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CEW

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

Maulik Jasubhai Shah Hemant K. Shetty Hemant K. Shetty

EditorIAL Editor

Mittravinda Ranjan (mittra_ranjan@jasubhai.com)

Deputy Editor

Sujatha Vishnuraj (sujatha_vishnuraj@jasubhai.com)

Editorial Advisory Board Contributing Editors

Sub Editor

D P Misra, N G Ashar, Prof. M C Dwivedi P V Satyanarayana, Dr S R Srinivasan, R B Darji, R P Sharma Bernard Rapose (bernard_rapose@jasubhai.com)

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MARKETING TEAM & OFFICES

Vol. 54 | ISSUE No. 08 | AUGUST 2019 | Mumbai | ` 150

news Industry News Technology News

News Features

BASF Landmark Project in association with NMMC Integration of Social Business Model with Safe Drinking Water Supply and Affordable Sanitation Facilities Masooma Pathre, Deputy General Manager, New Business Development , BASF

Fearures

Jayati Mukherjee

Corrosion Problem in Water and Wastewater Treatment Prof A S Khanna, IIT Bombay (Retd), Chairman SSPC India

32

Homogenization in Wastewater Treatment Plants Krishna Kumar, Deputy Manager of Technical Support, Grundfos India

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Zero Liquid Discharge Concept and a Few Business Cases Mr Ajay Popat, President , Ion Exchange India Limited

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Sustainable Decarbonization through Circular Bio-Economy

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4 • August 2019

18

Urban Water Issues, Approach to Sustainable Solution, and Smart Water Management Inspiration: WaterEX World Conference 2019 24

Mumbai

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08 16

International case Study: Tagus Estuary Clean-up Project How Smart Wastewater Management leads to Urban Sustainability Alexandra Serra, Aguas de Portugal International, (Executive Board Member) Antonio Frazao, Aguas do Tejo Atlantico (President) Pedro Povoa, Aguas do Tejo Atlantico, (Asset Management Department Director) Case Study: Aeration and Mixing Brought Hussain Sagar Lake’s Ecosystem Back to Life Toufiq Mirza Baig, Marketing Manager, Eurotek Environmental Pvt Ltd

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51

PRODUCTS 54

events 63 PROJECT UPDATE

64

book shelf 66

Exclusive Interview 67

Ad Index 70

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Editor: Ms. Mittravinda Ranjan, 3rd Floor, Taj Building, 210, Dr. D N Road, Fort, Mumbai 400 001.

Chemical Engineering World

CEW Industry News RIL’s Chairman & Managing Director Shri Mukesh D Ambani’s Address at the 42 nd Annual General Meeting (Post – IPO) Mumbai, India: At the 42nd Annual General Meeting (Post – IPO) of Reliance Industries Limited, the Chairman & Managing Director Shri Mukesh D Ambani has presented Company’s account on business and financial performance for the year ended 31st March 2019.

Reliance became India’s largest and most profitable company both in public and private sector with multi-sector diversification, with one of the major growth engines being ‘Oils to Chemicals’ division. Along with other growth engines, this one has done exceedingly well. In this segment, Reliance has made a record contribution to the Indian economy. As the largest exporter, the Company generated ` 2,24,391 crore exports to 107 countries accounting for 9.8 percent of India's total merchandise exports. The Company is the highest payer of custom’s and excise duty amounting to ` 26,379 crore.

The ‘Oils to Chemicals (O2C) Business’ is formed by the integration of refining and petrochemicals businesses. This vertical has the ability to convert oil to high-value chemicals and new materials with life-enhancing ability. As the world moves towards renewable energy sources and electric vehicles, Reliance has positioned itself far ahead of the curve to create new value. At Jamnagar, the Company operates with a Complexity Index of over 21.1, which is the highest globally for a refinery. Higher complexity signifies a high degree of integration of units, feed flexibility, product manufacturing capability, and consequently the ability to maximize margins. Reliance O2C business achieved a revenue of ` 5.7 lakh crore, exports of ` 2.2 lakh crore, and EBITDA of ` 52,041 crore.

The Company processed 68.3 million tons of crude during the year maintaining the record of over 100 percent operating rate. Despite being in a challenging global environment, the Company achieved a gross revenue margin of USD 9.2 per barrel, maintaining a margin of USD 4.2 per barrel over the Singapore complex.

The Company also derived the full benefits of Refinery Off-Gas Cracker through the polymer production increase by 18 percent to 5.8 MMT. The Ethane sourcing investment achieved superior returns for capitalizing on the feedstock flexibility in a volatile environment.

All units of the Gasification complex have been safely commissioned. The Gasification complex is tightly integrated with the refinery and petrochemical complex at Jamnagar. The business focus is presently on completing this integration, capacity utilization, and efficiency.

The Butyl Rubber project with equity and technology from SIBUR of Russia, one of the global leaders in this business, is nearing completion and will be commissioned this year. This is a great example of India-Russia cooperation. Reliance and BP signed a Joint-venture in the petroleum retailing business. In a significant new initiative, BP is acquiring 49 percent stake in our petro-retail business. Reliance will get ` 7,000 crore from BP for this transaction.

Reliance is also going to make the biggest foreign investment in the history of the company, which is also one of the high-value foreign 8 • August 2019

investment in the country. Saudi Aramco and Reliance have agreed to form a long-term partnership in Oil to Chemicals (O2C) division.

In terms of the understanding between the parties, Saudi Aramco will invest in Reliance for a 20 percent stake in O2C division at an Enterprise Value of USD 75 Billion for the O2C division. This investment

by Saudi Aramco is subject to due diligence, definitive agreements, regulatory, and other customary approvals. This Partnership will cover all of RIL's refining and petrochemicals assets, including 51 percent of the petroleum retail JV. Saudi Aramco will also supply 500 KBPD of crude oils on a long term basis to RIL's Jamnagar refinery. This signifies perfect synergy between the world's largest oil producer, and the world's largest integrated refinery and petrochemicals complex.

Since its inception, RIL’s Jamnagar refinery has been processing Saudi oil every single day for 20 years. This longstanding relationship of two decades, based on mutual trust, is going to be transformed into a partnership of growth potential for many more years.

In context of Natural Gas Business, Reliance is re-emphasizing its shale gas business in USA. The present focus is on India.

In coal-bed methane block, RIL’s focus is on augmenting production. The joint venture with BP will play a major role as a producer of natural gas.

With world-class deep water infrastructure in the east-coast of India, the JV is uniquely positioned to monetize over 3 trillion cubic feet of discovered resources in the KG D6 block. The JV has committed an investment of ` 35,000 crore in three deep water fields in this block.

The projects to develop these gas-fields are amongst the most complex, being executed anywhere in the world. These will commence production from the first half of 2020. With an expected peak production of one billion cubic feet per day, equivalent to nearly 30 percent of India's current indigenous gas production, the JV will emerge as a major contributor to India's energy security.

Clariant Chemicals Q1 profits up by 20.3 percent; Sales grew by 11.9 percent Mumbai, India: Clariant Chemicals (India) Limited reported profit before tax of ` 18.4 crore for the quarter ended June 2019, as compared to profit before tax of ` 15.3 crore for the quarter ended June 2018 – a growth of 20.3 percent.

The Company reported sales growth of 11.9 percent, at ` 295.8 crore, for the quarter ended June 2019, as against ` 264.3 crore for the corresponding quarter in the previous year.

“Clariant has delivered a robust quarter with a relentless focus on costs, backed by a product portfolio powered by value added offerings. Clariant continues to execute its strategy to deliver shareholder value. Our ongoing emphasis on delivering strong financial results in the short term, while building a sustainable business for the future through excellence in Safety, Compliance and Customer Centricity continues,” explained Adnan Ahmad, ViceChairman & Managing Director.

Chemical Engineering World

CEW Industry News Almatec Extended Line of C-Series AODD Pumps with New C40 and C50 Models

technology backed by world-class research and development will support the Brazilian government’s mandate for ethanol blending and reduce GHG emissions” he added.

This joint endeavor will ensure a consistent, customized approach and the latest technologies while responding to market requirements. Customers in Brazil will benefit from competitive pricing, single window responsibility and local availability of after-sales service.

Duisburg, Germany: Almatec, part of PSG, a Dover company and premier manufacturer of specialty pumps, has extended its line of solid plastic C-Series Air-Operated Double-Diaphragm (AODD) Pumps to include new C 40 (1-1/2”) and C 50 (2”) models. Engineered to be a more cost-effective alternative to similar plastic pumps, Almatec C-Series pumps feature an industry-leading design that increases bolt torque to improve pump safety when compared to competitive pumps. What further separates the C-Series is the incorporation of Almatec’s exclusive Perswing P® air control system, which offers superior efficiency to optimize production rates and lower energy costs.

Ideally suited for the most difficult pumping applications, C-Series pumps ensure the suction and discharge ports are available as separate housing parts with different footprints. This feature allows the C-Series to be quickly and easily matched to existing installations. C-Series pumps do not have any mechanical seals, drives or rotating parts that cause wear over time, which improves reliability and extends product life. C-Series pumps feature self-priming and dry run capabilities, critical considerations for most pumping applications.

The C-Series pump line now consists of five pump sizes – C 10 (3/8”), C 15 (1/2”), C 25 (1”), C 40 (1-1/2”) and C 50 (2”). The wetted housing parts are made of either abrasion-resistant polyethylene or chemically resistant PTFE. For applications in explosive atmospheres, C-Series pumps are available in versions that conform to ATEX requirements according to the 2014/34/EU directive.

Praj and Dedini Joined Hands in Brazil Pune, India: Praj Industries has announced that it has entered into a Cooperation Agreement with Dedini S/A Indústrias de Base to provide ethanol production technologies to the Brazilian market.

This paves the way for Dedini to market Praj’s novel technology solutions to set up ethanol production facilities using grain-based feedstock and modernize existing ethanol plants in Brazil. Praj’s scope includes technology license engineering and supply of critical equipment, whereas Dedini bears responsibility for manufacturing equipment, site supervision, customer assistance and logistics.

With its wide connect and strong market reach, Dedini brings to the partnership its manufacturing and execution capabilities in the region. Praj’s expertise includes standalone and flexible molasses to ethanol, corn to ethanol plants of varied capacity, higher stillage concentration, zero liquid discharge, biogas/ bio CNG and 1.5G corn fiber to ethanol technologies along with modernization solutions.

Giuliano Dedini Ometto Duarte, Director President at Dedini says, “We are proud of this association with Praj Industries as it represents the agreement of two globally recognized companies, bringing to the market proven technologies, competitiveness and customization for our clients.”

Ion Exchange Inaugurated its New R&D Centre in Patancheru, Telangana Hyderabad, India: Leaders in water and environment management solutions, Ion Exchange (India) Limited, has recently announced the launch of its new Research & Development Centre at Patancheru in Telangana.

The centre will focus on the company’s Chemicals, Resins and Membranes business. It will also provide technical and scientific support to the company’s existing technology and engineering segments for designing new processes and products.

With an investment of around INR 300 million, the R&D Centre will develop new resins, membranes, polymers and speciality chemical technologies related to water, waste water treatment, process separation and purification, speciality process application and catalysis. The microbiology lab within the centre will lay emphasis on enzyme research and application specifically for the textile and food & beverage industry. Many of these products will be import substitutes with very large potential for enhancing the company’s exports.

This state-of-the-art R&D centre is spread over 24,000 sq ft and certified by the Department of Scientific and Industrial Research (DSIR). It includes latest analytical instruments and is manned by a team of highly qualified and experienced researchers.

Praj Industries is a leading global process solutions company, driven by innovation and integration capabilities, offering solutions to add significant value to bio-energy facilities, Critical process equipment & skids, brewery plants, industrial wastewater treatment systems and HiPurity water systems.

Brazil based Dedini is an engineering major and market leader in the supply of alcohol distillation plants, among other lines of products and services.

Speaking during the inauguration of the R&D centre, Mr. Rajesh Sharma, Chairman and Managing Director, Ion Exchange (India) Limited said, “Ion Exchange has been in the forefront of R&D in water and waste water management since 1965. Being pioneers in this industry we have been investing a significant portion of our revenues in research and new technology development thereby maintaining our leadership in markets we serve. Our new R&D centre which is an expansion of our current research and development facility in Hyderabad and Navi Mumbai and will provide an impetus to enhance our competitiveness not only in India but globally.

Through our innovations and R&D initiatives we will continue to ‘Make in India’ cutting edge sustainable solutions for industries, institutions, homes and communities”.

“We look forward to a mutually rewarding association with Dedini,” says Shishir Joshipura, CEO and MD at Praj. “Praj is confident that its pioneering

With continued innovations, the new R&D centre will offer newer solutions to Ion Exchange customers in India and across geographies it serves.

10 • August 2019

Chemical Engineering World

CEW Industry News Lanxess Remained on Track after A Stable Second Quarter Cologne, Germany: Specialty chemicals company Lanxess is on track despite the weaker economy and geopolitical uncertainties and can look back on a stable second quarter. EBITDA pre-exceptionally declined only slightly by 1.4 percent to EUR 286 million, nearly reaching the figure of the strong prior-year quarter of EUR 290 million.

Due in particular to the weak demand from the automotive industry, sales volumes declined in the Engineering Materials and Specialty Additives segments. In addition, earnings were burdened by a weak chrome-ore business. However, this development was nearly offset by the company’s stable portfolio and advantageous exchange-rate effects, especially from the strong US dollar. The EBITDA margin pre exceptionally remained stable at 15.8 percent after 15.9 percent in the prior-year quarter.

EUR 58 million in the prior-year quarter. All of the segment’s business units except Leather contributed to the improvement in earnings. The EBITDA margin pre-exceptionally rose accordingly from 16.3 percent to 16.9 percent.

In the Engineering Materials segment, sales and earnings were burdened by weaker demand from the automotive industry. Positive exchange-rate effects did not compensate for this. Sales amounted to EUR 365 million, down 8.5 percent on the strong previous year’s figure of EUR 399 million. EBITDA pre exceptionals fell by 19.8 percent to EUR 65 million compared with EUR 81 million in the prior-year quarter. After 20.3 percent in the previous year, the EBITDA margin came to 17.8 percent and therefore remained at a good level. € million

Q2 2018

Q2 2019

Chan ge %

H1 2018

H1 2019

Chan ge %

“Our strategic transformation and more stable position are paying off – especially in these economically uncertain times. We delivered good results again in the second quarter and confirmed our guidance for the full year”, said Matthias Zachert, Chairman of the Board of Management of Lanxess AG.

a Sales

a 1,829

a 1,810

a -1.0

a 3,645

a 3,632

a -0.4

EBITDA pre exceptionals

290

286

-1.4

560

561

0.2

The specialty chemicals company expects EBITDA pre-exceptionally of EUR 1.000 billion to EUR 1.050 billion for the full year 2019. In the previous year, Lanxess generated earnings of EUR 1.016 billion. The company expects earnings to be slightly weaker in the third quarter and somewhat better in the fourth quarter than in the previous year.

EBITDA margin pre exceptionals

15.9%

15.8%

15.4%

15.4%

Net income1

97

100

3.1

178

184

3.4

Earnings per share (€)1

1.05

1.14

8.6

1.94

2.06

6.2

Net financial liabilities2

2,252

1,381

-38.7

1,3813

1,902

37.7

Employees

15,283

15,441

1.0

15,403

-0.2

Group sales came to EUR 1.810 billion in the second quarter of 2019, down 1.0 percent from the previous year’s figure of EUR 1.829 billion. Net income increased by 3.1 percent from EUR 97 million to EUR 100 million. Earnings per share increased more strongly – by 8.6 percent from EUR 1.05 to EUR 1.14 – on account of the lower average number of shares outstanding.

Lanxess completed its share buy-back with a volume of nearly EUR 200 million on June 12, 2019. The shares were cancelled as planned on July 9.

More balanced portfolio ensures stability: The Advanced Intermediates segment again proved its operating strength in the second quarter of 2019, despite the persistently weak demand from the agriculture market.

This was mainly due to the ongoing positive development of the Advanced Industrial Intermediates business unit and good project business at Saltigo.

The development of exchange rates likewise had a positive effect. Sales amounted to EUR 561 million, up 2.7 percent on the previous year’s figure of EUR 546 million. EBITDA pre-exceptionally increased by a considerable 10.3 percent from EUR 97 million to EUR 107 million. The EBITDA margin pre-exceptionally rose from 17.8 percent to 19.1 percent.

