VOL. 48 NO. 8 August 2013 US $ 10 ` 150
CHEMICAL ENGINEERING WORLD
Pumps & Valves Special
AUGUST 2013 VOL. 48 ISSUE 8 Mumbai ` 150
ChemTECH South 2013 10-12 October 2013, Chennai, India
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CEW Contents CHEMICAL ENGINEERING WORLD RNI REGISTRATION NO. 11403/66 Chairman Publisher & Printer Chief Executive Officer
Jasu Shah Maulik Jasubhai Shah Hemant Shetty
Vol. 48 | No.8 | AUGUST 2013 | Mumbai | ` 150
EDITORIAL Editor Chairman-Advisory Board Editorial Advisory Board Contributing Editors Sub Editor Copy Editors Design Team Events Management Team Subscription Team Marketing Co-ordinator Production Team
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4 • August 2013
Mechanical Grooving and Flanging / 30 – Andy Carter, Victaulic Pump Materials for Harsh Environments / 36 – Thomas Kränzler, Raimo Arola - Sulzer Pumps Ultrasonic Flowmeters / 42 – Cole-Parmer Case Study: Handling Tricky Situation with Ball Sector Valve / 46 – Volker Gatzert, Thomas Labahn - Schubert & Salzer Control Systems GmbH
MARKET INSIGHTS ► Rise in Sustainable Pumps and Valves Market / 50
PRODUCTS ► / 52 EVENTS ► / 64 PROJECT UPDATE ► / 65 BACK OF BOOK ► Ad Index / 67 Book Shelf / 68 Interview / 69 Riding High on the R&D – Pravin S Herlekar, Chairman and Managing Director, Omkar Speciality Chemicals Limited (OSCL) Cover Page Image by: Abaque®, part of PSG®
Printed and published by Mr Maulik Jasubhai Shah on behalf of Jasubhai Media Private Limited, 26, Maker Chamber VI, Nariman Point, Mumbai 400 021 and printed at Anitha Art Printers, 29-30, Oasis Ind. Estate, Next to Vakola Market, Santacruz (E), Mumbai-400055 and rd published from 3 Floor, Taj Building, 210, Dr. D N Road, Fort, Mumbai 400 001. Editor: Ms Mittravinda Ranjan, 26, Maker Chamber VI, Nariman Point, Mumbai 400 021.
Chemical Engineering World
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CEW Industry News BHEL to Supply Equipment for Kochi Refinery Kochi, India: Bharat Heavy Electricals Ltd (BHEL), the state-owned integrated power plant equipment manufacturer, has bagged a ` 265-crore order from Bharat Petroleum Corporation Limited (BPCL) for supplying the Gas Turbine Generator package for an energy efficient and environment friendly co-generation captive power plant for latterÊs refinery project in Kochi. The order envisages supply and supervision of three gas turbines of 34.5 MW rating each, with associated auxiliaries and control systems. The gas turbine will be operated in the cogeneration mode for meeting the power and process steam requirement of the upcoming Kochi refinery expansion project. The equipment for the project will be supplied by BHELÊs Hyderabad plant and Electronics Division, Bangalore. Erection and commissioning of the Gas Turbine package will be carried out by the companyÊs Power Sector - Southern Region. Â
RIL, IOC, Cairn in Race for HPL Stake Mumbai, India: Reliance Industries Ltd (RIL), Indian Oil Corp (IOC) and Cairn India to submit price bid in acquiring 31 per cent stake in beleaguered Haldia Petrochemicals Ltd (HPL). RIL, IOC, Vedanta Resources through subsidiary Cairn India, state-owned Oil and Natural Gas Corp (ONGC), gas utility GAIL India Ltd and Naveen JindalÊs Jindal Steel and Power Ltd had submitted expressions of interest to buy a 31 per cent stake in HPL held by the West Bengal government. Purnendu Chatterjee-led The Chatterjee Group (TCG), a joint promoter of HPL, will have the right of first refusal to match the highest bidder. Deloitte Touche Tohmatsu India is the transaction advisor to the West Bengal government and will manage the divestment.
Domestic Gas Production to Reach 183 MMSCMD by FY20: ICRA Mumbai, India: In the outlook of future discoveries, IndiaÊs domestic natural gas production, which has steadily declined in the last two years, is expected to increase around 183 MMSCMD by FY20 from 111 MMSCMD in FY13, according to a report by rating agency IRCA. The report said that the domestic natural gas production is expected to increase from 111 MMSCMD FY13 to around 125 MMSCMD by FY16, from existing or already discovered fields. This could further increase to around 183 MMSCMD by FY20. Factoring in certain production from future discoveries, the domestic production could increase to about 200 MMSCMD by FY25 notwithstanding the fall in the production from existing fields. The report further mentioned that domestic natural gas production has steadily declined over the last two years to 111 MMSCMD in FY13 from 143 MMSCMD in FY11 primarily due to fall in production of KG-D6 block from 56 MMSCMD in FY11 to 26 MMSCMD in FY13. The report further said the demand potential for natural gas is expected to significantly rise from 250 MMSCMD at present to 360 MMSCMD by FY20.
