42 • April 2017

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CEW Features and potential outages, and address them earlier during the review process. WSSC is implementing a new looping policy that should increase customer service and decrease operational costs, especially in areas that must be frequently taken out of service to complete pipeline inspections.

Figure 2: WaterGEMS model with various fire flow scenarios

reviews, and reduced review cycle times from an average of 73 days to 27 days for moderately complex projects over eight years, despite a two-fold increase in reviews. The following examples illustrate review time improvements: • WaterGEMS and SewerGEMS’ scenario and alternative capabilities allows organized and systematic modeling, so that other reviewers are able to use the model from where the original reviewer left off. And because model scenarios are created for each development phase of a project phase, each project can be reviewed for hydraulic integrity and adequacy easier and faster. This means that the developers who choose to move forward with a partial release of project phases can receive a quicker response from WSSC. • Environmental issues can also cause development engineers to re-consider alignments midway through the design process. Because hydraulic engineers have developed consistent models for each proposed development and system extension, the amendments to original alignments can be rapidly adjusted and re-analyzed. This means development engineers can make changes based on environmental issues more quickly and with less review time. 44 • April 2017

•

The Development Services Group can also be more responsive to system inspection changes during the construction process as they have access to the completed models.

On a larger scale, the increased review efficiency is improving customer service and the overall delivery speed of an estimated 160 annual development projects from planning and design phases to constructionready status. And because construction began sooner, revenues (through permit fees or new billing accounts) were collected sooner. Reduced Project Deliver y and Operation Costs WaterGEMS reduced the time needed to accurately size pipes to meet WSSC’s system constraints and standards. This resulted in faster communication and turnaround to consultants and developers. As WSSC can process development reviews more quickly, the organization can expedite its revenue collection by allowing more customers to connect to the system sooner.

Safer Water and Sewer Infrastructure Adequate fire flow is essential for safety. The fire flow capability in WaterGEMS enabled reviewers to perform fire flow analysis for numerous locations throughout a large or small network used for a project in a single run. Reviewers could model multiple scenarios under various system outage conditions, including routine inspections of large diameter pre-stressed concrete cylinder pipe (PCCP) mains, to optioneer the best solution that allows adequate fire protection. Using SewerGEMS also enabled WSSC to analyze system issues in wastewater infrastructure during the development process. This resulted in a better quality hydraulic design and ultimately protected the environment from future sanitary sewer overflows in new development areas. Information Mobility Increased Collaboration Workflows have been developed to help streamline collaboration between engineering, GIS, and consultants. For instance, simple GIS capabilities and the Model Builder functionality in WaterGEMS and SewerGEMS allowed reviewers to incorporate proposed pipelines within a development with existing pipelines in WSSC GIS container. WSSC improved workflow efficiency with more than an estimated 60 per cent reduction in review cycle times for hydraulic analyses of development and system extensions.

Author’s Details The use of WaterGEMS and SewerGEMS has also enabled the Development Services Group to spend less time modeling and analyzing a larger network of the system, identify problem areas

Perrine Parrod Sr Product Mktg Manager - Hydraulics and Hydrology bentley Systems E-mail:-Perrine. Parrod@bentley.com Chemical Engineering World

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CEW Features

Zero Liquid Discharge Solutions

ero liquid discharge is a concept that indicates no liquid effluent discharged from the process plant in surface waters which in effect completely eliminates the environmental pollution. I n o t h e r wo r d s, i t c a n b e t e r m e d a s conversion of the solute, ie, dissolved organic and inorganic salts or compounds i n t o s o l i d fo r m by m e a n s o f t h e r m a l evaporation and concentration. Apar t

from this, it also makes effective use of wastewater treatment, recycle and reuse concept thereby effectively contributing to water conservation through reduced intake of fresh water. This article discusses the challenges of zero discharge in variety of process plants and integrated wastewater t r e a t m e n t s o l u t i o n p r o v i d e d by P r a j Industries for one of the multinational chemical Industry.

Zero Liquid Discharge Technologies offered by Praj Praj has been dealing with complex effluent treatment and addressing the issue with the help of evaporation and concentration technologies. Being strong thermal base Praj offers various types of evaporators. Selection of type of evaporator depends on composition of the effluent.

Typical comparison of the various types of Evaporators: Offerings

Features/Applications • •

ECOVAP-FF (Falling Film)

• • • ECOPVAP – SF (Special • Falling Film) •

• •

ECOVAP – FC (Forced Circulation)

Thermo Vapour Recompression (TVR)

Mechanical Vapour Recompression (MVR)

ECODRY - TF (Agitated Thin Dryer)

46 • April 2017

Limitations

• Suitable for effluents with low TDS and TSS Higher heat transfer coefficient; hence lower • areas • Evaporation happens in tube Less power consumption

Relatively higher scaling tendency Unsuitable for high viscous liquids, high silica, hardness and TDS Wetting is affected due to scaling

All advantages of conventional falling film • evaporators • Adequate wetting rate is maintained by using specially designed spraying nozzle Less prone to fouling as compared with conventional falling film evaporator.

Reduced scaling tendency Unsuitable for higher viscous liquids, high silica, hardness and TDS

•

Higher recirculation flow rates, hence higher opex Lower heat transfer coefficient (HTC) as compared to falling film leading to higher heat transfer areas

• •

Suitable for effluents with high TDS & TSS Evaporation happens in vapour liquid separator (VLS) Suitable for high viscous liquid Relatively lower CIP frequency

• • • • •

Work on principle of steam jet ejector • Uses vapours from first or second effect Increase in steam economy – acts as additional effect • Works better on high pressure steam Lower maintenance as compared to MVR

Steam condensate gets contaminated with process vapours Require relatively longer time for plant stabilization

• •

• Driven by electrical energy Feasible when steam cost is higher and power • cost is lower Only startup steam is required for stabilization Once stabilized, vapours are recompressed and used for heating •

Makeup steam may be required to overcome heat losses Any vapour carryovers can be an issue with MVR, hence mist eliminators are mandatory and adequate H/D ratio of VLS to be maintained. Rotating equipment hence requires higher maintenance as compared to TVR

Zero clearance hinged scrapping blades • Heat recovery to reduce steam consumption Suitable to achieve zero liquid discharge (dry powder output)

Energy intensive operations

• •

• Film • •

•

Chemical Engineering World

Features CEW of specialty polymers and surfactants. To execute the effluent treatment plant for its manufactur ing complex, client awarded design, engineer ing, supply, erection and commissioning of 80 KLD effluent treatment plant for highly complex effluent with (Mechanical Vapour Recompression) MVR-based Evaporation Plant with pusher centrifuge to Praj. After successful installation and commissioning of evaporation plant client was able to produce Na 2 SO 4 salt at the outlet of centrifuge. Project Requirement Client was looking for reliable end-to-end solution provider including biological and thermal solutions to treat its complex, challenging and high TDS effluent. *Note: This comparison is based on Praj’s experience with highly complex effluents from various industries. Typical challenges of zero liquid discharge systems for chemical industry The above challenges can be handled by: ••

••

Innovative and customized solution offerings To reduce scaling tendencies, selection of appropriate pretreatment, operate evaporation system at low temperature To reduce capital investment, use various combination of evaporators Recover steam and process condensate for reuse and recycle Continuous operation of the system – minimization of CIP effluents

••

Use technologies like TVR or MVR for reducing the operating cost.

Project Details for Chemical Process Industry in India Praj recently executed turnkey project including conceptualization, design, engineering, manufacturing, construction and commissioning of effluent treatment plant, biological and MVR-based evaporator system for one of the leading chemical manufactur ing company having its manufacturing locations across globe. The group has business interest in area

Pilot Trials Praj carried out analysis and evaporation pilot trials at Praj Matrix – Research & Development Centre to get first-hand experience on effluent. Highlights of ETP and ZLD plant supplied by Praj •

Anaerobic System A s t h e e f f l u e n t f r o m s u r fa c t a n t manufacturing contains active anionic contents (AAC), the aerobic system would result in heavy foaming in the effluent. Hence, anaerobic system is an appropriate solution to destruct the AAC and then the remaining BOD can be reduced using aerobic system. The system is specially designed with fixed media in the reactor and higher retention of the reactor.

•

Condensate & MEE Bottom product Chemical Engineering World

Mother Liquor Salt from Centrifuge

Aerobic System Aerobic system post anaerobic and anoxic systems is provided to further reduction of BOD. As COD:BOD ratio was on high, aerobic tank was designed with high retention. April 2017 47

CEW Features Typical schematic for the treatment of effluent from chemical industry

•

“ECOVAP” Evaporation Plant Praj provided their unique evaporation technology called ECOVAP to concentrate high TDS effluent coming from the process. This is proven technology for treating complex effluents across the world. Praj recommended to go for MVR-based evaporator due to saving in energy and resulting into reduced opex.

••

Typical ETP Plant Operating Parameters ETP Parameters ETP Parameters SN

Particulars

Inlet

Outlet

Unit

Flow

m 3/day

TSS

291

≤100

mg/lit

BOD

1574

≤30

mg/lit

COD

4672

≤ 250

mg/lit

6.5 to 8.5

Phosphates

≤5

mg/lit

NH4+N

≤ 50

mg/lit

Praj has successfully installed and commissioned plants based on ECOVAP technology in various industries such as textile, chemicals and fertilizers, pharmaceuticals and food and beverages, etc.

Advantage Praj •• Turnkey solution under one roof - design, engineering, manufacturing, supply, installation and commissioning for effluent treatment, biological treatment and evaporation systems. •• Customized design, solution backed by piloting at R&D which ensures minimization of performance risk. Result of Commissioning of the Plant: •• For this project, Praj has successfully designed, manufactured and installed and commissioned integrated biological effluent treatment for difficult to treat effluent and evaporation plant followed by pusher centrifuge.

Typical Evaporation Plant Design Parameters Evaporation Plant Parameters SN

Particulars

Design Parameters

Unit

m 3/day

TDS

100000

mg/lit

TSS

1000

mg/lit

BOD

<500

mg/lit

COD

<1800

mg/lit

Phosphates

≤5

mg/lit

NH4+N

≤ 50

mg/lit

48 • April 2017

Contact Details: Praj Industries Ltd Environmental Engg Division Praj Tower, 274 & 275/2 Bhumkar Chowk-Hinjewadi Road Hinjewadi, Pune, Maharashtra 411 057 Tel: 020-71802000 E-mail: info@praj.net Chemical Engineering World

Features CEW Technical Article

Explosion Hazard and Safety in Industries Handling Metal and Alloy Powders Some of the metal and alloy powders handled in industries manufacturing and using these are combustible and have inherent explosion hazard. This article presents explosion parameters – minimum explosible concentration, maximum explosion pressure, deflagration index, minimum ignition energy and minimum ignition temperatureof 25 materials- aluminium paint ground, aluminium-grit, aluminium-iron alloy (50:50), aluminium-nickel alloy, bronze, calcium-aluminium alloy (50:50), calcium-silicon alloy (50:50), calcium-silicon-aluminium alloy (30:50:20), calcium-silicon-barium alloy (30:50:20), copper-silicon alloy, ferrosilicon, ferrochromium, ferromanganese, iron, iron-silicon-magnesium alloy, magnesium-silicon alloy (60:40), neodymium-iron-boron alloy, nickel-aluminium alloy, silicon, steel(100 Cr6), tantalum, tantalum-niobium alloy, titanium, titanium-niobium alloy and zinc - measured with CSIR-CBRI 20-L sphere, Hartmann apparatus and Godbert-Greenwald furnace for a range of particle sizes (74,37,22 and 10µm). The data may be used for evaluating explosion hazard involved in their manufacture, transport, storage and use and designing explosion safety measures.

he powder metallurgy industry has grown over the past few years due to economic gain in manufacturing net-shaped components in comparison to conventional metal working methods like casting. Many of the metal and alloy powders processed in these industries are combustible and pose explosion hazard in various powder metallurgy related activities and other metal working operations eg. material charging, grinding, sieving, milling, dust collection, casting, pneumatic transport, machining, welding, etc. Dust explosion may occur in these units/areas due to simultaneous presence of explosive dustair mixture and potential ignition source viz. electrical or mechanical spark, static electricity discharges, hot surfaces, etc. It takes only microseconds for a violent explosion to occur in a confined space. Subsequent rise in explosion pressure can have devastating consequences. The explosion parameters for identifying probability and severity of dust explosion and designing explosion safety measures are: minimum explosible concentration (MEC), maximum explosion pressure (P max), rate of rise of explosion pressure Chemical Engineering World