The Specialty Additives segment showed a stable development year-onyear in the second quarter of 2019. The termination of margin-dilutive toll manufacturing contracts and the weaker demand from the automotive industry, especially in the Rhein Chemie business unit, led to lower sales volumes. At EUR 506 million, sales were nevertheless on a par with the previous year (EUR 508 million), as advantageous exchange-rate effects and higher prices nearly offset this development. EBITDA pre-exceptionally fell slightly by 2.2 percent to EUR 89 million compared with EUR 91 million in the prior-year quarter. The EBITDA margin pre-exceptionally of 17.6 percent was close to the previous year’s level of 17.9 percent.

In the Performance Chemicals segment, the balanced portfolio ensured stability. In particular, the operating strength of the business units with water treatment and material protection products and positive exchange-rate effects compensated for the weak chrome ore business in the Leather business unit. Sales remained stable year-on-year at EUR 356 million. EBITDA preexceptionally increased by 3.4 percent to EUR 60 million compared with 12 • August 2019

15,441 3

Prior-year figures from continuing operations After deduction of time deposits and securities available for sale 3 Dec. 31, 2018 1 2

LANXESS is a leading specialty chemicals company with sales of EUR 7.2 billion in 2018. The company currently has about 15,400 employees in 33 countries and is represented at 60 production sites worldwide.

The core business of LANXESS is the development, manufacturing and marketing of chemical intermediates, additives, specialty chemicals and plastics. LANXESS is listed in the leading sustainability indices Dow Jones Sustainability Index (DJSI World and Europe) and FTSE4Good.

Forward-Looking Statements: This company release contains certain forward-looking statements, including assumptions, opinions, expectations and views of the company or cited from third party sources. Various known and unknown risks, uncertainties and other factors could cause the actual results, financial position, development or performance of LANXESS AG to differ materially from the estimations expressed or implied herein. LANXESS AG does not guarantee that the assumptions underlying such forward-looking statements are free from errors nor does it accept any responsibility for the future accuracy of the opinions expressed in this presentation or the actual occurrence of the forecast developments. No representation or warranty (expressed or implied) is made as to, and no reliance should be placed on, any information, estimates, targets and opinions, contained herein, and no liability whatsoever is accepted as to any errors, omissions or misstatements contained herein, and accordingly, no representative of LANXESS AG or any of its affiliated companies or any of such person's officers, directors or employees accept any liability whatsoever arising directly or indirectly from the use of this document.

Chemical Engineering World

TECHNICALLY ADVANCED SOLUTIONS - for Chemical Applications

ROTAN CD • • • • • • • • •

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ROTAN ED • • •

• • •

Torque capabilities in excessive of 800 ft-lb Iron, Steel and Stainless Steel construction Tungsten Carbide abrasive wear materials are available for abrasive duty applications Reversible direction of flow with double acting relief valve option available Flow rates max. 90 m3/h with differential pressure up to max. 16 bar.

Coupled direct to NEMA or IEC motor for speed up to 1750 rpm Directed coupled gearbox with NEMA or IEC electric motor eliminating alignment issues Adjustable rotor end clearance without opening the system to the atmosphere

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DEFENCE & FUEL

UTILITY

CEW Industry News INEOS Styrolution Hosted Groundbreaking Ceremony for its New 100kt Asa Plant in Bayport, Texas

the end of 2019 and remains subject to the approval of the relevant competition authorities. BASF will acquire the global, non-European PA6.6 business from Solvay including its 50 percent share in Butachimie’s adipodinitrile (ADN) production according to the agreement signed in September 2017. Subject to the approval of the transaction between Domo and Solvay and final approval of the relevant competition authorities, the transaction between BASF and Solvay is also targeted to close by the end of 2019.

The intended acquisition by BASF now comprises a total of eight production sites in Germany, France, China, India, South Korea, Brazil and Mexico. In France, BASF and Domo will also enter into a joint venture to produce adipic acid. Furthermore, three research and development centers in South Korea, China and Brazil and six technical consultation centers in Asia as well as in North and South America will be transferred from Solvay to BASF.

Bayport, Texas: INEOS Styrolution, the global leader in styrenics, has announced that the company hosted a groundbreaking ceremony for its new 100tk ASA (acrylonitrile styrene acrylate) plant in Bayport, Texas. The development of the new site is part of a bigger expansion plan for the Americas, which includes increased ABS (acrylonitrile butadiene styrene) capacity at the Altamira site in Mexico, while transition the ASA production to the new site in Bayport. The location of the new site was selected based upon its easy access to raw materials, being adjacent to the INEOS Styrolution’s styrene monomer plant, low cost utilities and proximity to major customer markets. The new site is expected to be operational by 2021.

The groundbreaking ceremony was hosted by Greg Musler, INEOS Styrolution Project Director. Attendees included local government and business leaders, engineering and construction representatives, and several project vendors.

Speakers at the event included Kevin McQuade, CEO INEOS Styrolution.

He emphasized the company’s ambitious plans for growth and INEOS Styrolution’s projects aiming at a circular economy for styrenics.

Alexander Glueck, President Americas at INEOS Styrolution, added: “I am excited to see us building the most efficient dedicated ASA plant in the world, here in Bayport. ASA is a versatile high performance styrenic resin. Its properties make it the material of choice for numerous outdoor applications.

ASA performs greatly in exterior automotive and construction applications.”

Cathy Culpepper, Vice President Manufacturing Americas, summarized her presentation on manufacturing and project excellence at Styrolution in one sentence: “Operating in a safe, environmentally and socially responsible manner is part of INEOS Styrolution’s mission.”

BASF Signed Agreement on Acquisition of Solvay’s Polyamide Business Ludwigshafen, Germany: To further expand its position as a global supplier of engineering plastics, BASF signed an agreement with Solvay in September 2017 on the acquisition of Solvay’s integrated polyamide business. In January 2019, the EU Commission approved the acquisition subject to certain conditions, including the divestiture of Solvay’s polyamide 6.6 production facilities in Europe.

Today, BASF, Solvay and Domo Chemicals agreed that Domo will acquire the European PA6.6 business from Solvay. This transaction is targeted to close by 14 • August 2019

The purchase price to be paid by BASF on a cash and debt-free basis would amount to € 1.3 billion. Solvay’s businesses to be acquired by BASF generated sales of around € 1.0 billion in 2018. At closing, approximately 700 Solvay employees will move to BASF. The intended joint venture between BASF and Domo in France will employ approximately 650 employees. BASF is planning to integrate the businesses into its Monomers and Performance Materials divisions.

With this transaction, BASF will benefit from improved access to important growth markets in Asia and South America, enabling the company to improve the close collaboration with local customers. BASF’s product pipeline and product portfolio of engineering plastics will be enhanced as well, which will strengthen the position of the company as a provider of innovative solutions for the transport, construction and consumer goods industries, among others.Through the backward integration into important raw materials such as adipodinitrile (ADN), BASF will be present along the entire value chain for polyamide 6.6 and be able to further increase the capacities to produce polymers.

Clariant Catalysts Expanded in the Middle East with New Office in Saudi Arabia Munich, Germany: Clariant has announced that the company’s Catalysts business inaugurated a new services and support office in Jubail, Kingdom of Saudi Arabia. Located in the eastern coast of the country, Jubail is the world’s largest industrial city and an important site for the petrochemicals market.

Clariant’s new office is thus ideally positioned to serve regional customers with its advanced catalysts for petrochemical and refinery applications, as well as offer dedicated assistance and technical services. The new branch is Clariant Catalysts’ fourth office in the Middle East and will play a key role in the company’s plan to strengthen its presence and partnerships in the region. The local team will be actively supported by Clariant experts from around the world.

Stefan Heuser, Senior Vice President & General Manager Business Unit Catalysts at Clariant,commented, “We are extremely pleased to forge closer ties with valued customers in the Middle East. The expansion demonstrates our commitment to the region, and will allow us to showcase our state-of-theart catalysts, which are designed to deliver excellent performance, and enable highly economical and sustainable production of numerous petrochemicals.”

Clariant’s portfolio for refinery applications includes catalysts for extremely efficient fuel upgrading and purification, as well as for removing sulfur, chlorine, arsenic and mercury. The company’s solutions for the petrochemicals industry comprise high-performance catalysts for producing main petrochemical building blocks, such as ethylene, propylene, butadiene and styrene, in addition to a complete range of catalysts for producing various grades of polypropylene.

Chemical Engineering World

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CEW Technology News Successful Startup of World’s Largest Dehydrogenation Plant using Clariant’s Catofin Catalyst Technology

Karratha, Western Australia. Stamicarbon has been chosen as urea licensor, and gas supply has been secured. The next milestone for the project will be financial close, which is expected by end of March 2020.

“This is a significant step forward for the Karratha Urea Project. We are now full steam ahead on this important project that will use the latest and best technologies available. We expect Haldor Topsoe’s innovative Syncor Ammonia technology to deliver significant economies of scale that will contribute to making this world-scale plant exceptionally competitive,” said Mr. Vikas Rambal, Founding Chairman and Managing Director, Perdaman Group.

Dehydrogenation Plant of Hengli Petrochemical (Dalian) Refinery Co Ltd (Photo: Hengli Group)

Munich, Germany: Clariant announced the successful startup of its Catofin catalyst at Hengli Group’s new mixed-feed dehydrogenation plant in Dalian, China. The new unit combines propane dehydrogenation (PDH) with iso-butane dehydrogenation (BDH) process technologies, and it will produce over 1 million tons of olefins per year -- becoming the world’s largest plant using Catofin catalyst technology.

The state-of-the-art process pairs Clariant’s Catofin catalyst together with McDermott’s Lummus process technology and is proven to enable high reliability and yields, cost efficiency, and simplicity. In addition to the Catofin catalyst, the facility is using Clariant’s innovative Heat Generating Material (HGM) to produce its on-purpose olefins.

Founded in 1994, Hengli Group is one of China’s foremost suppliers of petrochemicals. Hengli Group’s new dehydrogenation plant in Dalian, China is designed to process 500 KTA of propane and 800 KTA of iso-butane feeds to produce propylene and iso-butylene.

Guangqin Peng, Chief Engineer of Hengli Petrochemical (Dalian) Refinery Co Ltd, stated, “We are very proud of our achievements on this groundbreaking project. The fast, smooth, and successful startup of this world’s largest paraffin dehydrogenation unit would not have been possible without reliable and experienced partners like Clariant.”

Catofin is an extremely reliable technology for light paraffin dehydrogenation.

Operating at thermodynamically-advantaged reactor pressure and temperature to maximize yield, the process relies on Clariant’s highly selective Catofin catalyst and the company’s patented metal-oxide HGM to deliver high conversion rates. With the successful startup of the Hengli plant, this now marks Clariant’s 21st Catofin unit in operation, totaling over 9 million tons of olefin production capacity globally.

Stefan Heuser, Senior Vice President & General Manager Business Unit Catalysts at Clariant, added, “We are honored that our Catofin catalysts and Heat Generating Material were selected by Hengli for its new production facility. Together with our technology partner, McDermott’s Lummus Technology, we are proving, yet again, the outstanding benefits of Catofin for propane and iso- butane dehydrogenation.”

Perdaman Introduced Syncor Solution for World’s Largest Ammonia Plant Copenhagen, Denmark: Perdaman Chemicals and Fertilisers (Perdaman) has signed a licensing and engineering contract for Haldor Topsoe’s Syncor Ammonia solution for its Australian Dollar 4 billion ammonia/urea plant in 16 • August 2019

Syncor Ammonia is the state-of-the-art solution for large-scale ammonia production. Using industry- proven technologies and catalysts, it sets a new standard for single-train capacities that can enable double-digit reductions in production cost. Contrary to conventional two-step reforming, Syncor Ammonia uses a single-step autothermal reformer and reduces steam throughput by 80 percent. This enables exceptional economies of scale in large-scale grassroots ammonia plants.

“We are excited to continue our longstanding relation with Perdaman and support them in building a truly cutting-edge world-scale ammonia/ urea plant. Syncor Ammonia is an exciting advancement for the ammonia market and reinforces our conviction that Syncor is the best choice for largescale ammonia production,” says Ms. Amy Hebert, Deputy CEO and EVP Chemicals, Haldor Topsoe.

Syncor technology can also be applied in the production of methanol, syngas, and synthetic gasoline.

The New Innovation of Nanocoil to Clean-up Earth’s Microplastics Adelaide University, Australia: Microplastics are serious threats to mankind. It has its existence at almost everywhere viz ocean, air, pristine lakes; and that in turn causes infestation in marine animals and our food.

These microplastics are very challenging to remove as they comes with a very tiny-size, less than 5 mm across or smaller.

Plastic pollution is rampant and micro-plastics are prevalent in the environment. Apart from aggregating in the ocean, 94 percent of the Great Pacific Garbage Patch is made up of micro-plastics, which ends up with waste-water. It is also possible for micro-plastics to come into drinking water in case of faulty or inadequate treatment. Micro-plastics are usually originated from the disintegration of larger plastics, micro-fibers, tires, to name a few.

To face this situation, scientists have designed a nano-sized reactor named as nano-coil for disintegrating microplastics. This nano-coil may also be applied to the waste water before flushing into the environment for microplastic content fragmentation. The broken down components of micro-plastics could further be used as carbon-based food for plant-based life forms like algae.

Nano-coils are made up with hybrid material, which initiates chemical reaction upon combining with metals. The reaction between manganese metal and carbon results hollow nano-structured coils growing in helical direction. Such coils are about half of the width of human hair in length. The short-lived, highly reactive free radicals generated through manganese are responsible for this disintegration. Eventually this micro-plastic content is converted into carbon-di-oxide gas and water.

It has been observed that approximately 30 percent to 50 percent disintegration of microplastics is possible through this disintegration.

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CEW News Features BASF Landmark Project in association with NMMC

Integration of Social Business Model with Safe Drinking Water Supply and Affordable Sanitation Facilities

Water ATM dispensing purified water using BASF’s ultra-filtration membrane technology.

Beneficiaries taking water

It is very unfortunate that often people from lower-income group, with respect to their affordability, have to pay the most for their drinking water requirement. In Mumbai, safe drinking water consumes up to 15 percent of their earning. However, some places are improving with adequate initiatives and measures. In Turbhe Stores, a suburb in Navi Mumbai, the scenario is changing for better now. The area is now enjoying the availability of purified water, thanks to the new collaboration initiated by BASF and NMMC. This joint venture offers purified drinking water to Turbhe Store residents at just Rs. 8 per 20-liter-bottle at the Water ATM. Here the author has cited the business case with a comprehensive narration of the project’s phasewise movement.

Initiation: This Landmark Project was developed through a series of social dialog sessions in Mumbai during BASF’s 150 th anniversary activities in 2015 under the scope of Creator Space program, and now has come to fruition through an innovative & community-based social business model. The dialogues convened a wide array of representatives including residents, NGOs, local government bodies and representatives, academia, and industry.

Problem statement: The focus was on how to provid e safe & affordable 18 • August 2019

water as well as sanitation services to the needy community members through implementation of a business model with an emphasis on future sustainability of services. The project was titled as Equitable Distribution of Safe Drinking Water. To define the purview, re p r es entativ es ac ros s the s pec trum participated in a dialogue which later was culminated into a Whitepaper – Water for Mumbai. It is worth mentioning here that the report was published by Hon. Chief Minister of Maharashtra, Mr. Devendra Fadnavis in Oct 2016.

Conceptualization: Based on this whitepaper, BASF India created a unique social business model to address the access to clean water, and arrest of the water-borne diseases affecting community health, which in turn leading to illness, low productivity of working-class people, and absenteeism in schools. The model was socially oriented, economically sustainable, and could be handed over to the community after a period of two years.

Phase-I Implementation: BASF and its partner STEP (Sustainable Technosolutions for Environmental Chemical Engineering World

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Project highlights: • Innovative social business model in Turbhe has capacity to offer affordable drinking water to 10,000 people • BASF’s ultrafiltration solution along with other purification processes powers a “Water ATM,” which purifies water and converts it into safe drinking water • The “Landmark Project” will also establish an affordable sanitation facility and a social business model promoting hygiene • A unique sustainable concept of public-private partnerships for social project

Protection) chose Navi Mumbai Municipal Corporation (NMMC) School No 22 in Turbhe Store, located close to BASF’s site, for implementing the first phase of the ‘Landmark Project’, in close consultation and support of NMMC. Phase-I of the project, consisting of a ‘Water ATM’ and a rainwater harvesting system establishment for the school, was inaugurated on 2 nd Aug 2018 by the Honorable NMMC Mayor Jayawant Dattatray Sutar along with Dr N Ramaswami – Former Commissioner of NMMC, Dr Raman Ramachandran – Former Chairman and Managing Director of BASF India and Head of BASF South Asia, as well as other dignitaries.

The first phase of the project provided clean and affordable water to 10,000 Turbhe Store residents through water ATMs. These are the machines that dispense purified water using BASF’s ultrafiltration membrane technology.