6 • August 2013
South AsiaÊs 1 st Cellulosic Ethanol Demo Plant Gets Underway Pune, India: Praj Industries, the global process solutions company for bioethanol, alcohol and brewery, water and wastewater & critical process equipment has emerged as the first Company in South Asia to set up an integrated 2 nd Generation (2G) Cellulosic ethanol plant. The 2G Cellulosic ethanol demo plant will operate on different variety of biomasss with a capacity of 100 dry tonnes of biomass per day, which includes agricultural wastes such as corn stover, cobs and bagasse. The demo plant will enable Praj to consolidate its 6 years of R&D efforts, starting with laboratory trials to pilot scale trials. The same plant will also enable Praj to develop various biochemicals and bio products. The demo plant will seek to demonstrate var ious technical parameters including optimisation of water and energy integration and its impact on the capex and opex. The plant will also develop the entire value chain including biomass handling and biomass composition and its impact on the operations. Praj expects the project cost to be in the region of US$ 25 million (`. 145-150 crore). For this project, Praj will associate with VAAIL, an existing ethanol producer located in Western Maharashtra and a long term client of Praj. VAAIL will provide the land and allied services for the smooth operation of the project. Commenting on the ground-breaking, Pramod Chaudhari, Executive Chairman, Praj Industries, said: „Ground breaking of 2G Cellulosic ethanol plant is a giant leap in biotechnology and towards a more sustainable world. The greenhouse gas savings from Cellulosic ethanol is greater than those from 1 st Generation crop-based biofuels as well as fossil-based fuel and hence this project will play a vital role in reducing carbon footprints. The project site at Shirala gives us a locational advantage in terms of sourcing of biomass, utilities and manpower. We are delighted to work with VAAIL who has been our long term client.‰
BA S F E y e s B i g P r o f i t f r o m i t s I n n o v a t i v e Lifestyle Solutions
Prasad Chandran, Chairman and Managing Director, BASF
Mumbai, India: Chemicals maker BASF is targeting annual sales of EUR 100 million (about ` 820 crore) from its innovative solutions for affordable mass housing, food fortification, solar and wind energy and water purification. Prasad Chandran, Chairman and Managing Director, BASF, said that the company is in the process of tweaking its existing range of products and is undertaking research with product developers.
He added that the company will target the middle of the pyramid in developing countries, especially in India and the South-Asia sub-region. The aspiration levels of the middle-class population are growing and our product development will improve their lifestyle at a nominal cost. Chemical Engineering World
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CEW Industry News Freudenberg Continues Stable Growth in India L&T to Spin off Hydrocarbon Unit Mumbai, India: The hydrocarbon division of L&T has to be necessarily carved out into a subsidiary to achieve its potential and tap global opportunities, said A M Naik, Chairman, L&T, when addressing an extraordinary general meeting convened on directions of the Bombay High Court to obtain shareholders nod on the issue. A M Naik, Chairman, L&T
The L&T board has approved a scheme of arrangement for consolidating the assets and liabilities of its hydrocarbon business with its wholly owned subsidiary L&T Hydrocarbon Engineering Ltd (LTHE).
Coromandel Gets First Consignment from Tunisian JV Kakinada, India: The first consignment of phosphoric acid from Tunisian Indian Fertilisers (Tifert), a Tunisia-based venture of Coromandel International Limited (CIL), has arrived at CILÊs complex fertilisers plant located at Kakinada. The Tifert vessel left from La Skhira Port in Tunisia, with 31,269 tonnes of phosphoric acid, arrived at Kakinada Port and delivered the CILÊs share of 12,498 tonnes. It will leave to deliver the remaining part of about 18,771 tonnes to Gujarat State Fertilisers and Chemicals Limited (GSFC), the other Indian shareholder of Tifert. CIL and GSFC hold 15 per cent each in the share capital of Tifert. Tifert, set up in La Skhira in Tunisia by CIL and GSFC, the partners from India and Groupe Chimique Tunisien (GCT) and Compagnie Des Phosphat De Gafsa (CPG), from Tunisia, (both being Government of Tunisia entities.
RIL Eyes US Petrochemicals Sector Mumbai, India: On the back of the US shale gas business, Reliance Industries Ltd (RIL), the the Mukesh Ambani led oil and gas major, is now exploring opportunities in refinery & petrochemicals, fertilisers, power generation and coal mining in the western country. Reliance has already worked out investments of USD 1.5 billion annually for the next three years in the shale business there. It has invested USD 6 billion in shale operations till the first quarter of this fiscal and produced a cumulative 183.1 billion cubic feet of gas equivalent · comprising natural gas liquid, condensate and shale gas. The company posted an 84 per cent rise in revenue from its shale gas venture in the US on rising production during the first quarter. RIL has three joint ventures, with Chevron, Pioneer Natural Resource and Carrizo Oil & Gas, and a midstream joint venture with Pioneer for its shale business in the US. 8 • August 2013
Bangalore, India, July 2013- Freudenberg, the internationally-active family company, recorded another all-time high in India in 2012. Compared to the previous year, the company grew sales by 17 per cent to ` 1,114 crores (2011: ` 956 crores). At year-end the headcount rose by the same percentage and increased by 520 to around 3,524. „With this positive business development, our companies in India have yet again made an important contribution to the overall success of the Freudenberg Group,‰ said Dr Jörg Matthias Großmann, Regional Representative India of the Freudenberg Group and Chief Financial Officer of Freudenberg Chemical Specialities at the press conference in Bangalore. „Freudenberg successfully held its ground in a particularly challenging market environment.‰ The significance of India as a strategic growth market is underscored by the opening of the new Regional Corporate Center in Bangalore which will support the continued development of FreudenbergÊs companies in India. Furthermore, with its latest decision to invest ` 6 crores into a new EagleBurgmann manufacturing operation for non-metallic expansion joints in Chennai, the Group underpins its intention to foster engagement in the region. World-wide, the Freudenberg Group recorded sales of around ` 43,655 crores in 2012. This represents a year-on-year increase of around 5.3 per cent. Profit from operations (EBIT) increased by 4.1 per cent to ` 3,715 crores.