((dP/dt) max), deflagration index (K St), minimum ignition temperature (MIT) and minimum ignition energy (MIE). The explosion characteristics of number of dusts handled in industries are available for some particle sizes (Eckhoff, 1991; BIA,1997). However, there is always a need of measurement of explosion characteristics of dusts with specific sizes. The present work reports the explosion characteristics of various metal and alloy dusts for a range of particle sizes measured at CSIR-CBRI. The information and data from this study add to the current literature on explosion characteristics of dusts processed in metal industries and will be used to evaluate explosion hazard of units/areas handling similar dusts and designing the explosion safety measures. Experimental Procedures The explosion characteristics were determined for 25 dusts- aluminium-paint ground, aluminium- grit, aluminium-iron alloy (50:50), aluminium-nickel alloy, bronze, calcium-aluminium alloy (50:50), calcium-silicon alloy (50:50), calciumsilicon-aluminium alloy (30:50:20), calcium-silicon-barium alloy(30:50:20), copper-silicon alloy, ferrosilicon,

ferrochromium, ferromanganese, iron, iron-silicon-magnesium alloy, magnesium-silicon alloy (60:40), neodymium-iron-boron alloy, nickelaluminium alloy, silicon, steel(100 Cr6), tantalum, tantalum-niobium alloy, titanium, titanium-niobium alloy and zinc. The particle sizes of dusts selected for study are: 74, 37, 22 and 10 µm. Samples for particle sizes 74 and 37µm were prepared using traditional sieve analysis. Other samples were collected from manufacturers. Some dusts were investigated for all the particle sizes chosen while others for limited sizes. Explosion indices- MEC, P max and (dP/ dt) max were measured in 20-L Sphere (Mittal, 2012) consisting in a spherical combustion chamber, a dust storage container connected with chamber via a dust outlet valve, a pair of electrodes holding two pyrotechnic ignitors at sphere centre, and two piezoelectric and one strain gauge pressure sensors to record explosion development. Typical pressure-time curve recorded during dust explosion experiments is shown in Figure 1. Pressure trace starts at partially evacuated value of 0.4 bar(a). The blast April 2017 • 49

CEW Features

Figure 1: Typical pressure-verses-time trace during a dust explosion experiment in 20-L Sperical Vessel

of air that disperses dust starts at 40 ms and ends at 90 ms on pressure-time trace. Ignitor is activated at 100 ms at a chamber pressure of 1.0 bar(a). P ex is the maximum explosion pressure. Value of P ex, for a test at a given concentration, is highest deflagration pressure (absolute) minus pressure at ignition (normally 1 bar). (dP/dt) ex is maximum rate of pressure rise reached during the course of explosion. MEC, the lowest concentration of dust in air that ignites on contact with an ignition source and propagates a dust explosion, is determined following the standard procedure (ASTM, 2007a) using chemical ignitor (2.5kJ energy). The test commences with experiments at a high powder concentration. If this concentration of powder ignites, dust concentration is reduced in steps until no ignition is evident. An ignition is deemed to have occurred if maximum explosion pressure is at or above 2 bar(a). The test is then repeated with a lower dust concentration which is reduced further until a concentration is reached at which no ignition of dust/air mixture is observed in three consecutive tests. Explosion severity measurement experiments are conducted over a range 50 â&#x20AC;˘ April 2017

of dust concentration in accordance with standard procedure (ASTM, 2010). Pyrotechnic ignitors (10kJ energy) are used. P max is maximum pressure and (dP/dt) max is maximum value for rate of pressure increase per unit time reached during the course of explosion for optimum dust concentration and equals maximum slope of a tangent through the point of inflexion in rising portion of pressure vs. time curve. Deflagration constant, K St, characterizing explosibility of the material is maximum value of dP/dt normalized to 1.0 m 3 volume measured at optimum dust concentration and defined by equation 1 (Eckhoff, 1991):

where, P - Pressure, bar T - Time, s Vs - Vessel volume, m 3 KSt- Dust deflagration index, bar.m/ s K St values rounded to nearest integer are used. Dusts are given explosion severity classifications St1 (K St<200 bar.m/s), St2 (200 bar.m/s >K St <300 bar.m/s) and St3(K St>300 bar.m/s). MIE, used to represent the ease or difficulty of powder ignition by electrical sparks

and arcs or electrostatic discharge was measured in 1.2-L Hartmann apparatus as per standard procedure (Mittal, 1996; ASTM, 2007b). The apparatus consists of a glass tube placed over a dispersion cup and fitted with two brass electrodes (3 mm diameter, 2-6 mm spacing) connected to a spark generating system having three units: variable capacitor bank; variable voltage supply/ continuous spark unit; and step-up transformer. With variable combination of capacitance and voltage, it is possible to obtain sparks with ignition energies in the range 0.5 mJ â&#x20AC;&#x201C; 3.2 J using this circuit. There is precise electronic synchronization between dust dispersion and spark onset. The ignition delay times can be selected between 20 to 200 ms with an increment of 20 ms. Energy discharged from the capacitor is calculated from the following formula (2)

Where, W - Discharge energy, J C - Total capacitance of discharge circuit, F V i - Initial voltage of charged capacitor, V V f - Final voltage of charged capacitor, V To establish MIEs, the tests are done by starting at relatively high spark energy levels using relatively large discharge capacitance which is reduced in steps until no ignition occurs for ten ignition trials. A weighed sample of dust is placed in dispersion cup. A blast of compressed air is used to disperse the dust in the glass cylinder where it is ignited by spark between two electrodes. Ignition trials of this dust-air mixture are attempted, after a specific ignition delay time, by spark discharge from the charged capacitor. The stored energy discharged into the spark and occurrence or non-occurrence of flame is recorded by visual observation of flame propagation away from the spark gap. If flame propagation is observed, the energy of the spark is reduced until no flame propagation is seen for Chemical Engineering World

Features CEW ten consecutive tests. The minimum ignition energy is sought by varying dust concentration, spark discharge energy and ignition delay time. Experiment is started with a dust loading corresponding to dust concentration twice as high as the experimentally determined MEC or 250-500 g/m 3 and â&#x20AC;&#x2DC;go/no-goâ&#x20AC;&#x2122; spark energy is estimated. Once a limit is found for a particular dust concentration, the procedure is repeated for higher and lower dust concentrations until a roughly parabolic curve is obtained for ignition energy verses dust concentration. MIE is determined from the MIE vs. concentration curve.

Figure 2: Maximum explosion pressure for metal and alloy dusts

MIT, lowest temperature of a hot surface that will cause a dust cloud to ignite and propagate flame, determines temperature classes of electrical equipment. GodbertGreenwald furnace (heated section: 3.9 cm diameter, 23 cm long, 0.27 l volume) was used to measure MIT as per standard procedure (Mittal, 1996; ASTM, 2006). The initial tests are carried out at dust concentrations at which the maximum pressure, P max, and the maximum normalized rate of pressure-rise, K St, are found. The dust is placed in a dust holder at the top of temperature controlled furnace with an open bottom. Temperature of the furnace is set at a predetermined value. The dust is dispersed by the compressed air downwards past the hot surface of furnace to see if ignition occurs and flame is produced. Ignition is defined as the flame exiting from furnace chamber. Furnace temperatures, as well as dust concentrations are varied to ensure that auto ignition temperature is measured at most easily ignitable concentration. Results & Discussions The MEC values measured for the dusts ranged from 20 to 400 g/m 3. These are given in Table 1 and can be used for evaluation of probability of explosion in a stated dust-air environment.

Figure 3: Deflagration index for metal and alloy dusts Chemical Engineering World

Explosion severity measurement experiments were conducted for dust concentration range 30-2000 g/m 3 for April 2017 â&#x20AC;˘ 51

CEW Features all sizes of dusts. Pressure-time curves were recorded. Experimental curves were analysed and values of P ex, (dP/dt) ex and K St(=dP/dt)ex.V 1/3 were estimated for each experiment. The values of P max and K St corresponding to optimum dust concentration were determined for each particle size. The Pmax and KSt values at optimum dust concentration for dust particle sizes studied are presented in Figure 2 & 3. These figures indicate that P max and K st both increase significantly with decreasing size of dust particles from 74 to 10µm. Explosion severity experiments examine consequences of dust explosion. Maximum explosion pressure (P max) and pressure-rise rate, (dP/dt) max, describe violence of combustion of dust-air mixture in a closed vessel. The dust deflagration index is used to describe the severity of explosion increasing from dust explosion class St1 to St3. Figure 3. shows maximum explosion pressure for the dusts varies from 6.4 to 12.8 bar. The deflagration index values presented in Table 1 indicate explosion class of dusts as: St1- aluminium grit (74 µm), aluminium-iron alloy (37 µm), bronze (10-22 µm), calcium-silicon-aluminium alloy (37-74 µm), calcium-silicon-barium alloy (10-74 µm), copper-silicon (1074 µm), ferrosilicon, ferrochromium & ferromanganese(10-22 µm), iron (10-37 µm), iron-silicon-magnesium (10-22 µm), neodymium-iron-boron alloy(22-74 µm), nickel-aluminium alloy (37 µm), silicon (10-22 µm), steel (2237 µm), tantalum (10 µm), tantalumniobium(10-22 µm), titanium(22-74 µm), titanium-neobium (10-22 µm) and zinc (10-37 µm); St2 - aluminium-iron alloy (10-22 µm), aluminium-nickel alloy (22 µm), calcium-aluminium alloy (37 µm), calcium-silicon alloy (22-74 µm), calcium-silicon-aluminium alloy (10-22 µm), magnesium-silicon alloy (22-74 µm) and nickel-aluminium alloy (10-22 µm); and St3- aluminium paint (37-74 µm), aluminium grit (10-37 µm), aluminiumnickel alloy (10 µm) and calciumaluminium alloy (10-22 µm). Out of 25 52 • April 2017

dusts examined, 16 are St1; 2 are St2; 1 is St3; and 3 are St1 & St2, 1 is St1 & St3, 2 are St2 & St3 depending on particle size. MIEs were determined for 12 dusts for their various particle sizes over a range of dust concentration following the procedure explained above. Experimental results on MIE measurement are presented in Table 1. The minimum value of MIE was <1 mJ for 22µm titanium. The experimental data indicate that ignition sensitivity increases (MIE decreases) when moving from higher size to lower micron-particle dust clouds. The MIT is an indication of the sensitivity of a dust cloud to auotoignite at elevated temperatures. The MIT for each particle size of dust was determined in GodbertGreenwald furnace starting with dust concentrations at which the maximum pressure P max, and the maximum normalized rate of pressure-rise, K St, were found as per standard procedure. Experimental results are presented in Table 1. MIT decreases with decreasing particle size, increasing the probability of explosions with small-sized particles over larger particles. The MIT for the dusts tested ranged from 270 to 950 oC. The experimental values of MEC, Pmax, KSt, MIE and MIT for the dusts studied in present investigation are in close agreement to that published for dusts having sizes closer to that involved in present study (Eckhoff, 1991; BIA,1997). Explosion Safety Measures- Overview Control of explosion hazard in industries manufacturing/handling metals and alloys should involve: evaluation of material processed; identification of areas/units susceptible to formation of combustible dust-air mixture; and defining parameters including the explosion characteristics of powders handled forming the basis of safety measures for various unit operations early in the project or process life cycle; and communication of hazard and control strategy to personnel involved in various plant operations and other concerned persons.

The explosion characteristics are used for designing explosion prevention - control of dust cloud concentration (equipment maintenance, local exhaust, ventilation, and housekeeping) and control of ignition source and explosion mitigation measures- explosion venting, explosion suppression, explosion isolation and containment. Every equipment has a list of safety measures depending on explosion/safety characteristics of the powders being handled. Explosion suppression system is designed to detect the pressure wave/ flame at very start of an explosion and deliver dry, inert chemical extinguishing agents into a developing initial deflagration. The suppression system can be activated either by pressure, optical or vent sensors. Any deflagration travelling through interconnected equipment is quickly and efficiently extinguished, preventing any spreading explosion damage. Venting is passive method to relieve explosion pressure in a confined unit containing combustible material. Open venting is not the popular choice in industries. Flame-quench vents may be used for venting the explosion. Mechanical isolation is a cleaner means of explosion protection. Explosion pressure is determined by use of isolation valves. When an explosion actually occurs, the pressure travels into a single or double acting valve which seals the pressure wave inside the valve and prevents it from spreading through the equipment. The safety measures are designed in accordance with standards (NFPA,2013,2014,2016, 2017b). In explosion-prone areas having probability of dust explosion outside the process units, it may be recommended to provide explosion venting or blast resistant walls as per building codes and an electrical area classification should be used as per standard (NFPA, 2017a) Chemical Engineering World

Features CEW S.No

Dust Name

Aluminium-paint ground

Aluminium- grit

Aluminium-iron alloy (50:50) Aluminiumnickel alloy Bronze

Calcium-aluminium alloy(50:50)

Calcium-silicon alloy (50:50)

Calcium-silicon-aluminium alloy (30:50: 20)

Calcium-silicon-barium alloy (30:50:20)

Copper-silicon alloy (30% Cu,10%Fe)

Particle Size, Âľm

MEC, g/m3

MIE, mJ

MIT, oC

204

850

162

800

106

750

700

300

720

820

240

750

220

730

200

102

950

700

400

540

360

580

560

520

130

690

220

670

650

640

610

Tantalum

560

140

730

120

700

680

640

290

750

260

720

220

700

180

680

Ferrosilicon

130

>850

800

530

>850

430

>850

720

700

500

650

320

590

230

540

310

680

280

640

140

720

680

650

160

330

130

300

100

250

160

1200

680

140

1000

650

120

840

640

880

860

400

Tantalum-niobium 22 alloy 10

750

720

Titanium

510

450

270

Titanium- niobium 22 alloy 10

700

Zinc

320

618

780

240

510

580

210

300

500

Ferrochromium

Ferromanganese

Iron

Iron-silicon-magnesium alloy Magnesium-silicon alloy (60:40)

Neodymium-iron-boron alloy

Nickel-aluminium alloy

Silicon

Steel(100 Cr6)

Table 1. Explosion Characteristics of Metal and AlloyDusts-CSIR-CBRI Study Chemical Engineering World

April 2017 â&#x20AC;˘ 53

CEW Features Conclusions Explosion hazards associated with metal and alloy powders influence the specifications of operating procedures, equipment, air conditioning systems, electrical area classification and room construction, etc. It is therefore necessary for metal/alloy manufacturers to understand the explosion hazard of the powders handled in their facilities and assess the level of deflagration risk. Dust explosion data specific to metals and alloys for different sizes of dusts is a powerful tool in explaining the real risk from explosions to those managing and operating these facilities. The information and data presented may be used for designing explosion safety measures for units/areas handling similar types of dusts. References • ASTM (2010). Standard test method for explosibility of dust clouds, E1226. West Conshohocken, PA: ASTM International. •

ASTM (2007a). Standard test method for minimum explosible concentration of combustible dusts, E1515. West Conshohocken, PA: ASTM International.