BASF runs the project on land provided by NMMC at Bharat Ratna Dr Babasaheb Ambedkar Vidyalaya School No 22 of Turbhe store.

Waterlife India has designed and supplied the solar-powered cashless machines; and STEP implemented the project. Residents’ access to the purified water was designed with a payment system through debit card.

20 • August 2019

Each 20-litre-water-bottle costs Rs 8.

The system currently serves to more than 1000 residents and over 900 students from the school. To increase the program’s reach within the community, appropriate distribution model formation is in progress.

Water is getting purified by using BASF’s innovative ultrafiltration membrane technology – Inge. It utilizes patented and highly robust Multibore fibers made from PESm, a modified Polyethersulfone, and also an in-toout filtration process. The membrane consists of extremely tiny pores with a diameter of 20 nanometers to provide a secure barrier against suspended solids, viruses, other microorganisms, and thus let only pass the pure water. The provision for rain water harvesting using BASF’s Elastopave ensures the returning of rain water as groundwater.

This innovative social business model has introduced a sustainable safe water supply into a community, which is in need of drinking water, affordable sanitation, and hygiene. Normally CSR projects in India provide facilities for free, which creates a challenge towards project sustainability. Through the Landmark project, safe drinking water and sanitation facilities are being provided

at an affordable cost to an economically impoverished area, thereby ensuring sustainability of the project. The revenue stream from the minimal payment collection helps to ensure its long-term viability with continuous fund in-flow for the maintenance of water ATM and rainwater harvesting system. Regular awareness program on sanitation and hygiene in schools, nearby residential areas, and public health centers are being conducted to enhance and spread the model awareness as well as the importance about water, sanitation, and hygiene. As a part of its corporate volunteering program, BASF employees are now working in communities to create awareness about sanitation, importance of clean drinking water, and general hygiene.

Phase-II Implementation: This phase will include refurbishment of an NMMC toilet and setting up a unit for hygiene products near the toilet. This phase of the project will use BASF’s innovative solutions sourcing from its diverse portfolio viz construction chemicals, care chemicals, and performance materials businesses. This unique model can be replicated anywhere in the world.

Conclusion: Public private partnership as evident in BASF’s Landmark project is a great example of how Corporates can join hands with Local Government Bodies to solve the community challenges through the usage of innovative and sustainable technologies. The need is to generate strong commitment, openness, and collaboration between Government Bodies like NMMC and Corporates like BASF. Author

Masooma Pathre Deputy General Manager New Business Development BASF

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Urban Water Issues, Approach to Sustainable Solution, and Smart Water Management Inspiration: WaterEX World Conference 2019

By Jayati Mukherjee

In Indian context, water is the most abused natural resource. Ever growing population, climate change, infrastructure aging, etc are some of the bulging challenges being faced by our water industry. If we narrow down our scope to urban area, some more will be factored in. The most prominent drivers amongst them are: agriculture economy, and rapid urbanization as well as industrialization. Owing to these reasons, though the aggregate water availability remains almost unchanged, the per-capita water availability is reducing day by day. With this context, smart water management would be the most effective remedy. Now the million dollar question is: how to achieve that to the optimum extent? What are the industry best practices? The article aims to discuss various urban water issues and the smart water management best practices adopted by prominent business houses.

Current Water Situation in India: Water is a national resource with no alternative. To explain the criticality of the issue, let’s check out some statistics: India has around 18 percent of the world population with approximate 4 percent of water resources. Being a highly populous country, it is imperative that India has a huge need for water.

Although the aggregate water availability is more or less constant, with ever growing population, the per-capita water availability is going down. As per the international norm, if the per-capita water availability is less than 1700 cubic metre, the situation is water stressed; and if it is less than 1000 cubic metre, the situation is water-scarce. Depending on the topography and hydrological factor of our country, many areas are either water-stressed or water-scarce.

It is forecasted that 54 percent area of India would be highly water stressed by Yr 2025. While we are heavily concerned about the scarcity of water, it’s worth mentioning that 97 percent of water is the sea-water; 2 percent of water forms the glacier; and remaining 1 percent is the fresh water, which can further be subdivided into ground water and surface water. We mostly use this surface water for all our requirements.

The issue of water-security has become 24 • August 2019

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CEW Features It is forecasted that 54 percent area of India would be highly water stressed by Yr 2025. The issue of water-security has become important with the reduced per-capita water availability. important with the reduced per-capita water availability. As per the current scenario, 75 percent to 80 percent of water is consumed in irrigation where the water efficiency is very low. Followed by this, there is also an allocation-need for drinking water supply and industrial water supply. At the advent of expansion and advancement of industry, the need for industrial water supply is on the rise.

Ecological and environmental needs are also to be factored in.

Restraints: • The biggest challenge is sustainable management and development of water for effective utilization. This translates to development & conservation of effective storage of water in varied form. Because of various environmental issues and land-acquisition problems, the water conservation along with smart & efficient water management is getting prominence these days.

Inadequate storage capacity is a prime contributor to it.

• Depletion of ground water due to over-exploitation is another concern.

Recharging of ground water is less compared to its use.

• Large special temporal variation also a significant contributor.

• Across the nation, the area-wise huge discrimination of rain-fall in rate as well as in quantity is another factorial.

Urban Water Management Issues: Sustainable water management has become a challenge due to growing rate of population, urbanization, and industrialization. Further granularization focuses on inappropriate urban infrastructure, sub-optimal usage of available water resources, depletion, and other associated elements. Major 26 • August 2019

consumers of urban water are industry and municipality, with their conflicting interest to get priority over each other.

On this note, it is worth mentioning that urban water management largely caters to domestic or drinking water supply, and industrial water supply.

• Inadequate water supply in many Indian cities has made the issue critical. The present demand for water is 40 to 45 billion cubic metres with a projection to rise up to 60 billion cubic metres by Yr 2025.

• Due to pollution, quality of drinking water is a big concern.

• Aging of water supply infrastructure, for being deprived of timely repair and renovation, has been adding to it.

• Another loss parameter is poor operation and maintenance system.

This is further reinforced by a vicious cycle of built-neglect-and-rebuilt, which is to be avoided at all cost.

• In major cities, there is a huge gap between demand and supply, mainly due to ever-increasing population.

Smart water management – some best practices in India: 1. Initiatives by Jamshedpur Utilities and Service Company Limited (JUSCO): JUSCO at its continuous endeavor has made Jamshedpur city famous for water purity. People can even drink it directly from the tap.

The city has attended a benchmark of 12.36 percent non-revenue water (NRW), which is the best in India. In

Jamshedpur, more than 70 million liters of water is being recharged and more than 7 million liters of water is being reused each year.

NRW Management: Along with the quality of water, they have established a very prudent loss-management system. To reduce the water consumption, the established loss management system works on twofold way: physical loss management and commercial loss management.

Physical loss management includes treatment works, arresting leakages through service reservoir management, and distribution system management. However, commercial loss management system includes metering consumer-usage, proper billing, disconnecting illegal links, and also segregating the entire area as District Metered Areas (DMA). Thus the loss is very well managed through proper and apt calculation.

Zero Liquid Discharge System: Along with NRW management system, JUSCO’s another prominent initiative is phase-wise movement to zero liquid discharge system. The focus at the initial stage is on total water recycling targeting the sewage treatment plant having working capacity of 10 million litres per day.

This makes the raw-water intake from river reduced as well as saved.

Even the portable water intake has also been reduced in several sectors by using this service water.

2. Initiative by National Water Development Agency: For urban water management, National Water Development Agency has made technology as their weapon through the implementation of waste-towealth concept. Under the national

The deficit of raw water availability is growing from 200 MGD to 400 MGD; and Delhi will need to manage water resources intelligently.

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Lighting of Lamp: H.E. Dr Rashid Alleem, Chairman - Sharjah Electricity & Water Authority; and Mr S Masood Husain, Chairman - Central Water Commission, Ministry of Water Resources, RD & GR, GoI & Chairman – Central Advisory Board, WaterEX World Expo 2019

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Secretary, Minister for Water Resources, RD & GR, Government of India; H.E. Dr Rashid Alleem, Chairman - Sharjah Electricity & Water Authority and H. E. Mr Carlos Pereira Marques, Ambassador of Portugal in India, Embassy of Portugal (L-R) Ms. Deeya Ray – Manager (Sewage Treatment Plant), Jamshedpur Utilities and Services Company Limited (JUSCO); Ms. Alexandra Serra, Executive Board Member, AGUAS DE PORTUGAL INTERNATIONAL S.A.; Mr Sourav Daspatnaik, Chief Executive Officer, Swach Environment Pvt Ltd; Mr Suryam Kasibhatla, V.P. & CoE (Water), Centre of Excellence – Reliance Industries Ltd; Mr Claes Tigerstrand -Senior Technical Manager, Head of Region South, Europe,Outokumpu; Mr Satyajit Chakraborty, Divn Manager, Water Management, JTO, and Lt. Col. Suresh Patil, Green Thumb Environment Protection Group(NGO) @Discussion on Various Projects as Case-Studies

(L-R) Mr Matiur Rahaman, Associate Director- Business Development, IoT & Mobility Solutions, Tata Communications; Mr V P Sreekrishnan, Executive Director (Trombay), Rashtriya Chemicals and Fertilizers Ltd; Mr M. K. Srinivas, Director General, National Water Development Agency; Mr Ajay Girotra, Managing Director, AG Dauters Waste Processing Private Ltd and Mr Shanesh Joshi, Head – Project Development Unit, Western Region, Tata Projects Ltd @Discussion on New Technology Innervations

28 • August 2019

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By Yr 2020, 21 cities in India are expected to run out of ground water mission of ‘Clean Ganga’, they started some hybrid annuity model with various purposes. One such is buying the sewage. The project has targeted the encroachments, which are happening at the river banks of main cities, and which are devoid of necessary permissions as well as necessary constructions. As an unfortunate consequence, sewage is being directly thrown to the river.

In this mission, the sewage water is being collected at one place, put that into treatment plant, and sent back to river.

3. Initiatives by TATA Projects: TATA Projects operates into industrial and urban infrastructure space; and their present focus is on integrated river rejuvenation, as because the surface water is country’s one of the major water resources and is to be taken care of. Recently they have conceptualized and worked on Dravyavati River Project at Jaipur, Rajasthan. Jaipur being a touristspot gets a good amount of tourist foot-fall. Owing to our ignorance for conservation, these rivers are immensely burdened with the regular off-load of untreated domestic sewage and industrial effluents; and much work is not happening towards the river protection. The Central Ground Water and Neeti Aayog together have measured the ratio of water withdrawal and the water-replenishment done. It is very unfortunate that this ratio has come out negative almost everywhere. As an addendum to the whole scenario, a good amount of GDP is lost due to inter-state water disputes.

4. Initiatives by Swach Environment Pvt Ltd: Delhi being in a very water-stressed environment, Swach Environment has taken up a 360 degree approach. To meet the industrial demand for water security, their focus is on both primary water dependency reduction and treated water usage boost up.

The organization has taken up a long-term strategy to make a shift towards covering operating costs through user fees. Adding a revenue generating water reuse component to a project lifts a project’s financial viability, and in turn reduces the burden on public finances. Along with this, Government policies are also aligned to support the development of treated wastewater reuse as a financially sustainable sector.

5. Initiatives by Green Thumb Environment Protection Group: The group identified a seemingly unnoticed constraint: wastage of major portion of rain-water in our country. In spite of adequate rainfall, owing to poor water management many places in our country are either water-stressed or water-scarce. With this thought, they focused on rainwater harvesting and made their mark with water management at dams.

They found that most of the dams are silted and therefore they embarked upon de-silting procedure. At the present days due to ever-increasing population, tree-cutting, grass uprooting, huge encroachment, and other associated factors, demand and supply are heavily imbalanced.

Survey revealed that one to one-andhalf feet of silt is coming down every year. In the bargain, we have more of silt and less of water. A proposition for cleaning up lakes, through the

removal of islands formed inside it, is placed to Government and which is under consideration.

6. A G Dauters Waste Processing Pvt Ltd: The organization works on the theme: grey water holds the key to the future survival of mankind. To elaborate this, water comes in various colours. One of the prominent colours amongst them is grey. It comes with various shades from dark-grey to lightgrey indicating the extent of pollutants in it. This grey water is non-drinkable, yet is used in irrigation and industrial purpose. The organization utilized the power of such grey water. To mention some statistics, India at these days produces approximate 62000 mld grey water and out of which, only approximately 18883 mld of water is being treated right now. During the process, the water becomes dark grey to light grey. If we look into the potentiality of this grey water, 5 times of India’s power requirement can be met from it. Approximately 31000 mld mineral quality of drinking water can be prepared from 62000 mld grey water. Along with, 24000 mld of fuel can also be generated.

These numbers correspond to the fact that such a huge potential is flowing down to river in the form of grey water without proper utilization. The organization is thus working on this grey water treatment with a mission to make every city, town, and village of India self-sustainable through producing their own power, own fuel, and own water.

Contact: jayati_mukherjee@jasubhai.com

Sustainable water management has become a challenge due to growing rate of population, urbanization, and industrialization.

30 • August 2019

Chemical Engineering World

CEW Features

Corrosion Problem in Water and Wastewater Treatment Water is the scarcest resource on Earth these days. About 71 percent of the Earth’s surface is water-covered, and the oceans hold about 96.5 percent of the water available on Earth in aggregate. If we move to drinking water source, the total share comes from large rivers, lakes, ponds, rain, and snow. Still it is very unfortunate to know that there are numerable places in the world which are devoid of natural drinkable water. Gulf and Saudi Arabia are heavily dependent on desalinated sea water for all their daily needs and cultivation. Many cities are dependent on the annual monsoon which provides enough water collected for the whole year. Mumbai is the best example for that. Nonetheless, this article is not to discuss the global water problem and how to make it available; instead, the author here has concentrated on the corrosion issue of water distribution system to household, establishment, and utility periphery.

Water from ponds, rivers, and lakes is first cleaned at one place and then it is distributed to houses, factories, and other utilities. The distribution is usually done through huge pipelines placed either underground or above the surface. In most of the cases, these pipelines are constituted by cemented pipes, cast iron pipes, or steel pipes.

For the steel pipe usage, both inside as well as outside corrosion problem need to be taken care of. The primary concern about the water quality is due

to the presence of toxic metals such as lead and mercury, deterioration of household plumbing, usual problems such as poor taste, and staining on laundry wash basins and drains.

In order to know whether the water will cause corrosion to a pipe or not, there is a method to measure called Saturation Index (SI). Langelier Saturation Index is to evaluate water quality data to determine if the water has a tendency to form a chemical scale. In order to use this

index, laboratory analysis is needed for pH, conductivity, total dissolved solids, alkalinity, and total hardness. Then the actual pH of water is compared to the theoretical pH (pHt) based on the chemical analysis. The Saturation Index is then given by: SI = pH - pHt The Saturation Index is typically either negative or positive and rarely zero. A zero Saturation Index indicates that the

Fig. 1 A typical water treatment plant

32 • August 2019

Chemical Engineering World

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CEW Features water is “balanced” and is less likely to cause scale formation. The scale, typically a carbonate residue, may clog the pipe thus reducing the flow; and may build up on hot water heaters thus imparting an alkali taste to water, reducing the water heater efficiency, and causing other aesthetic problems.

Table 1 presents a typical range of SI for drinking water, a respective description about the nature of the water, and general treatment recommendations. A negative SI suggests that the water is under saturated in context of carbonate equilibrium with greater corrosive

and sudden directional changes in terms of turns and elbows can lead to erosion and corrosion.

Treatment: The treatment to protect the steel pipes from corrosion caused by water consists of: 1. Addition of inhibitors influencing the SI value to remain in the range of 0.5 to (-1).

2. Application of suitable coating.

Use of inhibitor chemicals is the most effective method to control internal corrosion of steel pipes. Many of these inhibitors are either organic or inorganic

Table 1. SI Values and Recommended Treatment [1] Saturation Index Description

General Recommendation

-4

Severe Corrosion

Treatment Recommended

-3

Moderate Corrosion

Treatment Recommended

-2

Moderate Corrosion

Treatment May Be Needed

-1

Mild Corrosion

Treatment May Be Needed

-0.5

None- Mild Corrosion

Probably No Treatment

0

Near Balanced

No Treatment

0.5

Some Faint Coating

Probably No Treatment

1

Mild Scale Coating

Treatment May Be Needed

2

Mild to Moderate Coatings

Treatment May Be Needed

3

Moderate Scale Forming

Treatment Advisable

4

Severe Scale Forming

Treatment Advisable

potentiality.