ONGC to Set up Solar Grid in Karnataka Bengaluru, India: In a prospect of entering into the solar energy sector, Oil and Natural Gas Corporation (ONGC), the stateowned oil major, is planning to set up a 1,000-MW solar grid in an investment of ` 5,000 crore in Karnataka. In this regard, the company is in talks with the Karnataka Government for issuance of Renewable Energy Certificate (REC), power purchase rates and land to set up the solar power project. In another development, ONGCÊs attempt to rope in private sector explorers as joint operators in three coal-bed methane blocks in Jharkhand and West Bengal, is facing fresh hurdle. ONGC sources said that one of the awardees, Dart Energy (formerly Arrow), refused to take 25 per cent stake in North Karanpura and 10 per cent stake in Ranigunj block. The Australian company, however, accepted the offer for 25 per cent interest in Bokaro.
CPCL in Expansion Mode Chennai, India: Chennai Petroleum Corporation Ltd (CPCL), a subsidiary of Indian Oil Corporation Ltd, will invest ` 4,000 crore for expansion of its refining capacity, upgradation of refinery residues to distillates and others. A major chunk of the investment, up to ` 3,110.36 crore, will be towards the residue upgradation project. The project will maximise the distillate yield of the Manali refinery and increase the percentage of high sulphur crude processing. It involves installation of a delayed coker unit and revamping of existing hydro cracker unit along with other associated facilities, resulting in a 7 per cent rise in the yield of distillate. The project is scheduled to be completed by 2015, accorded for environment clearance by the ministry of environment and forests. Chemical Engineering World
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CEW Industry News Rockwool to Expand Footprint in India
UHDE India Bags Omnia FertilizerÊs Contarct
Hyderabad, India: Rockwool India & Middle East Group, a fully-owned subsidiary of Rockwool International A/S, Denmark, is planning to expand insulation business footprint in India by increasing its manufacturing capacity.
Mumbai, India: Omnia Fertilizer has awarded UHDE India a contract to render Engineering, Procurement and Supervision Services associated with the 10,000 MT Cryogenic Ammonia Storage Tank and associated systems at Sasolburg in South Africa.
The company had set up a manufacturing plant in Dahej, Gujarat, about three years ago to serve the local market. Samson Suresh, Head-Corporate Affairs, Rockwool, said that the company is set to hit the full capacity of about 30,000 MT a year by next year and will have to add new capacity. The company will expand manufacturing to meet the future demand.
The tank which is being built by Omnia Fertilzer to provide feedstock to their existing fertiliser plant will use Uhde IndiaÊs cup-in-tank floating roof technology, which has been successfully deployed in a number of similar installations. The project, the engineering for which will take 13 months to complete, is being executed by Uhde India in conjunction with their group company ThyssenKrupp Industrial Solutions, South Africa.
He added that Rockwool Group is working with various State governments, regulatory bodies and Bureau of Energy Efficiency to improve the energy efficiency through thermal insulations. It has also launched awareness campaigns for energy efficiency in association with GIZ, a German Energy Efficiency Agency Partner to IndiaÊs Bureau of Energy Efficiency.
IndiaÊs Imported Urea Cost Dips by 20% in Q1 FY13 New Delhi, India: India has imported urea at around 20 per cent cheaper price in the first quarter of this FY13 as compared with the average cost for last financial year. The cheaper urea imports could lead to lower subsidy burden on the government if domestic demand of urea remains constant. India has imported about 11.09 lakh tonnes in the April-June quarter of this fiscal, up by nearly 50 per cent from the year-ago period. IndiaÊs domestic production of urea is about 220 lakh tonnes. The country imported 80.44 lakh tonnes in the entire 2012-13 fiscal.
Dart Energy to Acquire ONGCÊs CBM Stake New Delhi, India: State-owned Oil and Natural Gas Corp (ONGC) will give 10 to 25 per cent stake in its four coal-bed methane (CBM) blocks to Brisbane-based Dart Energy Ltd as it looks to expedite production. ONGC has finalised partners for producing gas from below coal seams, called CBM, in the Jharia, Bokaro, North Karanpur and Raniganj blocks. The company is farming out 35 per cent stake in the four blocks to expedite gas production with the help of private sector firms. It had faced land acquisition problems and rig availability issues that has delayed production. Dart will get 25 per cent in the Jharia, North Karanpur and Bokaro block while in Raniganj it will get 10 per cent. In Raniganj, Londonlisted Great Eastern Energy Corp Ltd (GEECL) will be the lead partner with 25 per cent interest. 10 • August 2013
The contract reiterates Uhde IndiaÊs standing in the cryogenic tank and tank farm engineering and construction business. It has built over 75 cryogenic installations for liquefied chemicals in India and abroad including facilities for Ammonia, Ethylene, Benzene, LPG etc, in capacities ranging from 5,000 to 40,000 MT in a variety of modes including Lumpsum Turnkey. In keeping with this experience, it is still the favoured partner for grassroots, revamp and re-start projects for cryogenic tanks and tank farms in India and abroad, along with its other core competencies.