•

ASTM (2007b). Standard test method for minimum ignition energy of a dust cloud in air, E 2019-03. West Conshohocken, PA: ASTM International.

•

ASTM (2006). Standard test method for minimum autoignition temperature of dust clouds, E1491. West Conshohocken, PA: ASTM International.

•

BIA (1997). Combustion and explosion characteristics of dusts, Report 13/97 from BIA (Professional Association’s Occupational Safety Institute), published by HVBG (Federation of the Statutory Accident Insurance Institution of the Industrial Sector), Germany.

•

Eckhoff, R. K. (1991). Dust explosions in the process industries. Oxford: Butterworth Heinemann.

54 • April 2017

•

Mittal, M. (1996). An analysis of hazards in chemical industries, Indian Chemical Engineer, 38(2), 6980.

•

Mittal, M. (2012). Dust explosion violence measurement with 20-L Spherical Vessel, Chemical Products Finder, 31(5), 34-36.

•

9NFPA (2017a). National Electrical Code, Handbook, NFPA 70. Quincy, MA: National Fire Protection Association.

•

NFPA (2017b). Standard for the prevention of fire and dust explosions for the manufacturing, processing and handling of combustible particulate solids, NFPA 652. Quincy, MA: National Fire Protection Association.

•

NFPA (2016). Standard on the fundamentals of combustible dusts, NFPA 652. Quincy, MA: National Fire Protection Association.

•

NFPA (2014). Standard on explosion prevention systems, NFPA 69. Quincy, MA: National Fire Protection Association.

•

NFPA (2013). Standard on explosion protection by deflagration venting, NFPA 68, Quincy, MA: National Fire Protection Association.

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Author’s Details Dr.(Ms.) Manju Mittal Sr. Principal Scientist Fire Research Laboratory CSIR- Central Building Research Institute

Taj Building, 3rd Floor, 210 Dr D N Road Fort, Mumbai - 400 001 Tel: 022-4037 3636, Fax: 022-4037 3635 Email: industrialmags@jasubhai.com

Chemical Engineering World

CEW

Marketing Initiatives

New Marine Breakaway Coupling

he Mar ine2 launched by KLAW is 32 per cent shorter and 25 per cent lighter than alternative Marine Breakaway Couplings on the market and is designed to reduce stress on hoses used on offshore hose reel applications. The shorter design as shown in illustration A reduces coil disruption on the hose reel; unlike alternative designs (illustration B) that are longer and therefore increase hose stress and fatigue. The KLAW Marine Breakaway Coupling provides a safe parting point within the hose transfer system in ship-to-ship, shipto-shore and vessel to offshore platform transfers. The coupling is designed to activate in an emergency such as vessel drift in stor my conditions or pressure surge. When activated, the valves within the coupling shuts both upstream and downstream flow within the hose transfer system and allows immediate separation of the line. The KLAW Marine2 therefore minimises risk of spill and reduces the risk of

Illustration A demonstrates the advantage of the short Marine2 KLAW Marine Breakaway Coupling where less space is shown between the coupling and connectors and the inner hoses. Chemical Engineering World

damage to assets, injury to personnel, extended downtime and contamination of the environment. Like its KLAW predecessor, the Marine2 is designed to resist those bending moments and torsional forces expected f r o m f l o a t i n g wave m o t i o n s a n d t h e rigours of the marine environment and reacts only to those axial forces that occur in an emergency. The KLAW Marine2 also continues to use the proven and reliable KLAW Flip-Flap Valve system which delivers 100 per cent instant closure. KLAW Easy Reset Facility is also fitted as standard on the Marine2 which means the coupling can be serviced or reset after activation within the line – again reducing downtime and stress on the hose due to the reduced need for additional handling.

Marine2, the new KLAW Marine Breakaway Coupling, is 32% shorter and 25% lighter than alternatives and has been designed to reduce stress on reeled hoses.

15,000 KLAW units in reliable operation around the world. The KLAW Mar ine2 comes in standard n o m i n a l b o r e s i ze s o f 2 ” , 3 ” , 4 ” , 5 ” and 6” and is compatible with soft walled, hard walled and composite hoses. A var iety of end-connections are available including NPT and BSP threaded, flange connections and hammer union fittings.

T h e d e s i g n o f t h e K L AW M a r i n e 2 Breakaway Coupling is based on 18 years of successful field performance and over

Illustration B shows the disadvantage of alternatives: the longer coupling results in greater spacing between hoses and inner hoses. With additional hose winding over this coupling section, the additional weight again increases the stress on the hose and therefore an increased risk of fatigue.

Contact Details: KLAW Products Ltd Commerce Business Centre West Wilts Trading Estate Westbury Wiltshire BA13 4LS, U.K. Tel: +44(0)1373 827100 Fax: +44(0)1373 858877 E-mail: info@klawproducts.com info@klawproducts.com Website: www.klawproducts.com April 2017 55

CEW

Marketing Initiatives

Reverse Osmosis and Ion Exchange – Unique Process Steps to Minimize the Liquid Discharge

he application of water treatment technologies to achieve minimal liquid discharge (MLD) or zero liquid discharge (ZLD) is increasingly under consideration in today’s water stressed world. MLD and ZLD are processes that minimize or eliminate the discharge of water or liquids from a plant process. The reasons to implement these processes can be;

compounds. Another technology that can be used is ion exchange treatment (IX). This technology should be applied if a selective separation is preferred, eg, to remove specifically some ionic contaminants from the process water or to recover valuable ionic or non-ionic substances selectively. This separation can be achieved using a special IX product called scavenger, selective resin or adsorber resin.

Regulatory Cost saving from water recycling, and reduction of water discharge costs Environmental - Increase sustainability of industrial sites in water stressed regions

When interception technology is not possible, the client should consider an end-of-pipe treatment solution. In this case, the plant wastewater is collected and treated depending on the type of c o n t a m i n a n t s by e i t h e r m e c h a n i c a l , biological, or filtration steps to produce a water quality that can be reused in an upstream plant process.

•• ••

••

T h e r e a r e t wo t r e a t m e n t o p t i o n s fo r process water: internal recycling and the end-of-pipe treatment. The internal recycling is conducted inside the plant processes, and implemented by analyzing the water composition and the water quantity to make a so-called “pinch point” analysis. In this analysis, the water quality and water quantity are determined for a specific production step, and a decision is made as to whether it is possible to use the wastewater from a certain production step as the water supply for a separate production step. If usage is not possible, an interception technology may be used to get the water quality to the level suitable so that it can be reused. A typical technology for this is membrane technology. Depending on the type of contaminants, it can be microfiltration (MF) to remove bacterial substances, ultrafiltration (UF) to remove particulate a n d h i g h m o l e cu la r we ig h t o rg a n ics, nano-filtration (NF) to remove divalent salts and organics, or reverse osmosis (RO) to remove salts and small organic 56 • April 2017

In MLD/ZLD processes, it is common that both interception and end-of-pipe treatment options can be applied for overall wa t er management. Whic h treatment process is adopted usually depends on the size of the plant, and whether the treatment process is added to an existing plant. If an MLD/ZLD process implemented to an existing plant, in most cases an endof-pipe treatment is preferred since less new piping, and less interference with the existing process is required. In the following industrial examples, two MLD (minimal liquid discharge) processes, which were implemented in existing plants in India, are presented. These examples represent two different industries: the textile and the chemicals industry. Chemical Industry This zero liquid discharge wastewater treatment plant is located inside the wa t e r t r e a t m e n t fa c i l i t y s e c t i o n o f a

m a j o r s p e c i a l t y c h e m i c a l s p r o d u c e r. The wastewater plant processes treated s ewage water v ia UF ( u ltra filtra tio n ) pretreatment, cartridge filtration, and RO membrane desalination. The desalinated water is further treated by degasification, and ion exchange mixed bed columns installed with Lewatit MonoPlusS108H and MonoPlusM800 to prepare boiler feed water. The RO installation is a two-stage system with a capacity of 38 m 3/h. The feed water to the RO has a TDS in the range of 600–1,300 mg/l. The permeate has a TDS below 20 mg/l, and after mix bed application, a final boiler feed water quality of < 0.1 mg/l TDS and 0.02 mg/l silica. The concentrate is fur ther treated by high pressure RO. The permeate of this concentrate RO is reused in the process, and finally the brine concentrate is treated via an evaporation step to achieve the zero liquid discharge operation. Table 1: Wastewater treatment in the chemical industry

Industry

Chemical industry

Application

Wastewater treatment

Location

India

Product

Lewabrane RO B400 HR and Lewatit MonoPlusS108 +MonoPlus M800

Volume

48 pieces Lewabrane and 2,000l M+ S108 + 4,000l M+ M800

Production 38 m 3/hr capacity Water type

High salinity and organic loaded wastewater

Installation

November 2013

Chemical Engineering World

CEW

Marketing Initiatives The aim of this MLD process was to reuse the process water and recover y of the salt to •• Save feed water costs •• Realize cost savings by recovery of the •• Produce less waste T h e k e y t e c h n o l o g i e s t o a c h i ev e a water quality, which could be reused in the process, were the application of a scavenger resin, a softening resin process, and a reverse osmosis process.

Membrane Performance The water treatment installation was o r i g i n a l l y d e s i g n e d a r o u n d “ u l t ra l ow energy” seawater RO elements. However, after three years, these elements were replaced with Lewabrane RO B400 HR elements since a performance projection ( p r e p a r e d w i t h t h e L ewa P l u s d e s i g n software) showed that the required permeate quality could be achieved with standard test pressure BW elements operating at an even lower feed pressure. After start-up, the predicted performance advantages of the Lewabrane BWRO membranes were confirmed during routine daily operation. The RO feed pressure with Lewabrane RO B400 HR was throughout t h r e e ye a r s b e l ow 9 . 5 b a r ( w i t h t h e previous SWRO elements feed pressures were on average12 bar). The RO system salt rejection was approx 98.6 per cent (as compared to the 97.3 per cent rejection achieved with the SWRO elements). The new Lewabrane elements also provided an increased silica rejection (from 94 to 96.6 per cent) resulting in an increase of the cycle time between regenerations for the mixed bed ion exchange system. After three years in operation (with monthly cleaning), the RO system rejection level is still in the order of 97.5 per cent. Recently, the first stage Lewabrane RO elements were Chemical Engineering World

replaced with a Fouling Resistant Type (Lewabrane RO B400 FR) incorporating a 3 4 m i l fe e d s p a c e r ( r e c o m m e n d e d for wastewater application), which has resulted in a reduced cleaning frequency. Textile Industry The second industr ial example is a n i n n ova t i ve p r o c e s s i n t h e t ex t i l e industr y. The dying process requires high concentrations of salt to fix the dyes on to the cellulose textile. At the end of the process, the wastewater stream consists of a high concentration of salts and organics. Discharging the untreated wastewater would not only be harmful for the environment, it may also impact existing drinking water sources. Since the textile industry is an important employer, the Indian government strongly supports projects with MLD processes.