Reasons for Pipeline Corrosion: To dig deep, the factorials responsible for pipeline corrosion surfaced out as: 1. The pH of water 2. Oxygen content in water as it facilitates the rusting of metal thus causing degradation.

3. Water’s chemical make-up, as the minerals present in water influence the corrosion level. For instance, high levels of calcium can cause build-up level.

4. Water temperature is another prime contributor owing to its corrosion rate enhancing ability.

5. High water velocity, water turbulence,

36 • August 2019

chemicals which react with steel walls and form a thin layer thus protecting the pipe from further corrosion to happen. One such important inhibitor used for drinking water distribution is water soluble alkali silicates. It’s worth mentioning that such distribution is made of steel, stainless steel, copper, or nickel. The silicate reacts with available calcium in water and forms insoluble calcium-silicate layer on the top of the corrosion products, thus prevents further corrosion causing reaction due to aggressive water, carbonic acid,

chlorine, and chloramine. The amount of silicates used are in ppm level which forms a thin mono layer and therefore stops the formation of iron oxide and hence stops the corrosion [2].

These days many of the new water pipelines, getting installed at many cities in India, are choosing a polymer coating layer, especially a food grade epoxy coating with a suitable “C” value which controls the drag and also helps in controlling the corrosion.

From external side, the steel pipe used either above the surface or underground needs corrosion protection in the form of coatings. For above the surface pipelines, a suitable long term system (6-8 years) is shot blasting followed by inorganic Zinc Silicate primer and one/two coat of epoxy with top aliphatic polyurethane coat with total thickness ranging from 200 to 250 µm, depending upon whether the environment is C3 or C4.

For underground water-pipelines, till 2000, reinforced concrete was used as external protection to the steel pipe. However, many failures of such pipelines were reported due to ingress of chemicals, chlorides etc thus causing the pipeline damage; and presently a three layered PE coating has been accepted as the best solution. To add to it, use of coal tar is a coating option on specific areas.

Waste Water Treatment In context of wastewater, a great concern is the treatment and transportation of the same. It is the biggest source of corrosion as it has pH ranging from 1 to 14, toxic solvents, and bio-organics which can deteriorate the steel pipes. There are wide range of different wastewater components, such as Organic components - fats, greases, proteins, surfactants, oils,

Saturation index (SI) is to measure water’s corrosion causing capacity; pH, conductivity, total dissolved solids, alkalinity, and total hardness of water are to be ascertained to make the best use of SI. Chemical Engineering World

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CEW Features The water-soluble alkali silicates react with the available calcium in water and forms insoluble calcium-silicate layer thus preventing further corrosion. pesticides, phenols, and the inorganic components of raw sewage viz heavy metals, nitrogen, phosphorus, sulphur, acids, and a variety of strong alkalis.

In addition, gases such as hydrogen sulphide, methane, ammonia, oxygen, carbon dioxide and nitrogen are commonly found in wastewater.

Anaerobic decomposition of organic materials containing sulphur and nitrogen produces, hydrogen sulphide, amines, and volatile fatty acids.

Chlorine and ozone, which are usually added in the final stages for disinfecting can also cause corrosion. Biological bacteria such as sulphur-reducing bacteria (SRB) reduce sulphates to sulphites in an anaerobic environment and produce hydrogen sulphide (H 2 S) gas. Other aerobes, most commonly different strains of Thiobacillus, will oxidize the sulphur to sulphuric acid bringing pH to as low as 1.0, which can cause corrosion to metallic or concrete container.

Corrosion control of wastewater pipelines

internal

Steel pipes transporting sewage or waste water can corrode easily due to highly corrosive water ranging from pH 1 to 14, and also due to presence of various toxic gases especially hydrogen sulphide. Hence the internal surface of the steel or concrete or even ductile iron pipes. Bituminous enamel or coal tar enamel were at one time used to apply for internal and external surface of waste water pipelines [3], the details of material specifications can be seen in AWWA C203. However, due to emission of carcinogenic fumes during application,

2. Three layer polyethylene coating 3. Liquid Epoxy/elastomeric PU coating

use of coal-tar has been discontinued.

Thus the best coating systems for internal coating are :

Though there is no use of applying cathodic protection on water pipelines as it is mandatory in case of crude/gas pipelines, some users have already started putting cathodic protection also.

1. 100 percent solvent-free epoxy coating lining to a thickness of 500-1000 µm.

References

2.

Solvent-free epoxies or polyester coatings modified with glass-flakes can handle highly toxic waste.

3. High solid and high build, fast cure polyamide epoxy protects the internal surface very effectively.

4. 100 percent solids, spray-applied, aromatic poly-urea coating and lining system is suitable for use in immersion and internal lining.

In order to apply these coatings, proper surface preparation is required preferably Sa21/2 or better, followed by application of this coating. For bigger pipes diameters and tanks, these coatings can be applied using airless spray guns but for smaller pipe diameters, automatic pressure spray, and abrasive blasting can be used. It is also important to properly inspect the pipes by checking holidays if any, bond strength etc.

1 Brian Oram, Corrosive Drinking Water (Lead, Copper, Aluminum, Zinc and More), https://water-research.net/ index.php/drinking-water-issuescorrosive-water-lead-copperaluminum-zinc-and-more 2 A Corrosion Protection solution for drinking water distribution piping systems, http://docplayer. net/2140933-Folmar-a-corrosionprotection-solution-for-drinking-waterdistribution-piping-systems.htm 3 Shiwei William Guan, Corrosion protection by coatings for water and waste water pipelines, Water and Wastewater Program West Virginia University, PA, May 15, 2001 4 A.S.Khanna, Corrosion Protection of Underground Gas/Crude Pipelines, in “Corrosion and Materials in the Oil and Gas Industries”, CRS publisher, 2016 p 204-215

Corrosion control of External Waste water Pipelines Though a simple coal tar enamel coating can be enough for giving protection to a waste water pipeline, a polymer based coating usage is required to stop the movement of moisture and pollutants from the soil to the steel surface by slow permeation.

It is therefore expected to use all those coatings which are required for underground crude/gas pipelines:

Wastewater is the biggest source of corrosion as its pH is ranging from 1 to 14, and it contains toxic solvents and bio-organics which can deteriorate the steel pipes.

38 • August 2019

1. Single epoxy coating

Author Details

Prof A S Khanna IIT Bombay (Retd) Chairman SSPC India Chemical Engineering World

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CEW Features

Homogenization in Wastewater Treatment Plants Water being the highly abused natural resource in Indian context, it’s time to look for an alternate water resource.

Waste-water has come out as a potential substitute, which can be reused in industrial and agricultural purpose after apt and thorough treatment. Here the author has bade for a succinct account of the homogenization procedure.

Context: In view of India’s deteriorating water crisis, there is an urgent need to explore alternative means of water management. Wastewater treatment has emerged as a leading solution to ease water stress in the country.

Wastewater treatment plants can treat the contaminated water and retrieve the treated water in a usable format. This water has high potential in agriculture and industrial applications.

Felonies: Variations of flow in wastewater often presents a problematic situation for wastewater treatment plants. Sludge from wastewater must be kept in suspension because if it settles, the operation of the equipment will be hindered. Even pumps will not be able to operate properly as this semi-liquid could create blockages.

Way-out: Therefore, various stages of wastewater treatment by using submersible mixers is a preferred option to retain the solids in suspension. This this was possible with the help of thrust exerted by the submersible mixers into the liquid medium.

The wastewater generated from our daily activities must be freed from oil, color, and other chemicals present in it before it is let out to the environment. Once the initial screening and processing is completed, the liquid is homogenized to ensure that existing pollutants are evenly distributed. This will simplify the next step of neutralization as the contaminants will then be eliminated by injecting an acid or air flow into the mixture. Sometimes the treatment process also envisages

40 • August 2019

anoxic & anaerobic process in the system, where air cannot be used for homogenizing the liquid & keep the microorganisms in suspension. This would be made possible with the help of submersible mixers.

Scope of homogenization: This process of homogenization is particularly useful in all treatment plants that undergo major variations in maximum and minimum flow rates. Homogenization of liquids in large volumes is usually a voluminous task and requires large amounts of energy consumption to get the final liquid. In simple language, wherever we have solids / sludge, we require an equipment for homogenization.

Methods and procedures: There are three methods of homogenizationmechanical, pneumatic, and hydraulic.

The first method carries out this process using a mechanical stirrer. The second method uses bubbling and airlifts. Both these methods are known to have their drawbacks. While both mechanical and pneumatic homogenization consume high levels of energy, pneumatic homogenization also has an expensive cost label attached to it along with reduced efficiency and inability to remove residues. It also makes the tanks more turbulent. Hydraulic homogenization is a standard practice in wastewater plants where a submersible mixer is fitted to

the tank to homogenize the liquids. It is more cost effective in comparison to its counterparts and can also be used in homogenization processes without the requirement of air. The efficiency of hydraulic homogenization is decided by a term called ‘Thrust to Power Ratio (T/P)’, based on which the submersible mixers can be designed.

Mixers and flowmakers are used to homogenize sludge in wastewater treatment plants, sludge treatment systems, sewage pumping stations, centralized and decentralized wastewater treatment plants, industrial processes, and biogas. The equipment can be either direct driven or gear driven. The gear driven mixers would provide more thrust compared to direct driven mixers. This would be a primary reason of using gear driven mixers in huge / lengthy tanks.

The mixing velocity in the tank would be governed by influence zones / velocity profiles provided by the manufacturers.

Probable deterrents: Viscosity of the liquid can create a major hindrance in the mixing process, as liquids with different viscosity will require varying levels of power and propeller strength to get the homogenized product. Specific gravity of the individual liquids also challenges the process of homogenization. The specific gravity is the ratio of the density of a substance and a reference substance.

Wastewater treatment plants can treat the contaminated water and retrieve the treated water in a usable format. This water has high potential in agriculture and industrial applications.

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CEW Features The wastewater generated from our daily activities must be freed from oil, color, and other chemicals present in it before off-loading to the environment.

The specific gravity value of a substance will decide whether it will float or sink when placed in the reference liquid.

Critical elements: Submersible mixers and flowmakers are two critical components of the homogenization process. Submersible mixers are mechanical devices designed to mix or homogenize the liquids in the tank in an effective manner. These mixers are equipped with a powerful and energy efficient motor, coupled with a propeller

can dispose sludge that attaches itself to the mixer. These mixers are also equipped with thermal sensors, moisture system with an alarm and a leakage senor that monitors any potential leakages.

which creates flow in the tank. While most pumps are used to displace water, these mixers use power to create thrust that impacts the sludge in suspension.

Author Details

Conclusion: There are different types of mixers that can be used for this mixing, depending on the viscosity of the liquids and its applications. Latest mixers in the market are technologically superior to its conventional forefathers with multistage sealing system to prevent any sludge from entering and strong propellers that

Krishna Kumar Deputy Manager of Technical Support, Grundfos India.

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CEW Features

Zero Liquid Discharge Concept and a Few Business Cases Pollution and increased demand have made good quality water scarce and expensive, both in terms of direct cost of water, and the effect of unsuitable water on plant economics and product quality. Meanwhile, disposal norms are getting tighter and their enforcement stricter. The author here explained how to effectively and economically solve water scarcity problems by conserving vast volumes of water and protecting the environment by reducing discharge while generating substantial savings. Four case studies have also been cited to make an analogy.

As per the present scenario, good quality water has become scarce and expensive due to pollution and increased demand.

The mentioned expensiveness is imparted by the factorials viz direct cost of water, as well as the effect of unsuitable water on plant economics and product quality.

Meanwhile, disposal norms are getting tighter and their enforcement stricter. Ion Exchange’s effluent recycle solutions are integrated to yield optimal benefits. For instance, recycle systems are combined with specialty water treatment chemical programs that substantially reduce water discharge (for example, cooling tower blowdown); and state-of-the-art effluent treatment plants are integrated with Zero Liquid Discharge (ZLD) processes. These are backed by comprehensive operation and maintenance services for high performance continuity.

Industries that have installed our effluent treatment, recycle and ZLD systems have gained an excellent payback on their investment through: Assured availability of water for 1) process needs as well as low end uses 2) Less requirement of fresh water.

Therefore, considerable savings in fresh water costs 3) Additional savings through recovery of valuable by-products for reuse in process 4) Compliance with pollution control regulations and a clean environment through reduced/zero effluent discharge.

Process: Our ETP/RECYLCE/ZERO DISCHARGE solutions 44 • August 2019

LIQUID integrate

physiochemical, biological, membranes separation process, and multiple effective evaporators for optimum water recovery.

Based on the effluent characteristics, we customize various treatment process and equipments. Thus we offer a wide range of process separation equipments to remove different levels of contaminants like oils, suspended solids etc in the physiochemical process. Depending on the type of organic contaminants we offer the widest range of anaerobic and aerobic processes. For recovery of treated effluent, our range of membrane processes include ultrafiltration, nanofiltration, reverse osmosis (spiral, disc, and tube RO). To treat RO rejects and enhance further recovery of water, we offer a wide range of evaporators. The concept is integrated with complete solid waste management process that includes dewatering equipments.

Our ZLD systems have been installed in almost all industries. A partial list of some complex liquid waste we have treated to a level of zero liquid discharge include: • A refinery at Jamnagar (Gujarat, India) installed a water treatment plant that is designed to contain and treat all internal process/utility waste water and storm/fire water, with the objective of zero liquid discharge.

• A leading fertilizer company in North India has installed a recycling plant - design capacity 128 m 3/h. Cooling tower blowdown and regenerate waste from the demineralization plant are recycled and reused in process.

• A leading integrated steel manufacturer has implemented a series of near ZLD projects with the objective of reducing water conservation per tonne of steel produced to enhance their competitiveness through reduced water footprint.

Some case studies are given below:

Case Study 1: Ion Exchange has supplied a state-of-theart ZLD plant for a cement manufacturer in Gujarat. The plant was successfully commissioned in the year 2009 and is in operation since then. The total effluent generated from the utility department of the power plant, is about 500 m 3/day. This includes blow down from cooling towers, reject/effluent from softeners, DM plant, and pressure sand filters.

A sharp decline in the water levels of the region and an overall environmental consciousness led the company to set up the first plant of its type in their group, enabling them to achieve their vision for water conservation and zero discharge.

To treat the effluents, Ion Exchange recommended & implemented a scheme that includes extensive pretreatment of water, Indion Ultra filtration (UF) followed by two-stage Indion Reverse Osmosis (RO) and finally evaporation to handle the reject from the membrane systems. The plant, thus, recovers 85 percent of the waste water for reuse and achieves zero discharge. At the same time it helps conserve water by reducing fresh water intake through this recycling program.

Chemical Engineering World

Features CEW A plant can recover almost 91 percent of the wastewater for reuse and can achieve zero discharge through the usage of ultra-filtration, reverse osmosis, and evaporation.

Case Study 2 Ion Exchange has supplied a state-of-the-art ZLD plant for on EPC basis along with O&M for a synthetic rubber manufacturing facility in North India.

This is designed to treat 3000 m 3 /day of complex effluent generated by process with a treatment scheme, which includes physico chemical process and two stage biological process followed by state of the art membrane process consisting of Indion Ultra Filtration (UF), Indion Reverse Osmosis (RO), and finally evaporation (MEE) to handle the rejects from membrane systems. The plant, thus, recovers 91 percent of the waste water for reuse and achieves zero discharge.

Case Study 3 Ion Exchange has supplied a ZLD plant for a major synthetic fiber & polyester manufacturing plant in Gujarat.

This ZLD plant is designed to treat 50 m 3 /hr of waste water, with a treatment scheme, which includes Indion HRSCC, followed by Indion Ultra filtration (UF), two stage Indion Reverse Osmosis (RO) and finally evaporation (Multi effect evaporator) to handle the rejects from membrane systems.

The plant, thus, recovers 90 percent of the waste water for reuse and achieves zero discharge.

Case Study 4 Ion Exchange executed a very large ZLD project for a large automotive manufacturing company which also included a water treatment plant for industrial and potable water supply, domestic sewage treatment systems using advanced Membrane Bioreactor (MBR) technology apart from dedicated facilities for water and sewage treatment plants for the company’s township thus creating a world-class ‘Water Complex’ at the customer’s location.

Conclusion: The Ion Exchange ZLD systems provide numerous economic and environmental advantages wherein water is recycled and reused, accruing savings on the cost and treatment of raw water. Since all water is reclaimed, no effluent is discharged from the plant, minimizing the environmental impact of industrial activity.