Clariant Capacity Expansion Approved Mumbai, India: Clariant, a world leader in specialty chemicals, is proceeding with a 50 per cent expansion in capacity at its Azo pigments and pigment preparations plants in Roha, India. This recently approved investment will also enhance the capabilities and output at the site in a sustainable manner by reducing energy consumption and expanding the range of low VOC-containing Pigments Preparations offered to the market. These latest investments are intended to suppor t the strong market growth in India. They also mark another step in ClariantÊs effor ts to enhance its on-the-ground presence and offer more intimate customer service to customers in the emerging Indian and Asian markets. A new upgraded technical service laboratory for pigments has now commenced operations at its Cuddalore site (Tamil Nadu).
REC to Supply Solar Panel for Telugu Newspaper New Delhi, India: REC, a leading global provider of solar electricity solutions, will supply 25,720 REC Peak Energy Series solar panels aggregating to 6.5 MWp to power a ground-mounted tracker system in Andhra Pradesh, India. All electricity produced ă 12,289,500 kWh of clean, green electricity each year ă will be used for the printing of the Eenadu, the largest circulated Telugu newspaper in Andhra Pradesh, owned by the Ramoji Group. Being built by Photon Energy Systems Limited, a leading Indian EPC, the plant will be completed by the end of September, 2013. „RECÊs high efficiency and high quality solar panels with their 25 year linear power output warranty made REC a natural choice for this project. Chemical Engineering World
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CEW Industry News Aker Solutions Acquires I.D.E.A.S Mumbai, India: Aker Solutions has acquired UK specialist engineering company International Design Engineering and Services Ltd (I.D.E.A.S) to boost its asset integrity management services. Glasgow, Scotland-based I.D.E.A.S. has developed software and technology that dramatically improves the quality and accuracy of integrity and life time analysis for oil and gas assets. The analysis can be applied in all phases of the development of an installation, from design through construction, operation and life extension. Tore Sjursen, Head of Aker SolutionsÊ maintenance and modifications business, said that this acquisition strengthens the companyÊs offering of asset integrity management services. He added that I.D.E.A.SÊs technology can be used to predict the lifetime of an installation in a more effective manner. It also helps Aker to plan more targeted maintenance and inspection activities, and increases the quality and precision of services.
Linde India Announces Q2 Financial Results, Appoints new Managing Director Vadodara, India: Linde India Limited, a member of The Linde Group, has announced its unaudited financial results for the second quarter FY13 approved by the CompanyÊs Board of Directors. For Q2 2013, the Company reported a gross turnover of ` 3,496 million, a decrease of 4 per cent as against ` 3,627 million recorded in the same quarter last year. Linde India has Sri Kumar Menon, MD, South also announced that as part of its planned Asia, Linde Group leadership succession, Moloy Banerjee has been appointed as the Managing Director of the company and a member of its Board of Directors. Banerjee succeeds Srikumar Menon, who stepped down as Managing Director and from the Board of Directors. Menon will continue as The Linde GroupÊs Managing Director for South Asia, responsible for its businesses in India, Bangladesh and Sri Lanka.
Petroleum Ministry to Rework Shale Policy New Delhi, India: The Petroleum Ministry now will have to rework on its shale exploration policy after the Finance Ministry objected the MinistryÊs proposed move to allow existing oil and gas explorers to find shale gas in their respective blocks on the grounds that it was against the existing production sharing contracts. The Petroleum Ministry, which is working on a shale gas exploration policy, felt that this modus operandi would help faster exploitation of shale gas and the Petroleum and Natural Gas Minister M Veerappa Moily is of the view that as in the US, shale gas can emerge as an important new source of energy for India, too. In this regard, the other option is to hold auction rounds, which may take a couple of years more, as suitable policy is yet to be put in place.Public sector explorer ONGC has already undertaken an experimental project to explore shale gas. However, it cannot go ahead commercially because the country does not have a shale gas exploration policy. 12 • August 2013
MPL to Expand Product Portfolio Manali, India: Manali Petrochemicals Limited (MPL) is planning to develop new applications for its products in brake fluid, drilling applications, water proofing and others. The efforts seem to be aimed at dealing with the difficulties the company has had in recent times. The company is also exploring the possibilities of develop product applications in medical devices and said that it is confident of overcoming the difficulties through a modified product mix and by foraying into newer markets. Manali Petro operates in the polyurethanes (PUs) market that comprises of two sectors: Methylene di-isocyanate (MDI) and Toluene diisocyanate (TDI). The Indian polyurethane industryÊs performance during 2007-2012 had reported a double-digit growth while the market has remained stagnant in 2013.
Evonik to Expand Silica Capacity in Thailand Map Ta Phut, Thailand: Evonik Industries is expanding precipitated silica capacity at its Maptaphut site in Thailand. With an investment of double-digit million euro range, the expansion is expected to be completed by the first quarter of 2014. The expansion is in accordance with the growing demand for precipitated silica in Southeast Asia. The Thomas Haeberle, member of project is part of EvonikÊs plan to expand its the Evonik Executive global silica capacity by 30 percent between 2010 and 2014. „The purpose of our expansion strategy is to allow us to support the growth of our key customers in Southeast Asia and around the world,‰ said Dr Thomas Haeberle, member of the Evonik Executive Board and responsible for the companyÊs Resource Efficiency Segment.