In this process, the wastewater is first treated with a biological treatment (tertiary treatment) to reduce the amount of organics in the wastewater. This step is followed by quartz filtration. The process water is then passed through an ion exchange treatment stage consisting of a scavenger resin to remove the organic substances, followed by high TDS water softening. Since sodium sulphate is added during the process, calcium must be removed to avoid the precipitation of calcium sulphate. After the ion exchange sequence, the water is passed through a reverse osmosis system to remove salt and other remaining organics. The RO system operates at a recovery rate of 80 per cent. The RO br ine reject is fur ther treated by NF (nano-filtration) membranes to recover the sulphate, while the sodium chloride, which passes through the NF membrane, i s c o n c e n t ra t e d by a mu l t i p l e e f fe c t evaporator. Sodium chloride salts are

Table 2: Water quality after treatment step

Parameters

After RO membrane Treated effluent After scavenger After softening unit after tertiary resin resin treatment

7.5

TSS (mg/l)

6.7

5.5–6.5

6.3

3–4

NIL

Hardness (mg/l) 150–200

150–200

<5 ppm

NIL

TDS (mg/l)

11,000

10,500

<100

Colour (Pt/Co)

500–600

<50

NIL

COD (ppm)

150–200

30–35

NIL April 2017 57

CEW

Marketing Initiatives

finally dried in a solar pan (as solid waste). The concentrated sulphate from the NF process step is reused in the process. The efficiency of the different treatment steps can be seen in Table 2. The MLD treatment process is extremely efficient, and this underlines the advantages of an ion exchange pretreatment for an RO process. The lifetime of the RO elements in this process is 3-4 years, with the added benefit of reduced COD content from the scavenger resin treatment step to reduce the potential of bio-growth.

Conclusion Th e above industr ial ex amples show that the reduction of wastewater, even in challenging process industries is possible using the right tools. Ion exchange and reverse osmosis is a smart and efficient combination to treat wastewater with a high organics load and high salinity. Even with wastewater as feed solution final water quality, that can be used for boiler feed water, can be achieved by the combination of an RO system followed by polishing ion exchange mix bed.

organics from the wastewater that can pass through an ultrafiltration process and lead to potential biofouling in the RO process. Finally, for MLD/ZLD processes, it must be noted that it is often challenging to achieve standards, but innovative combinations of existing technologies make it possible to reach the targeted goal.

The use of scavenger resin as a pretreatment before RO should be considered, to remove

Table 3: Wastewater treatment in the textile industry

Industry

Textile industry

Application

Wastewater treatment

Location

India

Product

Lewabrane RO S400 HR and Lewatit CNP-80 WS

Volume

154 pieces Lewabrane and 7,500 lLewatit CNP-80 WS

Production capacity

85 m 3/hr

Water type

High salinity and organic loaded wastewater

Installation

August 2016

58 â&#x20AC;˘ April 2017

Contact Details: LANXESS India Pvt Ltd LANXESS House Plot No: A 162-164 Road No: 27, MIDC Wagle Estate, Thane (W) Maharashtra 400 604 Tel: 022-25871000 Website: www.lanxess.com Chemical Engineering World

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CEW Products Energy Saving Cabinet

Mass Spectrometer

The CHV110 Series highperformance vector energy saving cabinet is the latest achievement of many years of research and development, production and on-site modification in energy saving equipment for injection moulding machines. Energy saving modification brings exceptional vector control technology into the realm of injection moulding machines, saving more electricity and completely resolving past problems of V/F control methods influencing production cycles.

The Thermo Scientific MSO Plus mass spectrometer can be used in a wide range of applications and methodologies in both HPLC and IC. Only 12 inches wide, the MSO Plus MS is a compact mass spectrometer providing universal detection and characterisation of analytes in the 17-2000 m/z range. Compatible with existing LC and IC methods, the MSQ Plus MS is sensitive, rugged, powerful, easy to use and integrates seamlessly with LC and IC systems.

The energy saver can also be used in the modification of air compressors, central air-conditioning and escalators.

For details contact: Thermo Fisher Scientific India Pvt Ltd 102, 104, Delphi C-Wing Hiranandani Business Park Powai, Mumbai 400 076 Tel: 022-67429494 Fax: 91-022-67429495 E-mail: sagar.chavan@thermofisher.com

For details contact: Shenzenn Invt Electric Co Ltd No: 4 Bldg, Gaofa Scientific Indl Park Longjing, Nanshan District, Shenzehn, China E-mail: overseas@invt.com.cn or Circle Readers’ Service Card 1

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Level Switch Coat-Endure-T is an innovation resulting from an unmet need of a compact coating immune admittance based level switch. Whereas compact vibrating forks for liquids have proven to be very successful for space constrained silos; slurries and pastes tend to be sticky, where vibrating forks could malfunction due to a coating of application material. Coat-Endure-T is an improvement over traditional principle of admittance such that the coating immunity is controlled by the on-board microcontroller and can be adjusted easily. Suitable for both conductive and nonconductive media, the sensor is immune to fluctuations in process parameters like temperature, dielectric constant of the media and variable build-up patterns. It allows material independent calibration, faster installation and commissioning, and offers an easy to clean tri-clamp mounting for hygienic applications. The sensor works well with powders, solids, liquids, pastes and slurries, and comes with RoHS compliance.

For details contact: Sapcon Instruments Sapcon Instruments 131 Palshikar Colony Indore, Madhya Pradesh Tel: 0731-4757575 E-mail: sapconinstruments.com or Circle Readers’ Service Card 3

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Products CEW Densify Screw Feeder The densifying screw feeder is offered where the product to be bagged is fluidised. Density of such material is very low owing to entrapped air in the product. Such products are very difficult to handle owing to highly free flowing characteristics of the product. Due to low density of the product and high quantity of entrapped air, such products require bigger size of bag to accommodate the given weight of the product. The densifying screw feeder removes entrapped air from the product. Density of the product thus increases sufficiently enough to accommodate this material into the given size of the bag. However, some percentage of air still remains inside the product which controls the flow-ability of the product. For details contact: Jasubhai Engineering Pvt Ltd 64/a, GIDC Indl Estate, Phase 1, Vatwa Ahmedabad, Gujarat 382 445 Tel: 079-49003636, 49003737 Fax: 91-079-25831825 E-mail: mhd-sales@jasubhai.com or Circle Readers’ Service Card 4

Paddlewheel Flow Meter Malema’s paddlewheel (also called Tangential turbine) flowmeter line utilises sophisticated circuitry to foster signal conditioning, resulting in flowmeter systems that are smaller, easier to install and more accurate than ever before. Paddlewheel flow meters continue to be the most common way to measure flow electronically in a wide range of industries. The rotational velocity of the rotary wheel varies linearly with the average velocity of the fluid flowing through the flow meter. A square wave pulse is generated from magnets embedded in the vanes of the rotor wheel. Depending on the output version of the M-10000, the pulse signal is relayed directly, converted to a 0-10 V DC output or a 4-20 mA output. The voltage and current models are span adjustable over the flow range of the flow meter. For details contact: Malema 17 & 18 Hanumanthra Arcade 60 Feet Road, Pattegarapalya Main Road Vijayanagar North Bengaluru, Karnataka 560 079 Tel: 080-23504361, Fax: 91-080-23011205 E-mail: malema@malema.com or Circle Readers’ Service Card 5

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CEW Products On-line Chloride/Sulphate Analyzer Mettler Toledo Process Analytics offers an on-line instrument for direct measurement of corrosive ions found in power plant water and steam. Chlorides and sulphates cause pitting and stress corrosion in expensive power plant components such as turbines and boilers, leading to extensive maintenance and unplanned shutdowns. Monitoring these ions at low ppb levels has therefore been identified as key measurements in power plant chemistry. The Mettler Toledo Thornton 3000CS Analyzer provides on-line, trace-level chloride and sulphate measurements for corrosion control. The 3000CS uses microfluidic capillary electrophoresis, an ionic separation technology, to provide an alternative to expensive off-line methods such as ion chromatography and inductively coupled plasma. The unit features semi-automatic calibration and an intuitive touchscreen interface, allowing operation without the need for extensive training. Mettler Toledo’s Intelligent Sensor Management technology in the analyzer provides diagnostics that predict when maintenance or replacement of consumables will be required. For details contact: Mettler Toledo India Pvt Ltd 36/37 Jolly Maker Chambers II Nariman Point, Mumbai 400 021 Tel: 022-22024046, 22850516 Fax: 91-022-22029278 E-mail: deplmum@vsnl.com or Circle Readers’ Service Card 6

Dip Coating Manipulator Core-assembly dip coating system is developed to carry out the dipping operation effectively in automatic manner. Upon pressing the cycle start pushbutton, core package assembly is lifted by core holding arms. Side grippers hold the core-assembly arms moves down and dips into coating tank up to desired position. Core holding fixture moves up and remains at standstill up to 5 seconds for dripping excess paint. The geared motor unit oscillates the core-assembly through 45 o in either direction. At each extreme end, the core assembly is held in position for 3 seconds. After 3 oscillations, the core-assembly moves towards the unloading station. Side grippers of arms release the core-assembly. Unloading station starts moving towards the baking oven. All the operations are controlled by means of programmable logic control housed in a suitable located control panel. It facilitates to conduct the dipping operation in a programmed way in auto as well as manual mode. For details contact: Acme Tools E-10/11(2) MIDC Bhosari Pune, Maharashtra 411 026 E-mail: spm@acmetools.in / sales@acmetools.in or Circle Readers’ Service Card 7

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Products CEW Vibro Sifter Vibro sifter is available in standard cGMP and customised models with SS-304/316/316L contact parts and are effective in separation of mass composition of solids, liquid from solid and also gradation of materials as per particle size. Specially designed motor carefully positioned at the centre of the base plate to provide tangential thrust. Double and triple deck unit with different screens can be provided. Noiseless and maintenance-free unit with optimum use of space and low power consumption is available in size 12”, 18”, 24”, 30”, 36”, 48” and 60”. For details contact: IPEC Engg Pvt Ltd Plot No: 5175, GIDC, Ankleshwar Gujarat 393 002 Tel: 02646-221175 Telefax: 91-02646-225175 E-mail: md@ipecengg.com / marketing@ipecengg.com or Circle Readers’ Service Card 8

Digital Multi-gas Analyser Combining industry leading performance and a range of new and enhanced functions as standard, the MultiExact offers air separation plants a multi-gas analyser specifically optimised to industry requirements with GFX and paramagnetic measurements now augmented by servomex’s revolutionary TCD measurement sensing technology. TruRef technology offers class leading measurements for Ar, He and N2. mA auto ranging functionality, user-defineable air point calibration auto validation and auto calibration functions included as standard. Options include digital communication options, an internal valve block function and unique servomex flowcube flow sensor technology. For details contact: Spectris Technologies Pvt Ltd Plot No: A-168 MIDC Thane-Belapur Road, Khairane Navi Mumbai 400 710 Tel: 022-39342700 E-mail: MEI_Sales@servomex.com or Circle Readers’ Service Card 9

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CEW Products Milling

Octagonal Blender Shefa Industries offer high quality octagonal blender, which is a versatile blending machine, highly durable and provide better usage. This range of products is tested on different quality standards and is used for mixing and lubrication process of dry granules homogenously. These blenders are offered in different specifications, sizes, shapes and provide effective results for granules because of slow speed and octagonal shape of the container. These are packed in excellent materials and are used in pharma, food, chemical, cosmetic products, etc.