Chemical Engineering World

Author Mr. Ajay Popat President Ion Exchange India Limited

August 2019 • 47

CEW Features INTERNATiONAL CASE STUDY Tagus Estuary Clean-up Project

How Smart Wastewater Management leads to Urban Sustainability Tagus River covers the heart of two countries – Portugal and Spain, thus the river’s basin contributes immensely to the economic development of both the countries. With almost 3 millions inhabitants, several important industries, and with an extensive administrative divisions comprising of 19 municipalities, it is the largest SOE (Standard Operating Environment) of Western Europe. With this context, this case-study has got international prominence for contributing to modern economic development of both the countries.

Importance of Tagus Estuary: Tagus River is the longest river of the Iberian Peninsula. It flows west across Spain and Portugal for 1,000 km to end into the Atlantic Ocean near Lisbon. It covers the heart of Portugal and Spain, and has been of vital importance to the modern economic development of the two nations.

Tagus estuary is the largest estuary in Western Europe with about 34,000 hectares (84,000 acres), and regularly hosts 50,000 wintering waterfowl. It is an important natural reserve and includes the largest wetland in Portugal and one of the most importants in Europe. The estuary is a sanctuary for fish, mollusks, crustaceans, and especially to birds that stop-over on their migration between Northern Europe and Africa.

Tagus estuary plays a fundamental role not only in terms of ecological value but also in economic development. Several important industries and extensive areas of agriculture are located near the estuary. Almost 3 million inhabitants are concentrated in the north and south bank of the estuary, the highest population concentration in Portugal.

Problem Statement: Back in 1998, estuarine ecosystems were affected by highly polluting activities receiving wastes from agricultural and industrial activities and from large urban centers. Trancão

48 • August 2019

river, a tributary to Tagus estuary was the most polluted river in Europe. Some of the most beautiful beaches around Lisbon were heavily polluted. Constant and devastating floods due to functional failure of sewage network during storms provoked major losses in Lower Lisbon.

Wastewater treatment facilities were unreliable; and untreated domestic and industrial wastewater were discharged in the estuary. In fact the concentration of densely urbanized areas and industrial clusters in the region has resulted in strong and growing environmental degradation that could only be curbed through combined efforts and integrated solutions.

This situation was common across Portugal. Water Supply and Wastewater Sector was lagging behind, faced with poor performance, fragmentation in service provision, and lack of financial sustainability.

In many regions of the country, potable water did not reach minimum quality standards, the service was interrupted during summer due to vulnerable water sources, and information for the consumer was not available. Only 15 percent of the

population was connected to wastewater treatment facilities; many rivers were heavily polluted and a large extension of coastal area bathing waters were contaminated.

Project Conceptualization: The Central State realized that it was not possible to maintain business as usual and decided to start a transformative institutional reform. The strategy defined at the political level was based on combined efforts of public and private entities with a strong commitment of the State and the Municipalities. It was conceived and implemented an innovative governance model involving the Central State, through Águas de Portugal, and the local authorities (the municipalities around the estuary) in a public-public partnership where Águas de Portugal and the municipalities are shareholders of the two Wastewater Utilities (Águas do Tejo Atlântico and SIMARSUL) in the north and south bank of the estuary. These utilities operate under a 30 concession contract with a full cost recovery approach.

An ambitious Rejuvenation Project was set up for Tagus Estuary, involving the

The project strategy defined at the political level was based on combined efforts of public and private entities along with a strong commitment of the State and the Municipalities.

Chemical Engineering World

Features CEW integrated efforts of all key-stakeholders for the implementation of the following major actions: • Depollution of the waterlines (conception, construction, and O&M of high-tech STP for urban and industrial wastewater treatment by Águas de Portugal subsidiaries) • Requalification and reforestation of riverfronts by the municipalities • Sludge removal, treatment, and valorization by Aguas de Portugal subsidiaries • Fluvial regularization and flood control by the Central State through the national water authorities.

This integrated approach was also very important to gather the necessary skills together, to share management structures, to optimize investments, and to scale up the economies.

Implementation: The action plan implemented by Águas de Portugal subsidiaries (Águas do Tejo Atlântico and Simarsul) included an ambitious infrastructure investment plan of around 700 million Euro to expand and modernize sewerage systems for more than 3.8 million of inhabitants-equivalent.

It was a high scale and technical complex intervention. The treatment level of the Sewerage Treatment Plants (secondary, tertiary, and tertiary with disinfection) was defined taking into account the discharge location and the quality requirements of estuary waters for specific uses and also the re-use of treated water. All technological solutions considered the integration of the infrastructures in the landscape with mitigation of environmental impacts, innovative systemic models, and smart asset management to optimize efficiency, quality, and resilience.

In the north bank, Alcantara STP treats urban wastewater collected from approximately 900,000 households in

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The scope of Tagus-river-project was: • Depollution of waterlines • Requalification and reforestation of waterfronts • Sludge removal, treatment, and valorization • Fluvial regularization and flood control Lisbon and its outskirts. The sewerage system comprises of the Alcantara STP, 13 pumping stations, and 26 km of main sewers. The intervention included the WWTP expansion and the upgrade of its treatment standards (to secondary treatment and disinfection), reducing odors, and improving the landscaping.

For the preliminary treatment, Multiflo and Actiflo technologies were used in the upgradation of Alcantara STP, the latter being only used under wet conditions, when the tributary flows exceed the capacity of the Multiflo lines (3.3 m³/s). Subsequent biological treatment is carried out by biofiltration using Biostyr technology. The legal requirements for the quality of discharged waters are the followings: BOD < 25 mg O2/l; COD < 125 mg O2/l, SS < 35 mg/l and E.Coli: < 2000 Un/1000 ml. The plant is equally equipped with a deodorizing system with the capacity to treat 160,000 m 3 / h of polluted air. After

biological treatment, the wastewater undergoes ultraviolet disinfection and is finally discharged on the Tagus River under safe environmental conditions.

This STP is considered one of the best environmental engineering works in Portugal and it even features in international guides to the best industrial architecture to be visited. The existence of this STP may, however, go by unnoticed as it is unique in its carefully planned suspended gardens, making it perfectly integrated in the urban landscape. This eco-design also protects the facilities from extreme sunlight, sudden downpours, helps improve air quality, and promote urban biodiversity.

The intervention included complex civil works in the old downtown of Lisbon, for the construction of 2 interception chambers (with tidal valves) in the old 18th century drainage pipes, and the construction of interceptors and

Figure 1 – ALCANTARA STP. Aerial view of the rooftop.

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CEW Features wastewater pumping stations for the routing of the flow to the ALCANTARA WWTP. The GUIA STP is the second largest STP of the Great Lisbon region. It treats the sewerage of 800,000 people in a top touristic area in the coastal area near Lisbon: Costa do Estoril and Cascais.

Costa do Estoril is a residential and tourist area, with 720 thousand people equivalent, being one of the most attractive areas in Lisbon surroundings, due to its sandy beaches and appealing landscape. In the fifties, Costa do Estoril population was less than 200 thousand inhabitants, living in small agglomerations located mainly along the coastline, with independent sewer systems, including sometimes short submarine outfalls. In the sixties, these agglomerations experienced a rapid growth and new cities were born further inland, contaminating local streams and through them the coastal waters. Then water quality started to deteriorate and, in the eighties, most of Costa do Estoril beaches had incompliant and heavily polluted bathing water. An old STP was built in the 90’s just for wastewater screening. Integrated in the Tagus Clean Up Project, in the first decade of 2000, a new plant was built.

The project contributed to have a significant increase in the number of Blue Flags’ beaches, a European award to recognize the high quality European beaches.

Due to the sensitivity of the urban and environmental surroundings, the liquid phase of the new plant is fully underground. It is prepared to switch to different treatment levels in winter and in summer due to the bathing water quality requirements. The solid phase of the GUIA STP is located 5 km from the liquid phase and the sludge is pumped through a pressure conduit. A biogas energy production is incorporated in the solid phase. Presently GUIA STP is selfsufficient in terms of energy.

Other smaller STP were built and are being operated in both the banks of Tagus Estuary. In parallel, a comprehensive program was implemented to eradicate the wastewater discharges along the small rivers and channels.

R&D aspect of the project: Tagus cleanup project was also an opportunity for R&D. An integrated decision support system was created – Aquasafe. Aquasafe is an Operational Decision Support System (ODSS), awarded by International Water Association (IWA).It was designed by

wastewater experts with the support of Lisbon University; it connects complex mathematical modelling and several data acquisition system (excel, SCADA, SQL BD, Web services). It covers the Big Data of the urban water cycle from real time weather dataflow and energy to forecast the environmental effects of the discharge impact in the estuary and to support operational measures during flood events.

Conclusion: Tagus cleanup project is an international case study by its complexity and excellent results. In the last decade, it was possible to reduce the pollutant discharges significantly to assure biodiversity conservation and habitat restoration; and also to have a significant increase in the number of Blue Flags’ beaches, an European award to high quality European beaches.

These results were made possible due to an enabling institutional environment fostered by a sound governance system, diversified, and robust management models involving public (central and local) and private companies, clear regulatory standards, and state-of-the art engineering.

Authors Alexandra Serra Aguas de Portugal Internacional (Executive Board Member) António Frazão Águas do Tejo Atlântico (President) Pedro Póvoa Águas do Tejo Atlântico (Asset Management Department Director) 50 • August 2019

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Features CEW CASE STUDY

Aeration and Mixing Brought Hussain Sagar Lakeâ&#x20AC;&#x2122;s Ecosystem Back to Life

Hussain Sagar Lake is a tourist landmark located between Hyderabad and Secunderabad, and spread across an area of 5.7 square kilometers. The water-body was built on a tributary of river Musi to meet the water and irrigation need of the city. During last few years the water became so polluted that it was declared unsafe for comsumption. The lake became shallow due to siltation and accumulation of plant debris. A grave concern was voiced by neighborhood about the deteriorating condition of the lake. With this context, Hyderabad Metropolitan Development Authority (HMDA) has decided to go for a lake rejuvenation work in year 2016. The author here endeavoured to pen down a concise account of the work done.

Overview: Hussain Sagar Lake in India faced an inflow of untreated waste and pollution thus causing a decrease in dissolved oxygen (DO) level in water and foul odours in the nearby community. An even more critical threat was eutrophication, an excessive number of nutrients in the water-body choking out the natural aquatic life.

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Given the lake is stagnated, circulation and distribution of efficient aeration was needed to alleviate these issues.

Challenges: Hussain Sagar Lake is situated at a recreational area having regular footfall of many visitors. Due to the stagnancy August 2019 â&#x20AC;˘ 51

CEW Features Solution: Aeration Industries International has provided successful water restoration to large-scale waterways from the Olympic Games to small golf-course ponds around the world.

Eurotek Environmental Pvt Ltd has hands-on experience and an understanding about the needs of the lake cleanup and began the engineering process of developing a barge with aeration equipment set upon it. A pilot test was carried out and proven successful. The next step was to begin the restoration of the lake.

However, the challenge was to make the barge robust, so that it can hold six 10hp Aire-O 2 Tritons and two diesel generators. The barge was to clean one section of the lake at a time, while being maneuvered to the next location by a 75 hp OBM engine. The sludges within the lake as well as other pollution were broken down by the aeration and mixing, thus facilitating the revival of aquatic life.

Result: The waste and pollution had started to dissipate by the aeration and mixing generated by the barge unit in operation.

The dissolved oxygen level in water, as well as the water colour started improving, odour and turbidity were decreased, and fish quantity increased. The regular operating schedule of the barge is 9 am to 5 pm every day, which has resulted continuous visible improvement.

Impact: The project has had a huge impact on the lake’s ecosystem and brought the fish population back to life. The aesthetic value for the community has also been improved with the odour reduction and water-colour improvement. The health of surrounding plant-life has also been positively enhanced owing to this project.

The team of Eurotek and Aeration Industries found great value by working on this project with the improvement of community life and lake’s ecosystem. They bagged the award from World Water Leadership Congress’ Lake / River Aeration Systems in recognition of their work in this project.

of the lake owing to absence of outflow of water, finding out a solution for this issue was the need of the hour. The focus of the solution was to provide aeration and mixing in sections throughout the lake to support sludge digestion and mixing of the polluted water. Another deterrent was the heavy currents of lake water and high winds during rainy seasons. Therefore, the solution needed to be so designed that it can exhibit reliable performance in these varying conditions.

52 • August 2019

Author Details

Toufiq Mirza Baig Marketing Manager Eurotek Environmental Pvt Ltd Chemical Engineering World

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Marketing Initiatives

UNIQUE MODULAR CONCEPT MULTIPLE MEASUREMENT TECHNOLOGY IN ONE ANALYSER Real Time Water Quality Monitoring

Tethys manufactures various measurement technologies for water quality measurements such as UV Spectroscopy, UV Spectroscopy after gas stripping, UV Fluorescence, Colorimetric, Nephelometric, Electrochemical Sensors.

Tethys offers unique modular concept wherein multiple measurement technologies can be integrated in one analyser.

The unique modular concept of Tethys make online analyser allows to monitor simultaneously different parameters for waste water treatment plants with an

excellent stability and low operating cost.

Thanks to the Tethys R&D team who invented innovative modular concept for online water analysers which allows measurement of various parameters even if it follows different measurement technology – in one analyser. For example, Tethys can offer in one analyser – measurements like COD, BOD, TSS (UV Spectroscopy), Ammonia - NH4 (UV Spectroscopy after gas stripping), Oil-in-water (UV Fluorescence), Phosphate (Colorimetric), Turbidity (Nephelometric), pH, DO, TSS (External Sensor attachment).

Special features of Tethys water analyser: • Effluent Quality Monitoring System (EQMS) for measurement of COD, BOD, pH, TSS, Ammonia (NH4), TP, TN, Chlorine can be possible in one analyser for waste water treatment plant.

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• The UV source of xenon flash lamp has more than 10 years of life time • Automatic Zero calibration • Automatic cleaning facility • Multiplexing facility allows measurement of 6 sample stream • A USB port allows software updates & configuration backup/restore User-Friendly Interface The colour touch screen and intuitive interface makes very easy to test or configure the analyser. Many test functions allows to test and troubleshoot quickly a maintenance diagnostic.

An acid resistant protection film on the screen assumes an efficient long-term protection.

TETHYS Instruments 57, Chemin du Vieux Chene, 38240 Meylan-FranceTel : +33 4 76 41 86 39 Fax : +33 4 76 41 92 27 Mail : sales@tethys-instruments.com Web : www.tethys-instruments.com August 2019 • 53

CEW Products Vacuum System

Electro Magnetic Meter Vacuum system finds application in many fields, including pharma, chemical, plastic, food and pasta production, leather chemicals and centralized vacuum systems.

The instrument works on the principle of Faraday’s law of Electromagnetic Induction. A magnetic field is generated by the instrument in the flow tube. The fluid flowing through this magnetic field generates a voltage that is proportional to the flow velocity. This voltage is measured by the electronics and a corresponding output provided.

Vacuum systems are variable and optimized by the selection for the application and working parameters. It is possible to decrease power, saving in the range 30-40 per cent.

The condensor has been standardised with 1.5-m2², 3-m2² and 6-m2 cooling surface area. The material of construction can be given in mild steel/SS-304/SS-316 for shell and copper/Cu. Nickel/SS-304/ SS-316 for the cooling coil.

Universal power supply accepts any voltage from 90 to 265 V AC. Bi-directional flow measurement measures the flow in both forward and reverse directions. Built-in totaliser provides a separate totalized volume value for flow in each direction. Remote monitoring is easy monitoring of the process even in hard to reach places. Conforms to International Standards - designed to meet global requirements and available with international approvals.

For details contact: Toshniwal Instruments (Madras) Pvt Ltd 267 Kilpauk Garden Road, Chennai 600 010 Tel: 044-26448983, 26448558 E-mail: sales@toshniwal.net

For details contact: Toshniwal Hyvac Pvt Ltd 267 Kilpauk Garden Road, Chennai 600 010 Tel: 044-26448558, 26448983 E-mail: sales@toshniwal.net

The condensor helps in reducing the process time of drying, distillation, etc, by effectively condensing the condensable vapours.

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Hybrid - LRVP

Water Meters

Toshniwal leader in vacuum engineering for over 60 years, now provide further solution to your vacuum needs. Pompetravini’s experience in manufacturing of liquid ring vacuum pumps has acquired over 70 years is led to the creation of new improved liquid ring pumps that offer optimum performance and reliability. They offer minimal water consumption and an innovative impeller design that assure extremely quite operation and extending its life even under harsh condition. Pompetravaini has the most advanced manufacturing process with the objective to reduce manufacturing and shortening of delivery times.