Chemical Exports to Africa on the Rise Johannesburg, South Africa: Africa is presenting a busy market for IndiaÊs chemical exports as figures for Nigeria alone indicate considerable growth. Expor ts of chemical items from India to Nigeria alone have increased to about 5.6 per cent from 2012 to 2013, according to the Chemical Export Promotion Council of India (ChemExcil). In addition, total volume of expor ts to Nigeria this year amounted to USD 90.3 million as against USD 85.5 million last year, ChemExcil Executive Director Suhas Bhardi said at an exhibition that opened with over 80 companies in attendance. The Indian Chemical and Cosmetics Exhibition has been organised by ChemExcil in collaboration with the Pesticides Manufacturers and Formulators Association of India (PMFAI) and the Indian High Commission in Lagos. PMFAI President Pradip Dave said the African region offered most potential for improvement in the productivity of crops and the African governments have therefore given priority to development of agriculture in the region. Dave said that there was a good market for agrochemicals in Nigeria, adding that „it is estimated that the private sector agrochemical companies supply about 70 percent of the total CPP demand of approximately USD 120 million.‰ Chemical Engineering World
Steam Tube Bundle Rotary Dryer
Chemical Engineering World
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CEW Industry News Global Mechanical Seals Market to Expect Steady Growth: Frost & Sullivan London, UK: Holding fast against the ongoing economic turmoil, the global mechanical seals market is expected to grow at a steady pace over the long-term across all major end-user industries. Continued patronage from the oil and gas, chemical and pharmaceutical industries, together with the expanding base of pumps and compressors in the emerging BRIC economies, will stand the market in good stead. New analysis from Frost & Sullivan, Global Mechanical Seals Market, finds that the market earned revenues of approximately USD 2,691.5 million in 2012 and estimates this to reach USD 3,558.4 million in 2015.
Showa Denko to Construct Ethyl Acetate Plant Oita, Japan: Japanese chemical engineering company Showa Denko (SDK) will construct a 100,000 t per year ethyl acetate plant at its facility in Oita. Constructed using SDKÊs proprietary production process technology, the ethyl acetate plant is expected to help the company address diversified and sophisticated customer requirements, and strengthen its position as a stable supplier of high-quality products. The process technology utilises SDKÊs solid heteropolyacid catalyst, featuring the phosphorus or silicon atom core and 12 surrounding tungsten oxide units on a porous, chemically stable carrier. Currently operational at the SDKÊs production site in Indonesia, the technology directly adds ethylene to acetic acid, enabling efficient and highquality ethyl acetate production. Primarily manufactured on a large scale for use as a solvent, ethyl acetate also has wide-ranging applications, which include printing ink, paint, electronic materials, pharmaceuticals and agrochemicals, among others.
Foster Wheeler Subsidiary to Supply Services for Vietnamese Complex Thanh Hoa, Vietnam: Global Engineering and Construction Group, a subsidiary of Foster Wheeler, has secured a contract to provide project management and consultancy (PMC) services for the Nghi Son Refinery and Petrochemical Limited Liability CompanyÊs grassroots refinery and petrochemical complex in Vietnam. The Nghi Son Refinery and Petrochemical (NSRP) complex is scheduled to be constructed in the Nghi Son Economic Zone, Thanh Hoa Province, Vietnam. Under the contract, the company will be responsible for management and administration of the engineering, procurement and construction (EPC) contractor consor tium through to performance testing completion. Constructed with an estimated USD 9 billion investment, NSRP Complex will feature an integrated refinery for processing of 200,000 barrels of Kuwait Export crude oil per stream day, a petrochemical complex, with associated infrastructure, utilities and offsites facilities. 14 • August 2013
AkzoNobel to Divest Building Adhesives Business Rosendahl, Germany: AkzoNobel announced that it has received a binding offer for the purchase of its Building Adhesives business by Sika AG for EUR 260 million. The transaction, which is expected to be completed in the four th quar ter of this year subject to regular consultation with employee representatives, will see all of Building AdhesivesÊ approximately 550 employees as well as its two manufacturing facilities in Rosendahl (Germany) and Damville (France) and its products and brands transfer to Swiss-based Sika AG. The intended sale of Building Adhesives follows a strategic review of the businessÊ fit within AkzoNobelÊs portfolio. Building Adhesives is a standalone business within AkzoNobelÊs Decorative Paints business area, primarily serving the professional market in North Western Europe with a portfolio of brands and products including floor and wall leveling compounds, floor adhesives, tile setting, sealants and floor finishes. Its respected brands include Schönox, Casco, Cégécol, Synteko and EriKeeper. AkzoNobelÊs Wood Finishes and Adhesives business (which also operates under the Casco brand) is not the subject of this offer
Air Liquide to Invest More in Antwerp Basin Antwerp, Belgium: Air Liquide has signed a long-term contract with BASF SE (to supply carbon monoxide to its MDI (methylene diphenyl diisocyanate ) production unit located in Antwerp, Belgium. Air Liquide will invest in a new CO production unit located next to its existing facilities. This unit, which is scheduled to be up and running in the first quarter of 2015, will double Air LiquideÊs CO production capacity in the Antwerp basin · the largest chemical and petrochemical basin in Europe. The overall investment will amount to around EUR 50 million. This unit will be designed and built by Air Liquide Engineering and Construction teams, using state-of-the-ar t technologies that offer energy efficiency as well as optimal performance and safety.