For details contact: Shefa Industries Gala No: 1, U K Quari Compound Gandhi Nagar, Vikhroli (W) Mumbai 400 083 Tel: 022-25942473 E-mail: shefaindustries@yahoo.co.in or Circle Readers’ Service Card 10

The TAP Cone Mill has conical sieve which is particularly well-suited for deagglomeration and sizing of granular products. This design considerably increases efficiency. It sets new benchmarks with regards to modularity handling and maintenance in dry powder as well as wet prowder milling. Every Tapasya sieves and mills are made of high grade SS with polished product contacting surfaces. For details contact: Tapasya Engg Works Pvt Ltd Plot A/212, Road No: 30 Wagle Indl Estate Thane, Maharashtra 400 604 Tel: 022-61579400 Fx: 91-022-25825243 E-mail: sales@tapasyaindia.net or Circle Readers’ Service Card 11

Bearing Isolator The VB45-S Bearing Isolator provides permanent bearing protection to rotating equipment with premium protection against contamination ingress and lubrication loss. The VB45-S utilizes Inpro/Seal’s patented XX Interface coupled with an enlarged contamination chamber to achieve an IP66 rating, the standard for premium ingress protection against both harmful dust par ticulates and powerful water jets from all directions, making it one of the best performing Bearing Isolators available. For superior protection against lubrication loss, the VB45-S utilizes an enlarged D-Groove to capture oil and return it back to the bearing housing or a grease band to block grease from traveling down the shaft and escaping from the bearing housing. The VB45-S employs a compact design with only a 0.625 in (15.88 mm) overall (axial) length, making it the shor test IP66 rated Bearing Isolator available. A shor t overall length allows for easy installation often without the need for equipment modifications. For details contact: Dover India Pvt Ltd 40 Poonamallee Bypass Senner Kuppam Chennai 600 056 Tel: 044-26271020, 26271023 E-mail: sales.psgindia@psgdover.com CircleReaders’ Readers’Service ServiceCard Card123 oror Circle

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Products CEW Instrumentation Pipe & Weld Fittings Excel Metal & Engg Industries offers wide range of instrumentation fitting and valves for use in diverse range of industries and are capable to provide their customers with best possible solutions to meet their various requirements. The production process followed is of higher standards with its modern production and quality assurance facilities where due attention is paid at every level with maximum resource utilization.Excel Metal & Engg Industries offers instrumentation pipe and weld fittings in SS, brass, carbon steel, alloys, etc, in size range from 1/8 to 2 inch piping; NPT, ISO/BSP and SAE threads; according to ASME B31.1 and B31.3. All threads are protected with a cap. For details contact: Excel Metal & Engg Industries 177/181 J T Bldg, 3rd Kumbharwada Lane, Mumbai 400 004 Tel: 022-23892476, 66394004 Fax: 91-022-23884109 E-mail: info@excelmetal.net / excelmetal@mtnl.net.in or Circle Readers’ Service Card 13

Sliding Vane Pumps Blackmer offers its new GNX and GNXH Series sliding vane pumps. The market’s only alignment-free reduced speed positive displacement pumps, Blackmer GNX and GNXH Series pumps are designed to handle a wide range of non-corrosive, non-abrasive industrial liquids and petroleum products. Manufactured with a larger operating range than competitive designs, Blackmer GNX and GNXH Series pumps offer higher flows and higher pressure. These pumps are available with a robust, commercial-grade gear reducer with more operating speeds that allows for precise flow selections. GNX and GNXH Series pumps are self-priming and the self-adjusting vanes help maintain this capability. In addition, they are the only alignment-free pumps that can dry run without damage during self-priming and line stripping.These pumps are currently available in 2- and 2.5-inch flanged port sizes. Larger 3- and 4-inch flanged port sizes will be released later this year. Combined, these sizes provide flow capacities ranging from 20 to 500 gpm (76-1,893 L/min) at working pressures up to 175 psi (12.1 bar). Both 90 and 180 degree porting are standard. GNX and GNXH Series pumps are suited for both portable and stationary applications. Typical applications include fuel oils, lube oils, jet fuels, gasoline, edible oils and a variety of solvents and thinners. For details contact: Dover India Pvt Ltd 40 Poonamallee Bypass Senner Kuppam, Chennai 600 056 Tel: 044-26271020, 26271023 E-mail: sales.psgindia@psgdover.com or Circle Readers’ Service Card 14

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CEW Products Twin Screw Conveyor

Rocking Piston Vacuum Pumps

Twin screw conveyors are generally required to handle sluggish fine powders. The pitch of the screw increases towards discharge end. This helps fluidization of the material and improves flowability of the product. In such installations the bagging rate comes down to 3 to 4 bags/ minute using twin screw conveyor while accuracy comes down to 50 to 70 grams/Sigma for 50 kg weighing.

Indovac has developed indigenously in conformity with the international standard product known as rocking piston vacuum pumps. These are available in single and double head models. The pumps are completely dry running hence absolutely no oil at exhaust. All parts are made in aluminium LM6 grade and pistons are Teflon or PTFE/silicon. Any grade can be made as per the requirements

For details contact: Jasubhai Engineering Pvt Ltd 64/a, GIDC Indl Estate, Phase 1, Vatwa Ahmedabad, Gujarat 382 445 Tel: 079-49003636, 49003737 Fax: 91-079-25831825 E-mail: mhd-sales@jasubhai.com or Circle Readers’ Service Card 15

For details contact: Indovac Pumps & Engg Co 21 Anand Raj Indl Estate, Sonapur Lane B/h Asian Paints, Off LBS Marg Bhandup (W), Mumbai 400 078 Tel: 022-65062751, 25664973 Telefax: 91-022-25664917 E-mail: indovac@yahoo.co.in or Circle Readers’ Service Card 16

Mass Flow Controllers Designed specifically for OEM and process integration, BASIS is Alicat’s smallest footprint instrument. It controls gas flow rates used for mixing or diluting, or supplied into processes such as gas analyzers, custom blending manifolds and burners. BASIS has been qualified and accepted by customers within gas chromatography, gas mixing, and sputtering for film coating, as well as burner applications. The BASIS is accurate at very low flow rates (eg, 1 sccm), performing better than other mass flow controllers in its price class. Its high turndown ratio - as high as 200:1 - means that fewer devices are needed to control a wide range of flow. Fewer instruments and a compact size ensure a space- and cost-saving fit, without sacrificing performance. BASIS also has a rapid control response time of 100 ms, not attainable on most flow controllers of its size and ease of use. Its industrial interface facilitates rapid integration into gas flow systems. The BASIS line of mass flow controllers come in three flow ranges: 1-100 sccm, 5-1000 sccm and 0.1-20 slpm. They can be configured with six selectable gases - Air, Ar, CO 2, N 2, O 2 and N 2O - or with He or H 2. For details contact: Halma India Prestige Shantiniketan Gate No: 1, Tower C, 7th Floor ITPL Main Road, Whitefield Mahadevapura, Bengaluru Karnataka 560 048 Tel: 080-67475300 E-mail: sunil.balan@halma.com 18 or Circle Readers’ Service Card 17

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Products CEW Platinum Cured Silicone Tube Imapure is platinum cured silicone tubing designed for peristaltic pump and fluid transfer in pharma and biotech applications. Imapure is translucent silicone tubing known for its ultra smooth bore to prevent any particle entrapment. It is especially designed to comply with requirements of critical food and pharmaceutical standards of regulatory markets. Imapure is manufactured by using PLC controlled latest extrusion technology and advance grade platinum cured silicone and manufactured and packaged in clean room class of ISO7, ISO 9001 QMS and ISO 14001 and OHSAS 18001 certified facility. It is inspected by laser online inspection device to maintain critical dimensional consistency and laser etched for traceability. It complies with FDA 21 CFR, USP Class VI and ISO 10993. It has excellent transparency with no odour and taste. It has extractable study available upon request and excellent biocompatibility due to inertness to tissues and cells. It is sterilizable by using different techniques like autoclaving, ethylene oxide and gamma radiation. It is also available with FDA compliant colour coding for ease of identification and custom dimension, hardness and length size also available. Another most important part of tubing is its extractables and leachables data can be provided upon request and by signing with NDA procedures. For details contact: Ami Polymer Pvt Ltd 319 Mahesh Indl Estate, Opp: Silver Park Mira-Bhayander Road, Mira Road (E) Thane, Maharashtra 401104 Tel: 022-28555107, 28555631, 28555914 E-mail: mktg@amipolymer.com or Circle Readers’ Service Card 18

Precision Balances Citizen’s new and improved precision Series incorporates unique and unequalled high end technology built to match the highest international standards. The result is tenfold increase in weighing performance which maintains their proven, simple and easy to use operator interface. Attractive quality of this new design is demonstrated by the CE mark at conformity along with the Citizen ISO 9001:2008 Certification For details contact: Citizen Scale (I) Pvt Ltd Citizen House, Unit No: E-2, Plot No: 11, WICEL Opp: SEEPZ Gate No: 1 Andheri (E), Mumbai 400 093 Tel: 022-42437700, Fax; 91-022-42437800 E-mail: sales@citizenscales.com or Circle Readers’ Service Card 19

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CEW Products Wiped Film Evaporator Wiped film evaporator (WFE) is used for evaporation/concentration of heat sensitive liquids and slurries under vacuum conditions. It employs thin film technology which yields high heat transfer coefficients making the process highly effective. Due to a short residence time, higher jacket temperatures are possible without thermal degradation. The evaporator is used for concentration, distilling, stripping, dehydration and deodorisation of products which are heat sensitive or viscous. The equipment can handle wide range of feed compositions ranging from 1% to over 95% concentration.WFE has several advantages. The operation is continuous with a single pass, the self-cleaning continuous contact wipers produce and renew the thin film. Such an operation improves product yield, avoids residue and colour formation. It has an internal condenser (optional) that minimises the pressure drop and maintains vacuum.

For details contact: Dalal Engg 36/37 Jolly Maker Chambers II Nariman Point, Mumbai 400 021 Tel: 022-22024046, 22850516 Fax: 91-022-22029278 E-mail: deplmum@vsnl.com or Circle Readers’ Service Card 20

Dualstream Wet Gas Flow Meters or Circle Readers’ Service Card 10

Solartron ISA’s Dualstream meters are designed for direct installation at a wellhead or flow line, either top side or subsea. Stable and reliable with a typical lifespan greater than 20 years, Dualstream meters are ideal for unmanned platforms and marginal field development as well as for ultra deepwater installation. The Dualstream family consists of four products Dualstream Venturi, the original wet gas metering system, is a cost-effective solution for allocation or monitoring gas flow rates. Applications include tie-ins to existing infrastructure and multi-well fields, in which production fluids remain relatively constant throughout the field’s life. The Dualstream Venturi is generally used in combination with test separators or tracer dilution techniques. Dualstream 1 is a multiphase measurement solution for allocation or monitoring gas condensate wells. It is typically used on a per well basis at the wellhead or in the flow line. Standard field instrumentation makes it ideal for remote wellheads or unmanned platforms. The Dualstream 1 is recommended when real-time, high-accuracy gas measurement is a fundamental requirement, and water measurement accuracy is required for efficient well operation. Dualstream 1 replaces the need for test separators or tracer dilution techniques. Dualstream 2 is a multiphase measurement solution typically used on wells with high levels of liquids, which can cause gas rate over read. The Dualstream 2 uses a dual pressure differential technique to measure liquid levels and a proprietary algorithm to achieve real-time, multiphase measurement. Dualstream 3 utilizes a unique, patented Solartron approach for water fraction measurement for real-time measurement of phase fractions in wet gas applications. Its flow meters incorporate multipath, non-intrusive sensors that have demonstrated excellent performance in oil and water continuous flow and proven to be extremely robust in handling changes in field hydrocarbon compositions. For details contact: Solartron ISA (A Unit of the AMETEK Oil & Gas Business Unit) Hackworth Industrial Park Shildon, County Durham DL4 1LH, U.K. Tel: +44 (01) 1388 773065, 774888 E-mail: sales.solartronisa@ametek.com or Circle Readers’ Service Card 21

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Products CEW Diaphragm Type Vacuum Pumps These pumps are for vacuum and pressure applications. Portable, oil-free, noiseless made of special graded aluminium diecastings. Diaphragms are made of special 2 ply nylon reinforced Neoprene rubber. Widely used for laboratory, pollution control equipment, material handling equipment, medical instruments, dentist, gas charging in AC, photographic developing machine, plastic welding, nebuliser, cement aeration, etc. For details contact: Indovac Pumps & Engineering Co 21 Anand Raj Indl Estate, Sonapur Lane B/h Asian Paints, Off LBS Marg Bhandup (W), Mumbai 400 078 Tel: 022-65062751, 25664973, Fax: 91-022-25664917 E-mail: indovac@yahoo.co.in or Circle Readers’ Service Card 22

Bottom Discharge Centrifuge with Scraper The process of filtration is similar to other types of centrifuges the difference being in the method of unloading the solids. The scraper cuts the solid cake while the basket is rotating at a slow speed. The solids are discharged through openings provided in the basket bottom and bottom base/inertia plate. For details contact: Hydro Tech Engineers Plot No: 8 (AWM) Indl Development Colony Nr CIPET, GNDU Road Amritsar, Punjab 143 104 Tel: 0183-2256262, 2256363 E-mail: sales@hydrotech-engineers.com or Circle Readers’ Service Card 23

Spectrometer The latest miniature spectrometer from Ocean Optics offers high-sensitivity CMOS detector performance, acquisition speed up to 3,000 scans per second and onboard spectral buffering to ensure data integrity during reaction monitoring. The Ocean FX spectrometer is ideal for high-speed sorting and grading in production environments, measurement of transient events, and reaction kinetics monitoring for drug development and similar applications. Ocean FX is anchored by a high sensitivity CMOS detector with good response in the UV; is available with interchangeable slits; and captures up to 3,000 spectral scans per second, depending on the performance of the operating system to which it is connected. Its onboard buffer holds up to 50,000 spectra so users do not miss a single data point during kinetics measurements. Also, Ocean FX allows users to operate the spectrometer via Gigabit Ethernet, Wi-Fi and USB. Ocean FX is available in versions optimized for the UV-Vis (200-850 nm), Vis-NIR (350-1000 nm) and extended (200-1025 nm) wavelength ranges. Enhanced-sensitivity and custom and OEM configurations are also available For details contact: Halma India Pvt Ltd Prestige Shantiniketan Gate No: 1, Tower C, 7th Floor ITPL Main Road, Whitefield Mahadevapura, Bengaluru Karnataka 560 048 Tel: 080-67475300 E-mail: sunil.balan@halma.com or Circle Readers’ Service Card 24