Lifestyle choices, population growth and climate change are placing increasing demands on our water supplies. It is important that we do not take this precious resource for granted and that we all use water wisely to ensure that there is enough for everyone in years to come. Water saving habits started now will become a way of life for the future. Toshniwal provides a comprehensive water meter portfolio to meet the world’s water utility requirements. Toshniwal’s Series continues to be in the water industry standards. Our quiet, rugged and reliable industrial and domestic water meters achieve ultra-low flow measurement and meets or exceeds all standards.

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 03

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For details contact: Toshniwal Hyvac Pvt Ltd 267 Kilpauk Garden Road, Chennai 600 010 Tel: 044-26445626, 26448983 E-mail: sales@toshniwal.net or Circle Readers’ Service Card 04

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Products CEW Fluidized Bed Reactors

Filter Bags Parr fluidized bed reactors are used extensively in the chemical process industries. The distinguishing feature of a fluidized bed reactor is that the bed of solid particles or catalyst is supported by an up flow of gas.

This reactor provides easy loading and removing of catalyst. This is advantageous when the solids bed must be removed and replaced frequently. A high conversion with a large throughput is possible with this style of reactor. Such reactors inherently possess excellent heat transfer and mixing characteristics.

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

Filter bags in needle mesh type All materials compliant.

There are wide selection of filter media, eg, polypropylene, polyester, nylon, cotton, non-woven and various micron ratings from 1 to 200 (felt material); positive sealing arrangement with SS or rubber or plastic collar or by snap band type ring.

They are available in single and double length; and broad chemical compatibility.

For details contact: National Card Board Mills Plot No: 140-2/B/2 GIDC Estate Ankleshwar Dist: Bharuch Gujarat 393 002 Tel: 02646-252569, 222569 Fax: 02646-253002 E-mail: ncbmfilter@gmail.com

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AODD Pumps

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AODD Pumps M-Pump offers the best in the field of air-operated d o u b l e diaphragm pumps.

Features sidepor ted design; powder-coated metalic pumps; plastic center section for robust design; PP air valve assembly; single shaft design and low air consumption.

For details contact: Flowmatic Engg Co HO No: 107, 1st Floor SIDCO Estate, Tiny Sector Pattravakkam Diary Road Ambattur, Chennai 600 098 Tel: 044-48574900

Blagdon air-operated double diaphragm pumps for niche applications, to handle chemicals, solvents, acids, mother liquor, MDC and acetone. Pump comes with bolted leak-free design.

Available in SS-316L as a standard with SS-316L air valves for problem-free operation. Side ported suction and discharge single piece rugged design manifolds. No pilot valve air assemblies and less number of spare parts. Having largest installation base in major pharma industries across India and after sales service spread in all major cities for timely service.

For details contact: Samtech Engg Services Pvt Ltd W9, Water Works Road, Thiru-Vi-Ka Indl Estate Guindy, Chennai 600 032 Tel: 044-22502230, 22509473, 22504395, 22504396 E-mail: ravishankar@samtechengg.in / asan@samtechengg.in

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available felt and material. are FDA

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August 2019 • 55

CEW Products Bio Gas Blowers/Compressors

SS Rotary Blowers Swam offers its advanced technology, next generation SR Series blowers, equipped with latest features, enabling it more reliable, energy efficient and lower maintenance.

Bio gas blowers/compressors are available in wide range and available in two designs: the rotary lobe type and sliding vane compressors 20,000 m 3/hr.

These are either root type blower available in various MoC’s CI, CS and SS. They are available with parameters: rotary bio gas of capacity up to 20,000 m 3/hr, pressure up to 1.0 bar g; sliding vane compressors of capacity up to 5,500 m 3/hr, pressure up to 3.0 bar g. They are available in various MoC’s CI, CS, SS, etc.

Blowers are ruggedly built appropriate rotor shaft design, aiming at low deflection and sound level. The rotor profile of SR Series is computer generated, enabling better uniform clearance and higher volumetric efficiency.

The blowers are readily available for flows up to 1,300 m3/hr and pressure up to 0.6 kg/cm2.

For details contact: Swam Pneumatics Pvt Ltd C-2 Sector-3 Gautam Budh Nagar Noida, Uttar Pradesh 201 301 Tel: 0120-4696222 Fax: 91-0120-2443283 E-mail: sales@swamatics.com

For details contact: Swam Pneumatics Pvt Ltd C-2 Sector-3 Gautam Budh Nagar Noida, Uttar Pradesh 201 301 Tel: 0120-4696222 Fax: 91-0120-2443283 E-mail: sales@swamatics.com or Circle Readers’ Service Card 09

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Zero Liquid Discharge Plants Molasses based distillery effluent known as spent wash/vinasse/dunder/thin slops, is one of the most difficult applications for evaporators. These effluents are characterised by a high chemical oxygen demand (COD) and high volumes, creating a heavy pollution load on the environment.

SS Techno has developed various innovative evaporation technologies to achieve total zero liquid discharge solutions for the distillery industry.

SS Techno evaporators are designed for any steam pressure available with the customer and are guaranteed to give crystal clear condensate. The entire water can be recycled after proper polishing treatment. Raw effluent/post-biogas effluents have been successfully handled.

Special applications using alcohol vapours/excess vapours from sugar industry, instead of boiler steam have been also implemented.

Concentration of solids to any level from 30 to 95 per cent (w/w) has been successfully achieved in various plants as per the customers’ needs. Concentrate with 70 per cent solids (w/w) has been successfully incinerated in regular boiler by mixing it with primary fuel such as bagasse/wood chips/rice husk, etc.

Grain-based distillery effluents are popularly known as thin slops and are concentrated to be used as cattle feed by mixing with distillers wet grain soluble (DWGS).

For details contact: SS Techno Ltd 502 Mayfair Towers I Wakdewadi, Shivajinagar Pune, Maharashtra 411 005 Tel: 020-66524431 Fax: 91-020-66524434 E-mail: marketing@sstechno.com or Circle Readers’ Service Card 11

56 • August 2019

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Products CEW Dust Collection Cartridges Pleated dust collection cartridges are made of 100 per cent polyester media with different coatings on it, as per requirement of applications. Manufacturer of dust collectors originally designed to build the dust collection cartridges in equipment whereas pleated bags can be used for existing dust collector in place of conventional dust collection bags, without modifications. This polyester media is made of high tenacity filament yarn without using any binding agent. Thus, hard finished material is very stable against hot gas attached and structurally durable. This unique and hard finished material provides features of good pleat ability, high durability and unique structure of very fine filament yarn which offer high performance in filtration. Thermally tight bonded media provide washability, excellent pleatability, stable structure, fine dust release and good resistance of particle penetration into the media. These filter media are pleated in different pleated depths and height to accommodate desired filtration area. Construction pleated spun bonded filter media placed in a cylindrical configuration with support of metal core and encapsulated with metal-end caps to form pleated dust collection cartridges.

Features high filtration area up to 20 m2; universal fixing arrangements; open pleat spacing; low consumption of compressed air for cleaning; high air to cloth ratio and high filtration efficiency.

For details contact: National Card Board Mills Plot No: 140-2/B/2 GIDC Estate Ankleshwar, Dist: Bharuch, Gujarat 393 002 Tel: 02646-252569, 222569, Fax: 02646-253002 E-mail: ncbmfilter@gmail.com

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High-pressure Compressors With the Orkan Series, Sauer celebrates the premiere of a versatile compressor range that combines a number of innovative technologies. The Orkan high-pressure compressors will be available in various designs and are suitable for the compression of many gases and for a wide range of applications. The aircooled Series comprises oil-lubricated piston compressors and gas compressors of up to 110-kW for final pressures of up to 500-barg. Booster solutions with inlet pressures of up to 16-barg are also covered. The new series will enter the market approximately within the first quarter of 2020. The Orkan Series is based on a versatile, modular system. Various designs are ready to cater for special requirements. There are hermetically gas-tight and explosion-proof versions for helium, natural gas and hydrogen. In the hermetically gas-tight compressors, Sauer uses a new type of magnet coupling for the first time. It not only guarantees absolute gas-tightness but is also extremely low-maintenance and operates with maximum reliability.

A further novelty of the Orkan Series is the innovative cooling concept. The new CubeCooler enables recooling temperatures that are more than 30 per cent lower than those of conventional cooler configurations. For a high cooling capacity like this, Sauer Compressors arranged the coolers radially around the combined fan and flywheel. This cooling concept has already proven itself in the Sauer medium-pressure Series Breeze.

With its technical properties, the Orkan Series ranges between Sauer’s Hurricane Series and 6000 Series. Thus, Sauer’s portfolio of high-pressure compressors of up to 500-barg now covers the entire range of 4 to 230-kW. The Orkan Series is equipped with the new compressor control Sauer ecc 4.0 which stands for simple operation and a high degree of safety. Another advantage of the air-cooled compressors is the extremely compact and clear construction for this performance class.

Today, it focusses on the development, production and sale of medium- and high-pressure compressors for applications in commercial shipping, industries, the petroleum industry and the defence sector. The four product lines SAUER, HAUG, Girodin und EK focus on specific fields of application. The SAUER line comprises oil-lubricated high-pressure compressors for a wide variety of applications, while HAUG stands for oil-free and hermetically gas-tight compressors. The Girodin and EK lines offer special compressors for the naval market. Sauer Compressors’ modern reciprocating compressors for the compression of air and various gases reach pressures of 20 to 500-barg. Besides standard products, it offers customised solutions for individual customers, OEMs and companies that operate on a global stage. Sauer offers system solutions right up to complete turnkey installations.

For details contact: J P Sauer & Sohn Maschinenbau GmbH Brauner Berg 15 24159 Kiel, Germany Tel: +49 431 3940-0 E-mail: William.Koester@sauercompressors.de or Circle Readers’ Service Card 13

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August 2019 • 57

CEW Products Vacuum Pumping Systems

Tubular Reactors

Booster/dry screw pump vacuum pumping systems combine high pumping speed with deep vacuum levels and operate free of oil, water or other sealing liquids.

Parr tubular reactors use continuous reactant feed, a variety of heating and product handling options, with automation and data collection options.

Available in 2 and 3 stage configurations; flexible options for customisation – inlet filters for drying/powder applications; automatic solvent flushing; automatic nitrogen purging and nitrogen flushing; post condensers with receivers; automation and instrumentations; electric control panels with variable frequency drives; standard and flame proof type varying electrical motors; skid mounted systems with interconnecting piping and valves.

In this style, liquids and gases are introduced to one end of the reactor and these fluids are heated to the operating temperature and then flow through a fixed bed of packed catalyst where the reaction takes place.

For details contact: Everest B-44 Mayapuri Indl Area, Phase 1 New Delhi 110 064 Tel: 011-45457777 E-mail: enquiry@everestblowers.com

Tubular reactors are always used in a continuous flow mode with reagents flowing in and products being removed. They can be the simplest of all reactor designs. Tubular reactors are often referred to packed-bed reactor.

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

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Platinum-cured Silicone Hose Reinforced with Polyester Braiding Imafit is platinum-cured silicone hose reinforced with polyester braiding. It has excellent flexibility for pressurized fluid transfer application in pharma and biotech industries. Ami Polymer is catering these products to all pharma and biotech companies in India as well as overseas market. Imafit hose is manufactured under stringent quality parameters to have greater flexibility and minimum bend radius.

Imafit conforms to US FDA 21 CFR 117.2600 Food Grade Standard, USP Class VI and ISO 10993-1. It is certified by ROHS and TSE/BSE Certification (free of animal derived material). It is free of restricted heavy metals and Phthalate/Bisphenol/ Volatile Plasticizer. Complete validation package available upon request.

Imafit is manufactured from low volatile grade silicone resin. It is excellent in flexibility and has lot traceability features. It imparts no taste and odour. It is available with SS-316L Tri-clover end fittings in required length. It is also available in colored outer layer and custom colour coding. It has flexibility at lower temperature up to -80 oC and high heat resistance up to 180 oC. It is sterilisable by autoclave, ethylene oxide gas and gamma radiation. Sandwich printing technology in which fine layer of platinum-cured silicone is applied over printed hose. It gives permanent print which avoids direct product contact. It can be laser etched hoses for permanent identification on outer surface of hoses. It is for ease of on-product traceability. It is available with nylon braid reinforcement on request. It is also available with bi-colour coding strips/lining for colour coding based product identification to avoid mix-up while usage on request.

For details contact: Ami Polymer Pvt Ltd 319 Mahesh Indl Estate, Opp: Silver Park Mira-Bhayander Rd, Mira Road (E) Thane, Maharashtra 401 104 Tel: 022-28555107, 28555631, 28555914 E-mail: mktg@amipolymer.com or Circle Readers’ Service Card 16

58 • August 2019

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Products CEW SS Filter Housing Stainless steel filter housing is designed to offer wide range of fluid flow capacity and compatibility suitable for most types of cartridge filters.

SS-304 and SS-316 brushed/electropolished material construction for max corrosion-resistance in a non-code filter housing. Swing bolt closure design with 150-psig (10.3-bar) max operating pressure assures secure sealing and easy cartridge changeout.

Flow rates from 180 to 300-GPM. It is ideal for water, paints, photographic solutions, food and beverage products, petrochemical, pharma, plating solutions. All models available with vent and drains for easy cartrdige change and maintenance. Accept 27 round filter cartridges in length 10”, 20”, 30” or 40” from variety band. Accept cartridges with double open-end (DOE). Optional for SOE O-ring and 22y O-ring fin-end configuration standard shell O-ring to be Buna-N: silicon, Viton and EPRM. For details contact: National Card Board Mill Plot No: 140-2/B/2, GIDC Estate Ankleshwar, Dist: Bharuch Gujarat 390 002 Tel: 02646-252569, 222569 Fax: 91-02646-253002 E-mail: ncbmfilter@gmail.com or Circle Readers’ Service Card 17

PC-based Control Technology Beckhoff offers its expertise as a long-standing automation partner for the logistics industry. Open PC and EtherCAT-based control technology is ideally suited for optimising logistics processes and responding to quickly changing market trends. With open interfaces, modularity and scalable performance, it is the perfect fit for intralogistics solutions that are custom-tailored to individual requirements, while delivering technological and economic competitive advantages at the same time. Components for system-integrated connection to the cloud make it easier to implement IoT and Industrie 4.0 concepts in smart warehouses.

Due to its openness, PC-based control technology from Beckhoff fulfils the requirements for end-toend networking of intralogistics, production and distribution to perfection – one of the key challenges in the sector. PC-based control is based on a comprehensive portfolio of advanced Industrial PCs, TwinCAT automation software, EtherCAT as a fast communication system, decentralised I/O components and highly dynamic drive solutions. Integrated, cost-effective and flexible system planning is assured by the performance-driven scalability of the control platform, the flexible support for different fieldbus systems and the same programming and configuration software across all performance classes.

The TwinCAT automation software suite bundles all necessary machine functionalities: from PLC to motion control, robotics, HMI, safety and measurement technology through to integration of vision systems and cloud solutions. Open interfaces allow effortless integration of control functions into existing system and database structures. With support for standardised protocols, such as OPC UA, Beckhoff provides the prerequisites for implementing secure cloud communication in the smart warehouse. Users benefit from the openness of the control architecture also in this respect, for example through the unrestricted choice of cloud solution. All systems concerned – from I/O level to warehouse management and eCommerce software – can be fully connected.

For details contact: Beckhoff Automation Pvt Ltd Suyog Platinum Tower, 9 th Floor Naylor Road, Off Mangaldas Road Pune, Maharashtra 411 001 Tel: 020-67064802 Fax: 91-020-67064899 E-mail: a.phatak@beckhoff.com info@beckhoff.co.in or Circle Readers’ Service Card 00 18

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CEW Products Water Ring Pump & Booster Vacuum Pumping Systems Booster/water ring pump vacuum pumping systems are ideal for pumping wet gas mixtures at low pressure. Sealing liquid used being water gives this system good flexibility for use in various applications.

They are available in 2 and 3 stage configurations and are widely used in various essential oil, cardanol distillations and CNSL applications. Flexible options for customisation – inlet filters for drying/powder applications; post condensers with receivers; automation and instrumentations; electric control panels with variable frequency drives; standard and flame-proof type varying electrical motors; skid-mounted system with interconnecting piping and valves.

For details contact: Everest B-44 Mayapuri Indl Area, Phase 1 New Delhi 110 064 Tel: 011-45457777 E-mail: enquiry@everestblowers.com or Circle Readers’ Service Card 19

Automated Liquid Sampler A safe and reliable method for collecting multiple liquid samples from heated and pressurised reactors has been sought for many years. Parr Instrument Company offers the 4878 automated liquid sampler which can extract up to six liquid samples at a user-defined interval without the need for the continued presence of an operator.

Features touch screen controller with easy to navigate graphical displays; standalone design compatible with any new or existing Parr reactors and pressure vessels; user-definable parameters including time between samples, number of samples and number of loop sequences; capability to connect with mobile devices on both iOS and Android platforms.