Neptune Adds Abaque Series Peristaltic (Hose) Pump to its Product Line North Wales, US: Neptune Chemical Pump Co, a manufacturer of chemical metering and peristaltic pumps and part of Pump Solutions Group (PSG), has added the Abaque Series peristaltic (hose) pump product line to its portfolio for the Americas. All Abaque Series pumps sold in the Americas will now be manufactured and shipped from PSGÊs Neptune facility in Nor th Wales PA after having been manufactured at PSGÊs Blackmer facility in Grand Rapids MI since 2009. The move is being made to better align the Abaque line with other PSG products and ser vices that address the same primar y market segments. Chemical Engineering World
Chemical Engineering World
July 2013 • 17
CEW Technology News HoneywellÊs UOP Technology Selected for JapanÊs Petrochemical Plant Pune, India: UOP LLC, a Honeywell company, announced that it has been selected by Taiyo Oil Co Ltd to supply technology and catalysts to improve operational flexibility and increase petrochemical production at TaiyoÊs Shikoku Operations in Ehime, Japan. The plant will install UOP Tatoray process technology to allow it to boost yields of certain petrochemicals by more than 70 per cent, and give the plant more flexibility to produce petrochemicals or gasoline as demand changes. The new Tatoray unit is expected to produce 300,000 metric tonnes per year of mixed xylene and high-purity beneze, which will require no further processing. The unit is expected to start up in 2014. The plantÊs existing UOP Thermal Hydro-Dealkylation (THDA) unit converts heavy aromatics such as toluene to benzene, a high-value petrochemical used in the production of polymers, plastics and high-octane gasoline. Taiyo will convert the unit to use HoneywellÊs UOP Tatoray process technology. HoneywellÊs UOP Tatoray process converts toluene and C9 aromatics to mixed xylenes and high-purity benzene without the need for sulfolane extraction. The process can more than double mixed xylene production from a given naphtha feedstock, while significantly reducing the overall cost of production, making it one of the most economical ways to increase xylene and benzene yields in an aromatics complex.
ThyssenKrupp to Support MaÊadenÊs Ammonia Facility Ras al Khair, Saudi Arabia: German-based ThyssenKrupp, as a sub-contractor to Daelim, will provide its ammonia technology to Saudi Arabian Mining CompanyÊs (MaÊaden) manufacturing facility in the Arabian Gulf. As par t of the agreement, ThyssenKrupp Uhde will licence the technology, provide engineering planning and supply key equipment for the new ammonia plant, MaÊaden II. Being built near the port of Ras al Khair, Saudi Arabia, MaÊaden II facility will feature ThyssenKrupp UhdeÊs dual-pressure ammonia process and will have a production capacity of 3,300 tonnes per day. The eco-friendly process, which will consume lower energy, will enable single-train facilities to manufacture 3,000 to 4,000 tonnes of ammonia per day.
Rive Technology Raises Fund from Energy Investors Te x a s , U S : R i v e Te c h n o l o g y, a p r o v i d e r o f i n n o v a t i v e materials-based solutions for catalytic and separations processes in the petroleum refining, chemicals, water and biofuels industries, has raised USD 20 million in a Series D round of financing from energy investors. Led by Saudi Aramco Energy Ventures (SAEV) with par ticipation from Mitsui Global Investment and RiveÊs existing investors, the financing will support continued commercial deployment of RiveÊs molecular highway zeolite technology into the global refining industry. RiveÊs investors include The Blackstone Group, Charles River Ventures, Advanced Technology Ventures and N th Power. 16 • August 2013
European Court Endorses SudarshanÊs Stand Mumbai, India: Sudarshan, a leading global producer of performance colorants & effect pigments, has won an appeal in the European Courts against Clariant. The Court of Appeal, London has dismissed an appeal raised by Clariant Produkte (Deutschland) GmbH and awarded costs & damages for wrongful threats to Sudarshan. The appeal was in relation to an earlier judgment of the High Court of Justice in favour of Sudarshan. In terms of the earlier judgment, the court held that SudarshanÊs product, Sudafast Yellow 132, did not infringe ClariantÊs patent; ordered an inquiry into damages and awarded the costs of the action to Sudarshan. Clariant had issued wrongful threats to SudarshanÊs customers in Nov 2009, at a crucial point when Sudarshan had commenced globalising its business and entered the European market. Sudarshan tried to resolve the matter with Clariant amicably given that SudarshanÊs R&D Scientists had confidence that the Sudarshan pigment did not infringe any patent. Clariant refused to agree an amicable settlement. Since Sudarshan respects intellectual property rights, the company stopped promoting and selling Sudafast Yellow 132(PY191) in overseas market and in light of ClariantÊs unwillingness to retract their threats. Rajesh Rathi, Director of Sudarshan Chemicals, said that the estimated loss of turnover figure is to the tune of USD 4.8 million per year and is based on projected sales of Sudafast Yellow 132 into the countries protected by the Second Patents. The losses are wider than simply direct customer sales because in addition to this Sudarshan had invested in a new production line to produce Sudafast Yellow 132 at its Roha facility. However due to ceasing international sales we have incurred capital losses to the tune of US $2.4million as the production line was lying vacant.