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CEW Products Oil-free Reciprocating Gas Compressors NGH100 compressors have been designed to optimize operational capabilities in a wide variety of critical oilfield production operations, including wellhead transfer, artificial lift and vapour recovery. Blackmer NGH100 compressors are highly efficient horizontal opposed units featuring a non-lubricated design available in heavy-duty single-stage (NGH1013) and two-stage (NGH1023) configurations. A key operational characteristic of NGH100 compressors is their ability to handle sour gas that contains up to 8% dry hydrogen sulphide (H2S), which is a flammable, extremely hazardous byproduct of recovered crude oil and natural gas. To enhance their compatibility with sour gas, the NGH100 compressors feature select parts (that follow NACE guidelines) in all gas-containment areas. They incorporate steel wrist pins that ride on steel needle bearings for extra life under severe operating conditions. NGH compressors are constructed of ductile iron with a balanced forged-steel crankshaft. Piston rings and rider bands are made of PTFE/PEEK. NGH compressors have the capability to handle wet and dry gas, and offer flexible cylinder sizes for various flow rates and pressures and motor-speed capabilities up to 1,800 rpm. These compressors can achieve flow rates up to 3,000 MSCFD at max working pressures up to 1,500 psig (103 bar). For details contact: Dover India Pvt Ltd 40 Poonamallee Bypass Senner Kuppam, Chennai 600 056 Tel: 044-26271020, 26271023 E-mail: sales.pasgindia@psgdover.com or Circle Readers’ Service Card 25

Level Sensors Magnetic float level sensors are available for single level sensing and two level sensing. As per the level of liquid, float position changes and corresponding output is used for automation. Control unit is also available for automatic functioning of pumps or feeder. It is used for sensing the level of liquid in storage tanks, reservoirs, hoppers, etc. Separate model is also available which offers ten stages of LED indications for liquid levels and user can set pump On and Off function at any required stages. Capacitance type level sensor is suitable for sensing level at non-conductive liquids and solids. Level is sensed when SS probe of a sensor touches surrounding material in a hopper or tank. Sensor senses the same and offers NPN or PNP output with selectable NO or NC for further electrical interlock. It is suitable for free flowing materials. Length of probe can be offered to suit the requirement. Single sensor with two set points is also available for complete automation of hopper or tank. For details contact: Electronic Switches (India) Pvt Ltd Plot No: K-11, MIDC Area, Ambad Nashik, Maharashtra 422 010 Tel: 0253-6697701, 6603954 Fax: 91-0253-2380918 E-mail: electronic.switches@gmail.com or Circle Readers’ Service Card 26

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Products CEW Reflex Indicator

Counter-flow Impellers

Reflex type works on the principle of reflection of external light. When the medium is gas or steam, the light is reflected by the prismatic grooves of the glass which gives clear appearance. When the medium is liquid, the light gets absorbed and hence the indicative appearance becomes dark. It finds application in boilers, pressurised water tank, bulk storage tank and brine tank. For details contact: Filpro Sensors Pvt Ltd No: 130, 10th Cross Petechennappa Indl Estate Kamakshipalya, Magadi Main Road Bengaluru, Karnataka 560 079 Tel: 080-23286463 E-mail: sales@filprosensors.com

Flow generated by impellers tip is opposite to the bulk flow produced by the central part. In many case the slurry fluidity reduces due to high solid concentration. Tip of the impeller provides momentum to the fluid near vessel wall. These are mainly used for slurry with high slid concentration. It efficiently operates at much higher impeller to tank diameter ratio and have higher flow capacity than conventional impellers. For details contact: FEDA Inc B-37 Maruti Indl Estate Plot No: 59/1/2/3, Phase 1, GIDC Vatva Ahmedabad, Gujarat 382 445 E-mail: ashok.chaurasia@gmail.com

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Can Former LANICO offers a high-performance machine for the production of 3-piece aerosol cans. The newly developed Can Former CF 589 achieves production speeds of 500 cans per minute and processes super thin body material down to only 0,13 mm thickness. In doing so, the machine enables material savings of up to 30 per cent compared with conventional machinery. The new Can Former CF 589 offers supreme machine availability. During format changes, height adjustments can be performed in only 20 seconds without the need for additional tools. In accordance with LANICO’s Lego-style construction system, the machine uses modular tools, allowing a complete format change (diameter) in only 120 minutes. With the Can Former CF 589, the welded can pieces are fed and separated vertically. During further processing the spindle speed can be adjusted individually for each carousel with rotating tools. This way, the machine is fine-tuned to meet the specific demands of the tinplate material used. The Can Former CF 589 features the handy Recipe Management System (RMS), which integrates all the major production parameters, such as height, machine velocity and spindle speed. By accessing previous settings, parameter changes can be performed in only a few seconds. For details contact: LANICO Maschinenbau Otto Niemsch GmbH Broitzemer Straße 25-28 38118 Braunschweig, Germany Tel: +49 5318090614 E-mail: kaufmann@lanico.de or Circle Readers’ Service Card 29

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CEW Products Nauta/Conical Vacuum Dryers

Level Switch

Nauta/conical vacuum dryer is ideal for temperature sensitive materials. It is ideal drying system for hazardous/toxic material. Clean internal conical design provides complete discharge and reduces cross-batch contamination. Drive system and material feeding on top and product discharge through bottom helps in ease of process and material handling. Integrated vacuum pump system provided to match custom requirements. CIP system can be provided. Full validation services available including DQ, IQ/OQ, FAT/SAT protocols. For details contact: Shiv Shakti Process Equipment Pvt Ltd Shiv Shakti, 407 Shivam Chambers Next to Sahara, S V Road, Goregaon (W) Mumbai 400 104 Tel: 022-26788480, 26798554 Fax: 91-022-26798284 E-mail: sales@shivshaktiequipments.com sspepl@gmail.com

SLMR Orbit Paddle is an ideal level switch for all kinds of powder applications. It comes with foldable paddle mechanism for ease of installation and offers 2 potential free contacts with adjustable time delay. Suitable for chemical powders, plastic chips, PVC powders, cement, animal feed, food and pharma applications, and available with variable torque control.Flameproof enclosure (Gas Groups IIA, IIB) and flap action to discard clinging material are distinct features which make this instrument popular in different industries. Its direct stepper motor drive which does not need gearboxes and clutches makes it maintenance-free. SLMR Orbit paddle comes with RoHS compliance. For details contact: Sapcon Instruments 131 Palshikar Colony Indore, Madhya Pradesh Tel: 0731-4757575 E-mail: sapconinstruments.com

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Fork Level Switch Elixir-T-Uni is a compact level limit switch used in tanks, containers and pipelines. It is suitable for all kinds of liquids having viscosity up to 10,000 cP and density greater than or equal to 0.7 gm/cc. With an average surface finish of 0.8 Ra, this fork is ideal for hygiene-conscious applications. It comes with a service-friendly plug-in connection. Immunity to material build-up (such as foam), proven operation at a high temperature of 150 0C, silent operation for operator’s peace of mind and status indications for temperature overshoot and fork health are some distinct features which have made Elixir-T-Uni extremely popular specially in pharma and dairy industries. Elixir-T-Uni comes with IP-67 marking and RoHS compliance. For details contact: Sapcon Instruments 131 Palshikar Colony Indore, Madhya Pradesh Tel: 0731-4757575 E-mail: sapconinstruments.com or Circle Readers’ Service Card 32

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Products CEW Roots Vacuum Pumps

High Vacuum Pump (Oil-immersed)

The Roots-type pumps belong to the group of positive displacement delivery pumps. Two symmetrical pistons having an eight feature, housed in the pump body, rotate in opposite directions with no contact neither between each other nor with the pump body, meshing continuously. The pistons are driven by a set of gears with synchronised rotation, which guarantees friction-free movement. During rotation, a progressively growing space is created with corresponds to the suction stage: phases 1 and 2, being gradually decreased phases 3 and 4, compressing the volume of gas. This cycle is repeated four times per each complete rotation of the drive shaft.

The compact and quiet in operation, highly reliable and sturdy in design GL Series pump is an oil-sealed belt-driven pump operating according to the rotary vane principle with gas ballast valve. Oil, which is injected into the pump chamber, is used for sealing lubrication and cooling purpose. It is easy to maintain and guaranteed ultimate vacuum.

For details contact: Toshniwal Instruments (Madras) Pvt Ltd 267 Kilpauk Garden Road, Chennai 600 010 Tel: 044-26448983, 26448558 Fax: 91-044-26441820 E-mail: sales@toshniwal.net or Circle Readers’ Service Card 33

Double stage models from 180 m 3/hr to 300 m 3/hr are available to meet wide range of vacuum needs. For details contact: Toshniwal Instruments (Madras) Pvt Ltd 267 Kilpauk Garden Road, Chennai 600 010 Tel: 044-26448983, 26448558 Fax: 91-044-26441820 E-mail: sales@toshniwal.net or Circle Readers’ Service Card 34

Integrated Measuring and Dosing Mettler Toledo offers the ECB (Easy Control Box). The ECB connects any lab sensor and pump to make real-time measurement and controlled dosing available to non-experts. Combining data from all sensors in a single experiment allows researchers to quickly evaluate and compare experimental results and make decisions to speed chemical process development. Plug-and-play capabilities allow researchers to move sensors or pumps from one reactor to another within minutes.Pumps and balances connect to the ECB for automated pre-programmed gravimetric dosing. Linking temperature with dosing control enables reagent addition to stop in dangerous exothermic situations. Experiments can run unattended, allowing more experiments to be performed under safe conditions. SmartConnect technology makes connections with existing analog sensors plug-and-play. The sensor calibration and configuration data are on an integrated chip ensuring measurements are always accurate and precise applying the current sensor calibration data.Data from any analog sensor, such as mass flow, pressure, temperature or turbidity, is captured and stored in the experiment file together with other key process parameters. Additional sensor data leads to more knowledge about the reaction and better decisions to speed process development. As measuring and controlling pH precisely is essential for numerous applications, the plug-and-play pH module enhances the capabilities of the ECB significantly, enabling pH measurement and control from 50 mL up to multiple liters. For details contact: Mettler Toledo India Pvt Ltd Process Analytics Solutions Amar Hill, Saki Vihar Road Powai, Mumbai 400 072 or Circle Readers’ Service Card 35

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CEW Products Water Meter

Rotary Atomisers

The operation of the water flow meter is a simple user-friendly to operate easily. The water flow meter is an impeller multijet type flow meter with measuring inserts made up of engineering plastics. The water meter has a provision for fixing of external digital pulse sensors suitable for remote and digital pulse transmissions for monitoring through BMS systems and batching purposes with PLC, etc. These flow meters are used to measure the water consumption in apartments,flats, IT park area, hospitals and malls. Features removable / interchangeable element; sealed register water-proof (IP 67); corrosion-free powder coated body; EEC pattern approval; unaffected by external magnetic fields; and pulser’s coated body fitted without breaking the seal for remote flow totalisation and flow-rate indication. For details contact: Toshniwal Instruments (Madras) Pvt Ltd 267 Kilpauk Garden Road, Chennai 600 010 Tel: 044-26448983, 26448558 Fax: 91-044-26441820 E-mail: sales@toshniwal.net

Rotary atomisers are used in spray drying for atomising the feed into fine droplets. In rotary atomisers, the kinetic energy of wheel rotation is used for atomisation of the liquid. Droplet size of atomised liquid depends upon liquid properties, disc speed, disc configuration, etc. Bulk density is also one of the critical product requirements of spray-dried products. The desired results can be achieved by using different atomiser wheel configurations and optimising atomiser speed and relevant feed properties For details contact: New AVM Systech Pvt Ltd AVM House, 3B+3 Part, 1/3 Akurdi Indl Estate Opp: Ador Welding Ltd D-1 Block, MIDC, Chinchwad, Pune Maharashtra 411 019 Tel: 020-27459986, 27459987 Fax: 91-020-27459988 E-mail: avmtechnologies@vsnl.net

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Vertical Conveyor The vertical conveyor is designed and developed considering the requirement of material transfer from one floor to the other floor. The vertical conveyor system can be used for all types of application from minimum weight to maximum weight transfer based on the weight the conveyor will be designed and manufactured. It occupies less space compared to inclined conveyors and costwise it is more economical. The swing gate conveyor is designed and developed considering the FDA requirement, ie, the FDA audit norms crossing the conveyor with stairs either or under the conveyor will not be allowed. The conveyor is with robust design and of string mechanism controlled and operated through PLC programming and of pneumatic arrangements. To operate up and down and of forward reverse a remote box is provided on both the ends and same is interlocked with sensors for safety reasons such as if person is in front of the conveyor, it will not come down or in other condition not go forward. For details contact: Foreview Engg and Technology Pvt Ltd PAP-R-251, Nr Golden Garage Rabale, Navi Mumbai 400 701 E-mail: marketing@foreviewengg.com or Circle Readers’ Service Card 22 38