For details contact: Orbit Technologies Pvt Ltd B-50 Indl Estate, Sanath Nagar, Hyderabad Telangana 500 018 Tel: 040-67216354 Fax: 91-040-23801579 E-mail: orbit@orbitindia.com or Circle Readers’ Service Card 20

Custom-made High-pressure Solutions In addition to high-pressure compressors, Sauer Compressors also offers a wide range of accessories specially designed for medium- and high-pressure solutions. These include compressor controls, air and gas dryers as well as storage and distribution solutions.

The new Sauer ecc 4.0 compressor control system is a cornerstone in Sauer’s accessories portfolio. The control is based on an intelligent modular design principle that enables an exact adaptation to the individual version of the compressor. It is also highly customisable, because its software was developed entirely inhouse by Sauer. The new control supports communication via all common interfaces and can therefore be easily integrated into higher-level systems. In operation, the innovation convinces with its simple and intuitive usability via a 7” touch display.

Sauer also offers solutions for drying and storage that are individually tailored to the requirements of the individual application. There are two dryer series specially designed for high-pressure applications. The highpressure refrigerant dryers of the Sauer SRD Series are suitable for drying air and gases with final pressures of up to 420-barg and achieve a pressure dew point of 3-5oC. They can also be used as gas coolers. The high-pressure adsorption dryers of the Sauer SDD Series achieve reliable dew points of up to -40oC at final pressures of up to 350-barg. They are specifically designed and optimised for use with Sauer high-pressure compressors.

Also available is a wide range of high-pressure storage systems for wet and dry gases with capacities of up to 600 l and for pressures of up to 350-barg. Versatile condensate management solutions are available for proper condensate collection. Customers benefit from tailor-made solutions from a single source, carefully matched components and short delivery times.

For details contact: J P Sauer & Sohn Maschinenbau GmbH Brauner Berg 15 24159 Kiel, Germany Tel: +49 431 3940-0 E-mail: William.Koester@sauercompressors.de or Circle Readers’ Service Card 21

60 • August 2019

Chemical Engineering World

Products CEW Dust Extractors Dustcontrol UK offers a range of its highly effective equipment of both fixed and mobile cyclone-based dust extractors and air cleaners.

The DC 11-Module for example, which comes in several models, is an optimised stand-alone unit for source extraction and industrial cleaning. It has been designed to service up to six normal extraction points or several cleaning outlets at a time, and is modularly built, meaning it can be tailor-made to suit any manufacturing and production environment.

As with all of Dustcontrol UK’s equipment, the DC 11-Module can be fitted with Hepa 13 filters, meaning exhaust air can be safely returned to the work environment.

The company, based in Milton Keynes, has many years of experience in developing dust extraction solutions and centralised vacuum systems to fit client requirements in the manufacturing and production industries. They are experts in capturing dust at its source - both where and when it is created.

For details contact: Dustcontrol UK Ltd 7 Beaufort Court, Roebuck Way Knowlhill Milton Keynes MK5 8 HL, U.K. Tel: 01327 858001, Fax: 01327 858002 E-mail: sales@dustcontrol.co.uk. or Circle Readers’ Service Card 22

Frequency Inverters The new frequency inverters from the NORDAC PRO family can be optimally assigned to a wide range of application requirements. The functions of the modular Series can be extended by plug-in control, safety and option modules.

Users also benefit from a particularly compact design in booksize format. The inverters are available in a power range from 0.25 to 5.5 kW. This latest addition to the family carries a large number of interfaces. As well as the standard CANopen interface, a multi-chip for Industrial Ethernet enables the use of the most important real-time Ethernet standards via a single interface. Whether for ProfiNet, EtherNET IP, POWERLINK or EtherCat, the required protocol can be easily set by means of parameters. The devices can also be parameterised via the USB port without an external power supply (programming in the box). The SD card slot for saving and transferring parameters is also a novelty. In addition, five or six digital and two analogue inputs, two digital and one analog outputs, two potential-free multifunction relays, an HTL /TTL incremental encoder interface as well as a universal encoder interface are available.

As with all NORD frequency inverters, the NORDAC PRO SK 500P Series is equipped with a powerful PLC for functions close to the drive. The precise current vector control can provide the optimum torque in various load and speed situations and guarantees operational reliability with high overload reserves, which users need. The inverter operates either open-loop or closed-loop and can operate both synchronous and asynchronous motors. The integrated brake chopper for 4-quadrant operation is a part of the basic equipment for the entire Series, as is motor brake management, which is important. NORD supplies the inverters with integrated STO and SS1.

The new NORD solution for control cabinet installation is available as a machine inverter (SK 500P) and as an application inverter (SK 530P and SK 550P). In contrast to the fully equipped application inverter, the machine inverter is an economically optimised device with a reduced number of interfaces, however still performs functionally demanding tasks such as integrated PLC, closed-loop control and positioning. The SK 530P also features an SD card slot, USB interface, encoder interface and the possibility of expansion via an optional SK CU5 module. On the other hand, the SK 550P is the first choice for connection to control systems via Industrial Ethernet. Sale is expected to start in the fourth qu2019.

For details contact: NORD DRIVESYSTEMS Pvt Ltd 282/2 & 283/2, Plot No: 15, Village Mann Tal: Mulshi, Adj Hinjewadi MIDC Phase II Pune, Maharashtra 411 057 Tel: 020-39801217 Fax: 91-020-39801416 E-mail: monika.mishra@nord.com / pl.muthusekkar@nord.com or Circle Readers’ Service Card 23

Chemical Engineering World

August 2019 • 61

CEW Products Bi-metal Clad Metal Dali Electronics offers copper aluminium-claded bi-metal (Grade 80:20 or 85:15) from ready stock. Aluminium copper-claded bi–metal (AlCu) consists of copper (sheet metal) cladded on pure aluminium (base metal), both metals being diffused together to form an inseparable whole by roll bonding process. This is not an alloy and copper layers are not electro plating/galvanic coatings but are rather mechanically welded on aluminium with copper sheets.

Aluminium terminals are directly connected to copper terminals to carry current at a high voltage, a bi-metallic galvanic corrosion occurs, resulting in a high resistance at the joint. The heated joints are oxidized and looses contact resulting in sparks, voltage dropout power losses and failure, damage to machinery. When this is placed between aluminium and copper terminals at the joint (with copper facing copper and aluminium facing aluminium), bi-metallic galvanic corrosion is averted due to absence of air. It is thus used at dissimilar metals joints of aluminium and copper to make similar metal’s contact. This has been successfully evaluated and used by many of the world’s leading electrical equipment manufacturers.

It finds application in transformer bushings, busbar chambers, busducts, cable clamp, circuit breakers, isolators, overhead lines and connectors, panel boards, switch blades, switch plant, switchgears, terminal strips, motor control centers, cable end connectors, apparatus construction, cable thimbles in copper, current bars and similar parts, bi-metallic clamp and connectors, distribution and panel boards, overhead busbar trunking systems, packing and washers between aluminium and copper bars, sleeve shape insert in terminals in copper and aluminium, substation accessories like bi-metallic clamp and connectors, terminals of copper connecting conductors with aluminium conductors, etc.

For details contact: Dali Electronics 8a, Haroon Building 190 Shamaldas Gandhi Marg Princess Street Mumbai 400 002 E-mail: sleeves@domadia.com / sales@domadia.com or Circle Readers’ Service Card 24

Service with APP NORD DRIVESYSTEMS has developed an app for diagnosis, analysis, monitoring and parameterisation of NORD drive systems. The new NORDCON APP together with the NORDAC ACCESS BT Bluetooth stick provide a mobile commissioning and service solution and give users new options for control and optimisation of their NORD drives. This speeds up commissioning, simplifies maintenance and enables faults to be remedied faster.

The dashboard-based visualisation is useful for drive monitoring and fault diagnosis. With a help function and rapid access to parameters, parameterisation of drive units is simple and easy. In addition, the app has further practical features such as a backup and recovery function for simple handling of drive parameters, as well as an individually configurable oscilloscope function for analysis of the drive. Video tutorials and the possibility of direct contact with NORD Support additionally assist users in their work.

The NORDAC ACCESS BT acts as a bridge between the drive system and the app. The stick is connected to the software via Bluetooth and is used directly on the frequency inverter. Users therefore have practical access to the drive data and remain in full control of access. The NORDAC ACCESS BT can also be used without the app, to save parameter data. If the frequency inverter is damaged or the drive has to be replaced, the original parameters can be easily uploaded from the stick. Parameter transfer between a drive and a PC is also possible.

The NORDCON APP and NORDAC ACCESS BT are available for all NORD drive electronics and can therefore be used with decentralised frequency inverters as well as control cabinet solutions and with optional modules. The app is available for iOS and Android operating systems in the App Store or in Google Play.

For details contact: NORD DRIVESYSTEMS Pvt Ltd 282/2 & 283/2, Plot No: 15, Village Mann Tal: Mulshi, Adj Hinjewadi MIDC Phase II Pune, Maharashtra 411 057 Tel: 020-39801217 Fax: 91-020-39801416 E-mail: monika.mishra@nord.com / pl.muthusekkar@nord.com or Circle Readers’ Service Card 25

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CEW

NATIONAL

INTERNATIONAL

India Surface Treatment & Finishing Expo

Dates: 05-07 September 2019 Venue: Pragati Maidan, New Delhi Event: This Expo aims to offer the surface finishers with an impeccable

platform for business co-operation and technology dealings. The beauty of this show is that the participants can share all info with the selected audience while making relations with new clients. It is axiomatic that almost all surfaces made by ordinary machining and fabrication techniques are positively skewed and then make an unenviable effect on the bearing load of surfaces, destructively impacting the operation of the parts involved in applications. Hence, the need for specialized high-energy finishing procedures is essentially required to truncate the surface profile peaks.

For details contact: ACE Exhibitions Unit 308-309, Vardhman Sunrise Plaza Vasundhara Enclave, New Delhi 110 096 Tel: 011-40204421, 49538601 E-mail: sales@aceexhibitions.co.in analytica Anacon India and India Lab Expo

Dates: 19-21 September 2019 Venue: Hitex, Hyderabad Event: This Expo is more than just an exhibition. Not only it brings buyers and sellers together for business and networking, it also offers ample of networking opportunities attracting thousands of pharma and R&D professionals â&#x20AC;&#x201C; creating a complete pharma marketplace for your business. Join local and international suppliers as they are exhibiting at analytica Anacon India and India Lab Expo to showcase latest laboratory and analytical instruments and technologies. It is an ideal place for you to connect with buyers, purchasing authorities and heads of procurements across India and promote your brand to right target audiences.

For details contact: Messe Muenchen India Pvt Ltd INIZIO 507 & 508, Cardinal Gracias Rd Chakala, Andheri (E), Mumbai 400 099 Tel: 022-42554710 E-mail: avisha.desai@mm-india.in Electronica India

Dates: 25-27 September 2019 Venue: India Exposition Mart, Greater Noida Event: Electronica India is the leading platform in India focusing on electronic components, systems and applications. It features semiconductors, embedded systems, display, micro and nano-systems, and sensor technology, automotive, wireless and much more.

For details contact: Messe Muenchen India Pvt Ltd INIZIO 507 & 508, Cardinal Gracias Rd Chakala, Andheri (E), Mumbai 400 099 Tel: 022-42554700 Fax: 91-022-42554719 E-mail: info@mm-india.in Chemical Engineering World

International Exhibition of Chemical Industry and Science

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

Dates: 09-11 March 2021 Venue: Exhibition Munich, Munich, Germany Event: International Converting Exhibition Europe event will showcase product like chemicals and dyes, office and commercial supplies, packaging materials, plant, machinery and equipment, plastic and plastic products, business services, paper and paper products and much more.

For details contact: Mack Brooks Group Romeland House, Romeland Hill St Albans, Herts AL3 4ET, U.K. Tel: +44 (0)1727 814400 Fax: +44 (0)1727 814401 E-mail: info@mackbrooks.co.uk ACHEMA

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

For details contact: DECHEMA Ausstellungs GmbH Theodor-Heuss-Allee 25 60486 Frankfurt Germany Tel: +49 (0) 69 7564100 E-mail: exhibition@dechema.de August 2019 â&#x20AC;˘ 63

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 Shalimar Paints lays down the foundation of its Nashik manufacturing plant with a planned monthly production capacity of 2,180-kilolitres.

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

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

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

MINING MOIL recently said production at its Parsoda manganese mine is expected to begin soon. The mine will be operated by opencast mining method. MOIL has been granted mining lease of Parsoda manganese mine near village Parsoda, 46-km from Nagpur in the year 2016. The lease extends for 50 year period, ie, from April 22, 2016 to April 21, 2066 and the project cost is estimated to be ` 19.54-crore. The production is expected to be started soon. MOIL, 64 • August 2019

under the Ministry of Steel, operates around 10 mines, including six in Maharashtra and four in Madhya Pradesh. Balaghat mine is its largest, which produces top quality manganese ore.

Hindustan Copper Limited held a groundbreaking ceremony at Ghatsila Unit for construction of concentrator plant at Rakha, initiating Chapri-Sidheswar mine, a new mine development and Rakha mine re-opening projects. CMD informed that considering the opportunity to further increase the resource base of copper mineral in the State has finalized plan to undertake depth exploration up to 1,000-meter from surface in its existing lease area in next two years. Hindustan Copper Limited, the only copper mining Company in India, in its Unit located at Ghatsila has planned to implement total five mine expansion projects to increase the mine capacity from current 4.0 to 72.0-lakh tonne. Successful implementation of the project will also reduce country's dependence on imported copper concentrate.

Coal India (CIL) is expected to put another 25-30 million tonnes (MT) of coal under the hammer in the ongoing quarter. This comes after e-auction volumes dipped following the decision to pump more coal into the coal-starved power sector through fuel-supply agreements (FSAs). The coal behemoth has been able to book 54-MT of coal through e-auction till December (first three quarters) as against 79-MT in the similar period of the last fiscal year, registering a 31.65 per cent dip. On the other hand, its offtake via the FSA route to power plants increased by over 12 per cent. As more coal gets routed via the FSA route, e-auction volume will be low. Production in January-March was expected to be substantial, which will leave Coal India with more to offer in auctions. It is expected that another 25-30 MT of coal will be offered this quarter on the auction platform. South Eastern Coalfields (SECL), its most important subsidiary, registered a 13.1 per cent fall in production in December at 12.52-MT while Mahanadi Coalfields, the second-largest subsidiary, registered a 3.2 per cent dip at 13.05-MT. These two subsidiaries account for more than 45 per cent of Coal India’s production. Sales were low at 52.77-MT, which is a 1.2 per cent fall compared to December 2017-18. However, in the next fiscal year, the e-auction volumes are expected to dip further. E-auctions directly add to Coal India’s bottom line because the prices are often higher by at least 60 per cent over the notified price. Thus, effectively while the miner spends the same amount of money to mine the coal which is either sold as linkage or put under the hammer, it earns 20 per cent higher in auctions. Prices in the e-auction, however, are expected to remain stagnant in the ` 2,400 a tonne level backed by muted global coal prices. According to S&P Global Platts, the price of FOB Kalimantan 4,200-kilo calorie per kilogram GAR (gross as received) - which is imported in huge volumes by both India and China - has declined almost 22 per cent since October 1, given the sagging demand in China and improving supply in Indonesia.

Chemical Engineering World

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

Coal India aims to raise output from its troubled Rajmahal mine in Jharkhand to 60,000 tonnes a day, having resolved land-acquisition related problems which had crimped production to 20,000 tonnes per day. Coal from the Rajmahal mine helps NTPC run close to 4,200MW of power generation plants in eastern India, which supply power to Bihar, Jharkhand and West Bengal, and also to northern India including Delhi and Uttar Pradesh. NTPC’s generation capacities were faced with depleting coal stocks and lower power generation as supplies from Rajmahal dwindled. Reserves at Rajmahal within the land acquired by Coal India were almost exhausted and required expansion to keep production levels intact. However, land acquisition at two villages - Bansbiha and Taljhari - spanning 160-hectares, adjacent to the existing project turned out to be a lengthy process.

It led to drastic fall in supplies and stocks at the coalfield, as well as at two critical power plants in the region - at Farakka and Kahalgaon.

At present, Coal India is using 15 goods trains to transport coal from the Rajmahal mine to power stations in the region. One goods train can load up to 3,500 tonnes of coal. Coal India is also sending five loaded goods trains from West Bengal’s Ranigunj coalfields to augment supplies at power stations. At present, the entire production from Rajmahal is getting delivered to power plants and there has been no stock buildup yet.