Versalis Overhauls Hydrocarbon Resins Facility Versalis Priolo, Italy: Versalis, the chemicals arm of ENI, and Neville Venture have entered a strategic partnership agreement to manufacture hydrocarbon resins at the Versalis Priolo facility in Italy. Both companies have also signed a licence agreement corresponding to the feedstock that will feed the resin plants. The partnership, which marks a significant step in the Priolo facility overhauling framework, confirms the siteÊs central role in the Versalis strategic plan. Versalis CEO Daniele Ferrari said that overhaul activities started at the facility represent an example of an industrial integrated model and this agreement is a sign of the companyÊs commitment to innovation and the application of technological excellence instrumental to enhancing the plant strengths. „The path we have taken enables us to find innovative business solutions that, in turn, translate into opportunities for the area and the community we are part of,‰ Ferrari added. The new, high added-value productions, which are synergetic with the elastomer business, will be used in the production of adhesives, inks, coatings and rubber. Contributing to making the most of the cuts produced by the existing cracking facility, the new technologies will help Versalis to construct hydrocarbon resin manufacturing facilities. Neville Venture is a joint venture between US-based synthetic resins producer Neville Chemical and GTC, an engineering and technology company. Chemical Engineering World
Chemical Engineering World
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CEW Technology News U S U n i v e r s i t i e s t o D e v e l o p B i o p ro c e s s i n g Technologies New York, US: The US National Science Foundation (NSF) has awarded a research infrastructure improvement track-2 (RII Track-2) grant to universities in North Dakota and South Dakota for production of economically viable renewable replacements for existing petrochemicals. Secured by the University of North Dakota, South Dakota State University and the South Dakota School of Mines and Technology, the USD 6 million funding is aimed at establishing a Dakota Bioprocessing Consortium (DakotaBioCon) to conduct collaborative research. The consortium will focus on production of novel bioprocessing technologies for sustainable development of high-value chemicals and materials from renewable resources. Working together, the researchers will develop methods for isolation of lignin from the raw plant materials, its subsequent purification and conversion into renewable chemical and polymeric alternatives to petrochemicals. The grant has been issued under the NSFÊs Experimental Programme to Stimulate Competitive Research (EPSCoR) initiative.
Badger to Licence Technology for Saudi Cumene Production Facility Rabigh, Saudi Arabia: US-based Badger Licensing has received a contract to supply its cumene technology for Armco Services and Sumitomo ChemicalÊs manufacturing fa c i l i t y i n S a u d i A ra b i a . T h e fa c i l i t y, which will be built as part of the Rabigh Phase II Project in Rabigh, will produce 384,000 MT per annum of grassroots cumene. As part of the contract, Badger will Mar k Healey President, provide the technology license, engineering, Badger training and star t-up ser vices for the cumene unit, which is scheduled to go on-stream in 2016. Badger President Mark Healey said that Rabigh Phase II is an impressive project in the growing petrochemical industry in the Middle East and the company is proud to be associated with it. „I believe BadgerÊs proven cumene technology will enable the Rabigh Phase II Project to achieve a low cost of ownership by leveraging long catalyst cycles and high operational reliability,‰ Healey added.
AMPAC, Proteaf Technologies Enter into Joint Development Agreement CA, USA: AMPAC Fine Chemicals LLC (AFC), a wholly-owned subsidiary of American Pacific Corporation (APFC), and Proteaf Technologies LLC (Proteaf) announce the signing of an agreement for joint development and implementation of tools and technologies supporting continuous flow chemistry for fine chemicals manufacturing. Under this arrangement, Proteaf will supply AFC with development services and specialty equipment for continuous p r o c e s s i n g . A F C w i l l l ev e r a g e P r o t e a f Ês r e s o u r c e s , complementing its existing facilities and expertise in cGMP manufacturing, to offer a comprehensive value package to customers. AFC has a long tradition of using continuous processing for manufacturing fine chemicals; energetic chemistr y and chiral chromatographic separations have been operated as continuous processes at AFC for more than 15 years at commercial scale. AFC has demonstrated capabilities in process development, scale-up, and cGMP production of active phar maceutical ingredients (APIÊs) a n d r e g i s t e r e d i n t e r m e d i a t e s fo r p h a r m a c e u t i c a l a n d biophar maceutical customers. Proteaf offers scalable, application-specific solutions using continuous processing techniques for manufacturers of pharmaceutical ingredients and other specialty chemicals.
DKSH Performance Materials Strengthens Operations in China Beijing, China: DKSH Business Unit Performance Materials, a leading specialty chemicals distributor and provider of Market Expansion Services for performance materials, has strengthened its presence in Asia by expanding its infrastructure in China. Recently, a state-of-the-art innovation center in Guangzhou and DKSHÊs fifth China sales office in Chengdu were inaugurated.
Dow and JM Davy Suppor t PetroChinaÊs LP Oxo Facility
In response to the continued development within the region, DKSH has opened an innovation center to cater to the personal care industry in South China. Staffed by technical experts, the facility serves the whole South China market and provides a full range of tailor-made services to its business partners in application testing, formulation evaluation and development, quality analysis and more.
Jieyang, China: Pe t r o C h i n a G u a n g d o n g Pe t r o c h e m i c a l , a subsidiary of PetroChina, will equip its manufacturing facility in China with Johnson Matthey Davy (JM Davy) technologies and Dow ChemicalÊs LP Oxo Selector10 technology. The technology, with advanced liquid phase hydrogenation, which features a high conversion of propylene to alcohols, is used to produce 2-ethylhexanol, normal butanol and iso butyraldehyde. Built in Jieyang, Guangdong, the new LP Oxo facility will manufacture 85,000 MT of 2-ethylhexanol, 235,000 MT of normal butanol and 33,000 MT of iso-butyraldehyde per annum.
During the past few years, Business Unit Performance Materials has significantly optimized its operations in China and has recently opened its fifth China sales office in Chengdu (after Beijing, Hong Kong, Shanghai and Guangzhou) as part of its ongoing strategy for growth. From Chengdu, DKSH Performance Materials will cover the growing Western China market to offer clients and customers first class market expansion services as well as a wide range of specialty chemicals and food ingredients to business partners in personal care, pharmaceutical, food and beverage and industrial chemical industries.