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Water India 2017 Dates: 10-12 May 2017 Venue: Pragati Maidan, New Delhi Event: This event showcases products, services and solutions available in the water industry worldwide. The event will provide comprehensive insight into the water industry–best practices, latest technologies, alternative solutions, emerging opportunity and business prospective. For details contact: Organiser: Exhibitions India Group Email: mumbai@eigroup.in Website: www.waterindia.com Contact No.: +91 9821062872 Machine Tools Engg & Technology Expo Dates: 12-14 May 2017 Venue: Brilliant Convention Centre, Indore Details: METEX caters to industrial products and equipment, heavy and light machines, engineering systems and services, industrial equipment and accessories, industrial technologies, software and hardware, and other parts and components. It is an exciting event that witnesses the best buyer and seller relationship, and brings out the best of products and services. For details contact: Organiser: Indore Infoline Pvt Ltd Email: info@indoreinfoline.in Website: www.ind-expo.com Contact No.: +91-731-2703000 Plastasia 2017 Dates: 08-11 July 2017 Venue: Pragati Maidan, New Delhi Det ails: This event has built a reputation as the ideal place to discover the latest innovations in plastics, live demonstration/s, share ideas and most impor tantly secure orders. Today, Plastics has become omnipresent and an integral par t of day-to-day activities. For details contact: Organiser: Triune Exhibitors Pvt Ltd Email: info@plastasia.in Website: http://www.plastasia.in/ Contact No.: 080 - 43307474 India Machine Tools Show Dates: 28-31 July 2017 Venue: Pragati Maidan, New Delhi Details: IMTOS a biennial event showcases path breaking ideas and innovation in machine tools, material handling and automotive technology. The show witnesses participation from over 500 companies every year.. For details contact: Organiser: K & D Communications Ltd Email: kandd@engimach.com Website: http://www.kdclglobal.com/ Contact No.: 079-26460624 Chemical Engineering World

China (Shanghai) International Chemical Technology & Equipment Fair Dates: 23-25 August 2017 Venue: Shanghai New International Expo Centre (SNIEC) Event: The event will showcase wide variety of chemical technology and equipment associated with this field. Thus event like this will organize wide variety of workshops, seminar presentation and open forum questionnaires with the help of it the exhibitors will showcase products and services like pumps, compressors, thermal process, instrumentation, control, automation techniques, chemical industry apparatus and also regarding plants associated with this field. In addition to this the event will cordially invite all the eminent and distinguished exper ts associated with this field. For details contact: Organiser: Guangzhou Zhenwei International Exhibition Co Ltd Contact: Tel: + 86 (0)20 83953253 China Adhesive Dates: 23-25 August 2017 Venue: Shanghai World Expo Exhibition And Convention Center Event: China Adhesive is not only an event for adhesives industry but for all these related industry like package, construction materials, wood, windows, textile, aerospace, electricity, coating and decoration. The exhibition is expected to attract more than 300 exhibitors to display the latest products and technologies. Over 15,000 professional visitors from more than 20 countries and regions will attend the exhibition. For details contact: Organiser: CCPIT Sub-Council of Chemical Industry Contact: Tel: + 86-10-64288748 Air Quality & Emissions (AQE 2017) Dates: 24-25 May 2017 Venue: Telford, U.K. Event: TAQE 2017 is the ninth in a series of specialist air and emissions monitoring events will provide a fantastic opportunity for visitors to glean the latest information on regulations, techniques, standards, methods and technologies. Registered visitors (www. AQEShow.com) will receive free access to an international exhibition and a series of walk-in/walk-out workshops that will run in four rooms located within the exhibition hall. The exhibition will provide a unique opportunity to see most of the world’s leading organisations in air quality and emissions monitoring products and services.Visitors to AQE 2017 will include anyone with a professional interest in industrial emissions and ambient air quality. This will include the operators of regulated processes, regulators, environmental health officers, test houses, consultants, the media, researchers, academics, accreditation organisations, technology manufacturers and service providers. For details contact: Organiser: AQE Organiser Email: sb@amiplastics-na.com Contact: Tel: +44 (0) 1727 858840 April 2017 • 75

CEW Project Update

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

CHEMICALS M Chemicals proposes an expansion from 10-TPM to 35-TPM of its synthetic organic chemicals manufacturing unit in GIDC Sachin, district: Surat, Gujarat. The estimated cost of the expansion is ` 12-million. The current status of the project could not be ascertained. According to MoEF sources, EIA report has been prepared by Aqua-Air Environmental Engineers. The existing plant manufactures 10-TPM 6-Nitro, 1-Diazo, 2-Napthol, 4-Sulphonic Acid. The expansion entails addition of new products namely, 25-TPM G-Salt, R-Salt, Amido G-Acid, Aniline 2,4 DSA, Aniline 2,5 DSA, Para Nitro Chloro Benzoyl Sulphonic Acid, Sulfo Tobias Acid, Para Cresidine Ortho Sulphonic Acid, Schaffer’s Acid, Broenner’s Acid. Total plot area is approximately 1,650-sq m, out of which, 300-m 2 has been used for green belt development. 5-KLD effluent will be treated in-house ETP and 10-KLD effluent will be sent to common MEE of MEPL for evaporation.

Modvadar, district: Kutch, Gujarat. The current status of the project could not be ascertained. According to MoEF sources, existing products are 3-million sq m per month plywood, flush door, block board and veneer. The manufactured resin will be used for in-house consumption at the wood products plant. The project will come up on 11,603.62-sq m of existing land. The greenbelt area is 600-sq m. A base platform will be constructed for the resin plant; remaining will be MS structure.

Mamta Texdyes (Samba) proposes a synthetic organic chemicals manufacturing unit in GIDC Sarigam, district: Valsad, Gujarat. The project is spread over 2,250-sq m. The estimated cost of the project is ` 32-million. The current status of the project could not be ascertained. According to SEIAA sources, Eco Chem Sales Services is the environmental consultant. The proposed products are 200-TPM sulphur black grains, 300-TPM sulphur black liquid and the by-products are 250.1-TPM sodium thio sulphate crystal and 47.12-TPM sodium chloride salt. 700-sq m area has been proposed for green belt development. Industrial waste water will be treated in primary and tertiary treatment plant and treated waste water will be discharged into CETP Sarigam.

Eternis Fine Chemicals proposes an expansion of synthetic organic chemicals manufacturing unit from 42,200-TPA to 60,000-TPA in MIDC Kurkumbh, district: Pune, Maharashtra. The current status of the project could not be ascer tained. According to MoEF sources, total land area is 100,400-sq m and built-up area is 42,710-sq m. 33 per cent will be developed as green belt area. The project will entail: 1) capacity expansion of existing products and by-products; 2) addition of similar products and by-products; 3) introduction of new eco-friendly biomass boiler as replacement to furnace oil. Project involves manufacturing of fragrance from organic raw materials by chemical process like hydrogenation, esterification, Diels-Alder reaction, cyclisation, dehydrogenation, aldol condensation, etc, followed by distillation to match precise quality standards. By-products capacity will be augmented from 11,400-TPA to 20,000-TPA. The estimated cost of the project is ` 1,050-million. The power requirement 12,000KVA will be available through Government Electricity Board.

Resipol Adhesives proposes an expansion of synthetic organic chemicals manufacturing unit in village: Rajpur, district: Mehsana, Gujarat. The estimated cost of the expansion is ` 40-million. The current status of the project could not be ascertained. According to SEAC sources, the manufacturing of existing products, 2.0TPM benzyl alcohol, 1.1-TPM benzyl benzoate, 3.0-TPM benzoic acetate, 1.4-TPM sodium benzoate, 1.8-TPM sodium acetate will be discontinued and 300-TPM polyester resins (different grades) and alkyd resins (different grades), 90-TPM melamine formaldehyde resin and 85-TPM urea formaldehyde resin will be manufactured as new products. The plot area is approximately 6,033.00-sq m. Unit has proposed 2,000-sq m area for green belt development. Industrial effluent of 0.42-KLD after primary treatment will be evaporated in kettle type evaporator. Two DG sets each of 65-KVA will be provided. It was decided to recommend the project to SEIAA, Gujarat for grant of environmental clearance. Royal Wood proposes a 90-TPM phenol formaldehyde resin, urea formaldehyde resin, melamine urea formaldehyde resin and melamine formaldehyde resin manufacturing unit in village:

Panoli Intermediates (India) proposes an expansion of its specialty chemicals manufacturing unit and a new 10-MW coal-based captive power project in Unit-III, GIDC Nandesari, district: Vadodara, Gujarat. The estimated cost of the project is ` 100-million. The current status of the project could not be ascer tained. According to MoEF sources, the total plot area is 15,480-sq m. The capacity of isomers and DNCB such as 2:4 DCNB, 2:6 DCNB, 2:5 DCNB is to be augmented from 200-TPM to 2,200-TPM, or tho anisidine/para anisidine from 100-TPM to 1,100-TPM, or tho nitro aniline/para nitro aniline from 300-TPM to 2,300-TPM, isomers of DCA from 80-TPM to 1,080-TPM, isomers and DCNB such as 2:3 DCNB, 2:5 DCNB. isomers of DCNB such as 2:3 DCNB, 2:5 DCNB, 3:4 DCNB from 200-TPM to 2,200-TPM, H-acid from 50-TPM to 500-TPM and addition of a new product namely, 1,500-TPM derivatives of nitro phenol and a new 10-MW coal-based captive power project. 10-MW power requirement is to be met from MGVCL and 10-MW from the captive power project. The effluent will be treated in proposed effluent treatment plant.

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Project Update CEW district: Valsad, Gujarat. The existing land area is 1.5 acres. The estimated cost of the project is ` 7.5-million. Kalyan Industries is the equipment supplier. The project is waiting for environmental clearance. Civil work will commence in 3 months. The project is planned for completion in this year. According to SEIAA sources, the company has proposed primary treatment plant followed by evaporator for treatment of industrial effluent and has also proposed a multi-cyclone separator. FMC India is planning an expansion of its chemical manufacturing unit at IDA Patancheru, district: Medak, Telangana. The estimated cost of the project is ` 17.5-million. As of September the project was waiting for the environmental clearance. According to MoEF sources, the plot area is 4.027 acres. The company proposes to manufacture 50-TPM of products as part of the expansion. Green belt on 33 per cent of the land area will be developed and maintained. Power requirement will be made available through SPCPDCL. The project will be completed within 2 years. Globex Laboratories (R&D) proposes a pigments manufacturing unit at village: Dabhasa, district: Vadodara, Gujarat. According to MoEF sources, the project will come up in the existing land on 9,312-sq m. Kadam Environmental Consultants, Vadodara is the environmental consultant. The project will entail manufacture of 40-TPM red pigments, 40-TPM yellow pigments and 450-TPM dilute phosphoric acid. Environment clearance has been obtained for the products â&#x20AC;&#x201C; red pigments and yellow pigments. Construction work has begun, as EC and NOC have been received. Effluents generated will be treated in effluent treatment plant having MEE. The company has applied for Amendment in Environmental Clearance dated 26 th September 2012 for change in fuel from LDO to agro waste briquettes and addition of one raw material, ie, phosphoric acid and generation of dilute phosphoric acid (25 per cent basis) as by-product. Bohra Industries is implementing an expansion of its chemical and fertilizer manufacturing unit at Umarda, district: Udaipur, Rajasthan on 14,500-sq m of existing land. The project will entail expansion of single super phosphate capacity from 400TPD to 600-TPD, granulated super phosphate from 200-TPD to 300-TPD and addition of new products namely 150-TPD triple super phosphate, 550-TPD synthetic gypsum, 30-TPD Di-calcium phosphate, 160-TPD phosphoric acid, 0.3-TPD potassium fluoride, 150-TPD H 2SO 4 and 0.3-TPD Sodium Tri Polyphosphate (STPP). Machinery has been ordered from China. Civil work is in progress. The project is scheduled for completion in 2018. Ami Lifesciences proposes expansion of its synthetic organic chemicals manufacturing unit (viz, pharmaceutical bulk drugs and drug intermediates) from 65.70-TPM to 131.60-TPM in Padra, district: Vadodara, Gujarat. The estimated cost of the project is ` 87.046-million. Environmental Consultant to this project is Envisafe Environment Consultants. According to MoEF Chemical Engineering World