CIL, ONGC to produce coal-bed methane from 10 new mines: The Coal Ministry has identified 11 mines to produce coal bed methane (CBM). Of these, 10 will be worked on jointly by ONGC and Coal India Ltd (CIL). The two entities will also work on one mine with SAIL. Initially, ONGC will harness the gas and then CIL will extract coal from them. In addition to the mines with CIL, the two (ONGC and CIL) will also help develop Steel Authority of India Ltd’s Parbatpur coal block (Jharkhand). Here too, ONGC will first harness the CBM. SAIL had surrendered the Sitanala and Parbatpur coal mines. In its representations while surrendering the Parbatpur mine, SAIL had said there was a reduction in the area available for coal mining due to overlapping of mining area. SAIL had engaged MECON to prepare a techno commercial viability report, which declared the project unviable. The SAIL board had then decided to return the Parbatpur mine to the Coal Ministry.

JSW Energy, part of the Sajjan Jindal-led JSW Group, is believed to be in the race for buying out the thermal power assets of Monnet Power and Jindal India Thermal Power Ltd (JITPL) in Odisha.

Monnet Power’s 1,050-MW coal-based power plant near Angul was in advanced stage of commissioning. Monnet Power’s parent company, Monnet Ispat & Energy had won the Mandakini coal block in Odisha in competitive bidding, it surrendered the block later on grounds of economic unviability. Monnet Power had accumulated Chemical Engineering World

debt in excess of ` 5,000-crore. Though lenders had earlier denied a haircut in JSW Energy’s prospective deal to acquire majority equity in Monnet Power, the Sajjan Jindal-owned firm is still believed to be in the hunt for the asset. Besides Monnet Power, JSW Energy is also eyeing takeover of BC Jindal controlled JITPL’s 1,200-MW coal-based plant at Derang near Angul. The first unit (600-MW) of the 1,200-MW plant had begun commercial operations and started power supplies to the Odisha grid. This project has been completed at a cost of ` 7,537-crore which includes a debt component of ` 5,900-crore. JITPL has power purchase agreements (PPAs) with Odisha’s Gridco Ltd, Kerala State Electricity Board and Tata Power Trading Corporation.

Apart from JSW Energy, JITPL also had competing offers from Adani Power and Singapore’s SembCorp. The valuation of the prospective deal is not known.

NLC India (formerly Neyveli Lignite Corporation) which is in the hunt for buying out power assets, is understood to have shown interest in the 700-MW Odisha plant of Hyderabad-based Ind-Barath Power Infra Ltd (IBPIL). The power plant located at Sahajbahal, near Jharsuguda, has commenced commercial operations. Though the exact size of the potential deal is not known, the valuation could be anywhere in the range of ` 5,000-5,500-crore. In August last year, NLC India had floated an Expression of Interest (EoI) from companies owning coal and lignite-based power projects, for a possible acquisition.

NLC India’s installed thermal power capacity is 3,240-MW. It runs a 10-MW solar power unit and wind power assets with a capacity totalling 37.5-MW. Western Coalfields has received the environment clearance for its ` 263-crore expansion project in Nagpur district, Maharashtra.

The proposal is to enhance the production capacity of the Gokul open-cast mine to 1.875-million tonnes per annum (MTPA) from the existing 1-MTPA. The mine, located in 767.17-hectare, has a mineable reserve of 14.50-million tonnes. The clearance to the project is subject to certain conditions. Total cost is estimated to be ` 263-crore. Among the conditions specified, the company has been asked to get 'Consent to Operate' certificate from the State Pollution Control Board for the existing production capacity of 1-MTPA and also the 'Consent to Establish' for the proposed capacity of 1.875-MTPA prior to enhancing the production capacity.

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

August 2019 • 65

CEW

CEW Book Shelf Wastewater Treatment Fundamentals I Authors: Water Environment Federation and Association of Boards of Certification Price: $139.00 No of pages: 752 pages (Paperback) Publisher: Water Environment Federation About the book: The book covers all aspects of liquid treatment processes and helps operators prepare for the first three levels of certification examinations. In addition to learning the basics of liquid treatment, operators will gain a thorough understanding of critical aspects of biological treatment, nutrient removal and disinfection.

After learning from real-life examples, users can apply the material they learn to situations they encounter in their day-to-day work. Highlights of Wastewater Treatment Fundamentals include: detailed visuals and infographics; comprehensive math examples; practice questions for each module with lots of variety; accessible language for all levels of operators; easy to read format; and peer reviewed. This self-study manual aligns with updated Need-to-Know Criteria from the Association of Boards of Certification (ABC) and is based on WEFs extensive existing resource collection, including Operation of Water Resource Recovery Facilities, MOP 11.

Water and Wastewater Treatment Authors: Joanne E Drinan and Frank Spellman Price: $89.99 (Hardcover) No of pages: 300 pages Publisher: CRC Press (2 nd Edition) About the book: Lauded for its engaging, highly readable style, the best-selling 1 st Edition became the premier guide for non-engineers involved in water and wastewater treatment operations.

Water and Wastewater Treatment: A Guide for the Nonengineering Professional, 2 nd Edition continues to provide a simple, non-mathematical account of the unit processes used to treat both drinking water and wastewater.

Completely revised and expanded, this 2 nd Edition adds new material on technological advances, regulatory requirements, and other current issues facing the water and wastewater industries.

Using step-by-step, jargon-free language, the authors present all the basic unit processes involved in drinking water and wastewater treatment.

They describe each unit process, the function of the process in water or wastewater treatment, and the basic equipment used in each process.

They also explain how the processes fit together within a drinking water or wastewater treatment system and discuss the fundamental concepts that constitute water and wastewater treatment processes as a whole. Avoiding mathematics, chemistry, and biology, the book includes numerous illustrations for easy comprehension of concepts and processes. It also contains chapter summaries and an extensive glossary of terms and abbreviations for quick reference.

66 â&#x20AC;˘ August 2019

New Horizons in Wastewaters Management Editor: Elvis Fosso-Kankeu Price: $230.00 No of pages: 311 pages (Hardcover) Publisher: Nova Science Publishers Inc About the book: In the past few years, there has been a considerable increase in the number of new and emerging pollutants in the limited water resources around the world, posing a serious threat to human health and the ecosystems. These pollutants, which are also referred to as new chemicals without regulatory status, are poorly understood and therefore not properly monitored or effectively removed from wastewater using conventional methods. Relevant topics addressing these challenges are presented in this book containing 12 chapters, which are consequently divided into two sections (Section 1: Pollutants in Wastewater and Section 2: Wastewater Remediation Strategies). The first section provides a systematic review of recent detection methods suitable for the rapid and accurate identification of some emerging pollutants from wastewater. Further development in the book fairly complement the first part by providing solutions for the removal of the emerging pollutants from wastewater and restoration of usable water; innovative approaches encompassing inter-disciplinary processes supported by sustainable technologies are therefore the focus of the second part of the book. The enhancement of bioreactor systems with consideration of volumetric organic loads, membrane configurations and reactor types has been highlighted by authors as strategies to ensure increased biomass proliferation, high effluent production rates and high quality effluents. The development of smart materials for pollutants removal from wastewater being a promising trend for remediation of water pollution, could not be ignored in this book, which aims to emphasize on the latest sustainable and effective technologies. This has been taken care in a few chapters which that explore the synthesis of nanocomposite for various applications; in one, the synthesis of nanocomposite hydrogels (NCHs) has been contemplated to produce adsorbents with improved thermomechanical, electrical, optical, swelling properties and adsorption capacity contrasted with the traditional polymeric hydrogel; while a separate chapter covers a brilliant approach consisting to combine nanoparticles, carbon nanotubes and organic polymers to develop effective antimicrobial compounds with the potential to exhibit microbicidal activities against bacteria and fungi.

The ability to predict and assess the performance of the treatment process is very important to ensure that the system remains effective.

Chemical Engineering World

CEW EXCLUSIVE INTERVIEW

Interview CEW

Sustainable Decarbonization through Circular Bio-Economy Pramod Chaudhary Executive Chairman Praj Industries Limited

In an exclusive in-person interview with MittraVinda Ranjan of Chemical Engineering World, Pramod Chaudhari threw light on Praj’s endeavor in biofuel and bio-economy sector. He spoke about early days of his entrepreneurial journey, company’s market positioning in global context, present and upcoming projects, research and development initiatives, as well as the way-forward.

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August 2019 • 67

CEW Interview Advancements in agro-processing domain would be a socio-economic enabler.

Tell us about your inclination towards agro processing technologies that were not as developed in the early eighties in our country when you started your entrepreneurial journey.

Since my IIT days, I was very inclined towards agro processing and strongly believed that advancements in this domain would be a socio-economic enabler.

Besides providing additional revenue stream for farmers and creating jobs for rural youth, agro processing could provide a much-needed fillip to the rural economy, and country at large. After my education, I obtained valuable experience by working with multinationals, and then began looking for entrepreneurship opportunities.

I was familiar with the sugar industry and aware that sugar factories are usually located far from cities. Many sugar factory owners lacked exposure to technology that could create value from waste molasses generated in the manufacturing process.

My technical expertise and commercial acumen convinced me that to secure our future energy needs, the way ahead was sustainable decarbonization through a circular bioeconomy.

This was around the time when the concept of using biofuels was gaining prominence in Brazil and the USA. The concept of producing alcohol and ethanol as co-products from molasses was a new one which caught my attention. I was convinced it could be revolutionary for the sugar industry and evolve as an important source of renewable energy. For the first 15 years, Praj concentrated on producing alcohol from molasses and converting alcohol to ethanol to be used as biofuel.

India has been highly dependent on imports of crude oil to meet the energy needs. What has been the outlook of the Indian Government towards biofuels?

While the ballooning oil import bill – India imports nearly 80 percent of its crude oil 68 • August 2019

needs – is a major concern; the alarmingly worsening air quality in NCR has cranked up the urgency to find a sustainable solution.

India has committed to a target of reducing CO2 emissions by 33 percent by 2030 over 2005 levels. Given the carbon intensity of the transport sector, there is an urgent need to tackle this emission in a concerted fashion. The current government has a vision to produce 175 giga watts of clean energy by 2022 and reduce energy imports by 10 percent in 2022 and 50 percent by 2030. We believe the time is right to act on it.

Over the past five-six years, we have seen assertive actions by various stakeholders in line with strategic policy interventions by the government for the promotion of biofuels. This is helping us inch closer to achieve 10 percent blending of ethanol in gasoline as mandated.

Ethanol, a major contributor to the RTF (Renewable Transport Fuel) portfolio today, plays a major role in India’s ethanol blending program (EBP). Currently 6 percent ethanol is blended with gasoline, and as per the National Policy on Biofuels 2018, the Government has set the target to 20 percent by 2030.

To what extent will the use of biofuels help India curb fuel imports?

Currently, India consumes about 40 MMT of CNG per year out of which 65 percent is imported and demand in India is further increasing at 15 percent CAGR. The government has introduced the progressive policy, namely, Sustainable Alternative Towards Affordable Transportation (SATAT) scheme to curb imports.

Under SATAT, the government is promoting the use of Compressed Bio Gas (CBG) as a

complimentary fuel to CNG. Produced from agri residue, CBG is an environment friendly biofuel which also facilitates energy selfreliance. The government has announced an investment of Rs 1.75 lakh crore to set up about 5000 plants to produce CBG from agri-waste, cattle dung, and municipal solid waste. This move will utilize more than 62 million metric tonnes of waste generated each year in India.

Additionally, the government has set a target to triple ethanol production in four years to save Rs. 12,000 crore in India’s oil import bill by mixing ethanol in petrol.

Moreover, the mandate to switch to Euro VI is another important step for the automotive industry to increase ethanol blending. This could be done without making any changes to the existing vehicles that comply with Euro IV norms.

By partially replacing petrol and diesel with CBG as fuel, India can reduce its crude consumption by almost 15-20 percent and save around Rs. 80,000 crore. India currently incurs an import bill of Rs. 5.5 lakh crore each year.

The government has rolled out plans to support the growth of biofuels in the country and targets to increase the share of biofuels in India’s energy basket. I see this move not only as a game changer for the farming community but also as an opportunity to generate employment.

What are your thoughts on plans of Government to increase EVs in the country?

Regarding EVs, the picture is evolving.

There are several issues that are being debated. Some of them are on CAPEX affordability, feasibility for long distance travel, cost of battery, and most importantly, responsible disposal of battery from the environment perspective. Another point of discussion is about market penetration

Ethanol, a major contributor to the RTF (Renewable Transport Fuel) portfolio, plays a major role in India’s ethanol blending program (EBP).

Chemical Engineering World

Interview CEW Currently 6 percent ethanol is blended with gasoline, and as per the National Policy on Biofuels 2018, the Government has set the target to 20 percent by 2030. especially in rural areas and infrastructure development for charging batteries. In my view, multiple fuels will co-exist in the future.

Bio refining is getting lot of attention in India now. Tell us about the projects Praj is setting up with the PSUs.

Tell us about the foray and growth of Praj Industries in the global markets.

We are setting up 2nd generation (2G) integrated smart bio refineries based on our patented enfinity technology. The refineries process multiple feedstock/ biomass like corn and sugarcane residue, rice or wheat straw, various lignocellulosic biomass to produce fuel grade ethanol, bio chemicals, bio CNG, liquid CO 2, bio fertilizers, and power exported to the grid.

Praj was incorporated in 1984 with the objective to provide cutting edge solutions to the ethanol industry. Praj’s journey began with a foray into providing technology solutions to the agro-based process industry and its first break came from a sugar mill in India. The in-house development of technology for starchbased feedstock paved the way for its entry into international markets.

Praj went public in 1994 and branched out in the international market with orders from Indonesia and the Philippines. We complete 25 years in the South East Asian market this year.

Praj ventured into South America at the dawn of the new millennium where it carved a niche with 100 percent market share in Colombia to fulfill the country’s ethanol blending program.

Subsequently, we entered the European market with an engineering order for a grain-based plant and now have more than twenty references and many marquee customers. We commissioned UK’s first bioethanol plant of 1200 KLPD (420 MLPA) in 2007.

On the back of cutting-edge technology solutions, today, Praj is truly a global player with over 750 references in 75 countries across 5 continents.

Praj is ranked 8th in the reputed Biofuel Digest list as a hottest company in the advanced bioeconomy, making it the first Asian company to make it in the top 10 ranking.

Chemical Engineering World

The first batch of four integrated biorefinery projects are being executed in Uttar Pradesh, Haryana, Odisha, and Karnataka with four PSUs. Internationally too, we have been receiving a positive response from many countries in Europe.

What kind of competition do you foresee in the Indian biofuel sector?

In India, this sector has somehow been overlooked by large players though there are a few small and mid-sized ones. There are hardly any structured or strong R&D driven organizations who can be considered real competition. We are strongly driven

by R&D and have continued to expand our capabilities to develop complete solutions and innovative technologies for our customers.

With R&D being the backbone of Praj Industries Ltd, tell us about the initiatives taken in this space over the years.

Since the beginning of my journey, I always believed in the benefits that a business derives through organized innovation and R&D. Sustainability is at the core of Praj’s solutions that are driven by technologies emanating from its state-of-the-art R&D Centre, Praj Matrix, and our world class

manufacturing facilities in India. Certified by the Department of Scientific & Industrial Research (DSIR) and GOI, the facility has bench and pilot scale facilities to validate scientific assumptions and promote rapid commercialization.

In the first phase, we set up our first R&D unit in 1991 with four or five people. The second phase started in 2002 when we became more organized to innovate and respond to the demands of our customers.

The third phase has been the biggest and most transformative phase when we kicked off basic research in 2007 and incorporated basic research functionalities. An outcome of this phase is Praj becoming one of a handful of companies in the world to successfully develop and demonstrate 2nd generation ethanol technology.

We have a strong team of 90 technologists with our scientists engaged in research across green technologies for sustainability, including renewable chemicals.

What’s the future for your company for bio-based technologies?

Technology and innovation are core values at Praj and I believe our strong market positioning is a result of the technology edge that creates value for our customers.

Backed by three decades of experience in bio-based solutions, Praj is expanding its Bio-Energy basket by adding CBG technology. Praj’s demo plant is India’s first integrated, flexible, and highly instrumented plant that tests, improves, and optimizes production of CBG from different feedstock such as biomass, press mud, variety of agri waste, paper mill pith, etc.

Praj is working with Gevo, a US-based company, to produce jet biofuels. We are adapting their technology to tropical feedstocks like molasses and agri-residue.

We are also developing renewable chemicals like Xylitol, Vitamin E, Nisin, and Oleochemicals such as Natural Vitamin E, Phytosterol, Omega 3 fatty acid, and more.

August 2019 • 69

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