sources, total plot area is 23,760-sq m (existing 10,270-sq m and 13,490-sq m for expansion). The unit currently manufactures 2-TPM 1-Acetyl Naphthalene, 1-TPM 2-Acetyl Naphthalene, 6-TPM Itopide HCl, 1.20-TPM Loxapine Succinate, 0.30-TPM Amoxapine, 6-TPM Venlafaxine, 6-TPM Progunil HCl, 6-TPM CB-2-L-Valine, 0.60-TPM Nateglinide, 0.60-TPM Quetiapine, 24-TPM Carbomazepin and 12-TPM Oxacarbomazepin. The expansion will involve addition of new products. Water requirement from ground water source will be increased from 34.53-cu m/day to 181-cu m/day after expansion. Effluent generation will be increased from 9.35-cu m/day to 79.5-cu m/day after expansion. Highly concentrated effluent will be sent to captive incinerator for incineration. Remaining effluent (70-cu m/day) will be treated in the ETP comprising primary, secondary and tertiary treatment. Treated effluent will be sent to CETP for further treatment. ETP sludge, inorganic residue and incineration ash will be sent to TSDF. Spent carbon, organic residue will be sent to incinerator. Adi Finechem is planning a 40-TPA specialty products manufacturing project on a 2-acre land at an estimated cost of ` 400-million in village: Chekhala, district: Ahmedabad, Gujarat. The project is waiting for environmental clearance. RSPL is planning a 1,500-TPD soda ash plant and 40-MW captive power project in village: Kuranga, district: Jamnagar, Gujarat. Land acquisition is in progress. 85 per cent of land has been acquired. The project is waiting for environmental clearance. The entire project is planned for completion in 5 years from zero date. MINING Metabluu Power, a sister concern of Minera Udyog India, is planning a 75,000-TPA iron ore mining project in village: Devikonda, district: Karimnagar, Telangana. The project is awaiting Government approval. Aryan Ispat & Power is planning an expansion of its coal washery in village: Bamoloi, district: Sambalpur, Odisha. The project will come up in the existing 204.65-acre integrated steel plant premises. The capacity of the project is to be augmented from 0.70-MTPA to 5.70-MTPA. The cost of the project is ` 600.7-million. The project is awaiting environmental clearance and planned for completion in 1-year from zero date. According to MoEF sources, the expansion is based on heavy media cyclone (wet process) technology. The washery will produce washed coal of an average ash around 34% (GCV 4,350Kcal/kg), middling (ash content about 58%) of GCV around 2,350-Kcal/kg useable as fuel in FBC boilers. The proposed expansion will be the state-of-the-art with close circuit water system, classifying cyclone, high frequency screens, thickener and multi-roll belt press filters. Power requirement of 5-MVA will be sourced from its own power plant connected with the Grid Corporation of Odisha. April 2017 â&#x20AC;˘ 77

CEW Book Shelf Handbook of Solid Waste Management Authors : Frank Kreith and George Tchobanoglous Price : USD 99.79 Pages : 950 (Hardcover) Publisher : McGraw-Hill Education About the Book : This handbook offers an integrated approach to the planning, design, and management of economical and environmentally responsible solid waste disposal system. Let twenty industry and government experts provide you with the tools to design a solid waste management system capable of disposing of waste in a cost-efficient and environmentally responsible manner. Focusing on the six primary functions of an integrated system--source reduction, toxicity reduction, recycling and reuse, composting, waste- to-energy combustion, and landfilling they explore each technology and examine its problems, costs, and legal and social ramifications.

Waste Management and Sustainable Consumption Author : Karin M EkstrĂśm Price : USD 122.69 Pages : 254 (Hardcover) Publisher : Routledge About the Book: This book uniquely examines the social and cultural views of waste, shedding new light on the topic by emphasizing the consumer perspective throughout. Drawing on a wide variety of disciplines including environmental, economic, social and cultural theories, the book presents philosophical reflections, practical examples and potential solutions to the problem of increasing waste. It analyses and compares case studies from countries such as Sweden, Japan, the USA, India, Nigeria and Qatar, bringing out valuable insights for the international community and generating a critical discussion on how we can move towards a more sustainable society. This book will be of great interest to post-graduate students and researchers in environmental policy, waste management, social marketing and consumer behavior, as well as policymakers and practitioners in consumer issues and business.

Wastewater Treatment Plant Operations Made Easy Authors : Frank R Spellman and Joanne Drinan Price : USD 39.50 Pages : 243 Publisher : DEStech Publications, Inc About the Book :A concise guide to wastewater treatment operations for operator training, this book explains all operations clearly and illustrates them through worked examples. Chapter self-tests and comprehensive review exams (answers included) make this volume the perfect, practical guide to preparing for Wastewater Treatment Plant Operations certification or licensing. In addition, it is a valuable resource of information on wastewater treatment, data, operational material, process control procedures and problem solving, safety and health information, new trends in wastewater treatment administration/ technology, and numerous sample problem-solving practice sets.. 78 â&#x20AC;˘ April 2017

Water and Wastewater Engineering Author : Mackenzie Davis Price : USD 201.57 Pages : 912 (Hardcover) Publisher : McGraw-Hill Education About the Book : This book integrates theory and design. Fundamental environmental engineering principles are used as the foundation for rigorous design of conventional and advanced water and wastewater treatment processes. Reverse osmosis, membrane filtration, UV disinfection, biological nutrient removal and membrane bioreactors represent a small sample of the processes included. This book follows the flow of water through a water treatment plant and the flow of wastewater through a wastewater treatment plant. The design of unit water treatment processes includes coagulation/ flocculation, softening, ion exchange, reverse osmosis, sedimentation, granular filtration, membrane filtration, disinfection, and residuals management. In a similar fashion, the design of unit wastewater processes follows the flow of wastewater through a plant. The design of unit wastewater treatment processes includes preliminary treatment, primary treatment, suspended growth secondary treatment including biological nutrient removal, and membrane biological reactors. Residuals management includes applicable methods to meet the 503 rules. The text includes appropriate regulatory constraints and highlights safety issues. Hints from the field bring to the student real-life experience in solving technical issues. Chemical Engineering World

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April 2017 • 79

CEW INTERVIEW

“ We have emabrked around `1500 crores for the next phase of growth”

“There is significant interest across international companies who are looking at India as an alternative source to procure specialties chemicals to reduce dependency on Chinese market. With the growth of Indian economy, certain import substitutes are witnessing a good demand across end user industries, which was not the case earlier. Many such chemicals will see a positive trend in growth and I believe that we will be able to capitalize on these opportunities” says Rajendra Gogri, Chairman & Managing Director, Aarti Industries Ltd in an exclusive interview with Mittravinda Ranjan. Where does Aarti Group stand today since the company commenced its journey? Our journey started way back in 1975, when the Indian Government was encouraging small scale investments in chemical manufacturing to develop indigenous chemical industry for import substitution. My brother Chandrakant Gogri – Chemical Engineer from Bombay University and his partner saw an opportunity and set up the first small scale manufacturing unit in Dombivali near Mumbai. I joined the business in 1983 after completing my Masters in Chemical Engineering from USA, and over the next couple of years, we added more small scale manufacturing units in Tarapur and later in Sarigam Though we always wanted to set up larger units, but it was only during 1990 80 • April 2017

after the end of licensing raj era that the chemical manufacturers could set up large scale facilities. In the due course we started expanding our facilities through backward integration to have feedstock security and continued to have strong focus on developing inhouse R&D capabilities which has been a strong growth driver for our organization. Today, Aarti Group has 16 factories spread over 10 different locations where have developed diversified product portfolio of 125 specialty products through our in-house R&D which includes intermediates for dyes and pigments, agrochemicals, pharmaceuticals, rubber chemicals, home and personal care and serves over 800 valued customers in Indian as well as international markets.

How has Aarti Industries achieved strong global presence and recognised as one of the leading specialty chemicals player globally in a span of slightly over 40 years? Chemical industry as such has a very wide number of chemicals, but from the time we commenced on our journey, we wanted to be niche in our own space and develop our own R&D capabilities. Over the years, we have built key chemistries and wide customer base that we will continue to leverage as we further expand our capacities and operations. In-house research is on-going process for us at Aarti Industries to strengthen our technical competence and our technical teams work very closely with our customers to understand their needs and supply products to meet their specific requirements. Chemical Engineering World

INTERVIEW CEW We have developed strong customer relationships that are based on integrity, care and excellence. In the times of crisis like product shortage etc. we have always stood by our customers and honored the contracts, which has earned us the reputation of being credible long term suppliers for our customers. How are the market dynamics changing across various geographies and what part of production Aarti Industries exports? Initially, it was only the dye stuff intermediates that were being exported, but as the dyeing industry moved from West of Suez to the East, the exports of dyes intermediates saw a sharp decline in exports. However, our business remained immune to the market shift since we still had the same as also new clients who had set up their facilities in India and had continued buying from us. Moreover, there was thrust on the other sectors such as pigments, polymers, additives, agrochemicals where the developed nations started looking at India as a key supplier for products which is what gave the push in the last 10 years to our business as well. Globally crop protection companies are very bullish as far as growth is concerned and in the years to come we are witnessing a strong demand from this sector. Worldwide, there is a strong shift from metals to innovative engineering polymers on the materials side driven strongly by the application in the space of automobiles, aerospace, electrical and electronics sectors. We export almost fifty per cent of our total production to various countries. North America, EU, Japan and China are the key markets for us and in terms of volume, one third of exports are for North America, one third for EU countries and then for rest of the world. China is a big market for us and accounts for almost 16 per cent of exported products. Because of the slowdown the product prices have marginally declined but since we have Chemical Engineering World

a very wide geographical spread and expansive product portfolio, we are in a pretty good shape. In the years to come, we see a good demand for existing as well as new products across all segments from all key markets in North America, EU countries, Japan and China as well. Though Aarti Industries has been at the forefront of being a sustainable solution provider right from the beginning, initially did you face any issues in being accepted as the preferred supplier from the global chemical majors? No, we never faced any such issues right from the early years since we proactively engaged in following sustainable practices. While we offer niche chemistries to our customers, on the other hand we have continued to invest in improving our processes and efficiencies through our in-house research to comply with the changing regulatory standards. We have always believed in selfregulation and one such example in this direction was to set up effluent treatment plants across all our manufacturing units out of which some have now been upgraded to zero liquid discharge. Through our in-house research, we have developed several in-house technologies and introduced several process innovations like process to produce dry HCl to produce chlorosulfonic acid, a reactive dye intermediate. This new process offered two major advantages as it allowed us to utilise Dry HCl gas that was generated as the by product and eliminated the restriction of limiting capacity as there was no water. This technology picked up very fast since it allows the manufacturers to set up standalone plant with sulphur trioxide (SO 3 ) and there is no restriction on capacity due to lack of water content which are the major advantages of this process.

Strong thrust on innovation and R&D has been one of the key drivers for our business which has enabled us to carve our niche in the market space and become a preferred business partner for organisations of high repute not only from India but even seek strong international partnerships. We have pioneered in introducing various technologies in India, such as commercialising Continuous Loop reactor for Eco-friendly Hydrogenation Process and become a key global player for various hydrogenated products. There are few more process innovations that we have introduced in India especially for by-product recovery and reduction of effluents and energy conservation. We have been able to leverage on sustainability and convert it to our advantage and self-regulation has enabled us to gain the confidence of our customers. Credit also goes to the founders, accomplished technocrats with strong business acumen, who could foresee the changing market trends and nurtured the culture of research and development in the DNA of the organisation.

And now you are getting into Toluene chemistries targeted for the same users as for the benzene derivatives. Do you see an overlap here and if this will create a challenge internally for the company? There is no overlap here! Around 75-80 per cent of our specialty products are benzene derivatives and now we are getting into toluene chemistries, which have their own specific downstream usage. Though the products are targeted for the same end use industry it does not mean replacing the existing products but the intent is to expand product portfolio by leveraging on chemistries and customer base which will be a win-win situation for us as well as our customers. April 2017 â&#x20AC;˘ 81

CEW INTERVIEW What are your thoughts on the Make in India campaign and its impact on the specialty chemicals industry? Overall, it will be a very good move if the end users come and invest in India since this will create more opportunities for specialty chemical manufacturers like us. For the manufacturers, India will be a good market since the economy is growing, but backward integration may not be a very viable option because of lower volumes since, this makes sense only when the volumes are high. For lower volumes, procurement of chemicals would make economic sense which means good business for specialty chemical manufacturers. Just to give you an example, one of our customers backward integrated and ended up with the challenge of handling the co-product and still

had to procure product from us. However the government will need to address the challenges of infrastructure and policy related issues to create a level playing field for Indian and international players. We have backward integrated and positioned ourselves strongly in the market which has been a strong driver for our growth and we are confident to maintain a strong growth momentum in the years to come.

What are the future plans of Aarti Industries? Presently, we are trying to stabilize our new plants and working on products for B2B segment to supply in domestic as well as international markets. In the years to come we may get into B2C as well but that is too far at this point of time. We have established synergistic technology partnerships with international players to

develop new product pipelines and R&D will continue to be our core focus area to understand and serve the needs of our customers. There is significant interest across international companies who are looking at India as an alternative source to procure specialties chemicals to reduce dependency on Chinese market. With the growth of Indian economy, certain import substitutes are witnessing a good demand across end user industries, which was not the case earlier. Many such chemicals will see a positive trend in growth and I believe that we will be able to capitalize on these opportunities. In the past we have invested around Rs. 1200 crores over the last 4 years and have earmarked around ` 1500 crores for the next phase of growth. (This interview was orginally published in January 2017 issue of CEW)

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