18 • August 2013
Chemical Engineering World
Chemical Engineering World
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CEW Technology News Progress in Using Ethanol to Make Key Raw Material INEOS signs MoU with Sasol for High-density Polyethylene Joint Venture New York, USA: INEOS Olefins & Polymers USA (INEOS) and Sasol announced the signing of a Memorandum of Understanding (MoU) with the intent to form a joint venture to manufacture high-density polyethylene (HDPE). Final investment decision is expected to be made in the first half of 2014 with start-up of the plant expected at the end of 2015. „This joint venture demonstrates INEOSÊs continued commitment to the HDPE market and to growing end-use applications that benefit from bimodal technology. It enables two global companies to integrate with each partnerÊs upstream businesses the leading bimodal slurry technology on a world-scale asset,‰ said Dennis Seith, CEO of INEOS Olefins & Polymers USA. The envisioned facility would produce 470 kilotons per annum of bimodal HDPE using Innovene S process technology licensed from INEOS Technologies. The intention is to produce a limited number of grades allowing high grade efficiencies.
Oriental Energy Selects Innovene PP Process Ningbo, China: INEOS Technologies announced that it has been chosen to provide the Innovene PP process to Oriental Energy Company Limited based in Nanjing for its subsidiary, Ningbo Fuji Petrochemical Company Limited. The unit, to be built in Ningbo, Zhejiang Province, will take propylene from the upstream propane dehydrogenation process and produce 400 KTA of polypropylene resins including homopolymers, random copolymers and impact copolymers. „Oriental Energy Company is embarking on an ambitious expansion programme what would make it one of the major players in the market for olefins and polyolefins in China. We are pleased that the company has chosen to select us as technology provider to serve the important Eastern China market. The Innovene PP process is ideal for this facility as it provides proven technology and products already widely accepted in the China market‰, commented Peter Grant, Business Director of INEOS Technologies.
Disorder Can Improve the Performance of Plastic Solar Cells London, UK: Scientists have spent decades trying to build flexible plastic solar cells efficient enough to compete with conventional cells made of silicon. To boost performance, research groups have tried creating new plastic materials that enhance the flow of electricity through the solar cell. Several groups expected to achieve good results by redesigning pliant polymers of plastic into orderly, silicon-like crystals, but the flow of electricity did not improve. Recently, scientists discovered that disorder at the molecular level actually improves the polymersÊ performance. Now Stanford University researchers have an explanation for this surprising result. Their findings, published in the Aug. 4 online edition of the journal Nature Materials, could speed up the development of low-cost, commercially available plastic solar cells. 20 • August 2013
Washington, US: Ethanol from corn and other plants could become the sustainable, raw material for a huge variety of products, from plastic packaging to detergents to synthetic rubber, that are currently petroleum-based. This was the conclusion of an ar ticle published in the ACS journal Industrial & Engineering Chemistry Research. Yingzhe Yu and colleagues point out that a chemical called ethylene, now produced from petroleum, is one of the most important raw materials for everyday products. Ethylene is used to make hundreds of products, including polyethylene, the worldÊs most widely used plastic. Scientists have been seeking sustainable alternatives to petroleum for making ethylene, and YuÊs team reviewed progress in the field. They found that one particular device has the potential to make a highly pure ethylene product from ethanol with high efficiency and low cost. The device, called a fluidized bed reactor, works by suspending the chemicals needed to make ethylene inside the walls of a chamber. Newly produced ethylene exits through a pipe, while the rest of the material remains to continue production. YuÊs team discusses progress toward commercial use of such devices, noting that there would be „great significance‰ for promoting economic development.
BioNitrogen Selects Casale Technology Bern, Switzerland: Switzerland-based Casale Group has entered into an agreement with cleantech company BioNitrogen Holdings, to provide its ammonia and urea technology, and design experience, for BioNitrogenÊs first manufacturing facility in Hardee County, Florida, US. CasaleÊs technology and existing designs are expected to help BioNitrogen enhance the facilityÊs manufacturing capacity from 360t per day (tpd) to 520tpd. BioNitrogen president and CFO Br yan Kornegay Jr. said the technology will reduce both the investment per tonne of production and the engineering time. „We have partnered with Casale because it is the only company with such extensive in-house experience, expertise and technology in combined ammonia and urea plant technology, process and equipment design,‰ Kornegay added. Apart from Casale, BioNitrogen has contracted the CCC Group to build the facility and AMEC to manage all engineering for the project. BioNitrogenÊs Operations VP Ernie Iznaga said the company completed a comprehensive search for the best-in-class ammonia and urea technology providers and selected the Casale Group as having an impressive combination of technology, in-house engineering capability, responsiveness and cost for its requirements. „They are an excellent complement to the team and IÊm very confident they will accelerate completion of the engineering,‰ Iznaga added. Casale said it either built or refurbished more than 400 ammonia and urea facilities across the globe. Chemical Engineering World
Chemical Engineering World
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CEW News Features
Ethanol Production to Increase
W
ith the Minister of Petroleum & Natural Gas Dr M Veerappa Moily directing OMCs and ISMA „to make all efforts for expediting delivery of already procured quantity of ethanol,‰ the ethanol production is likely to grow in near future. Moily has asked them to expeditiously procure additional quantity of ethanol through fresh tenders to meet the requirement of 5 per cent mandatory Ethanol Blended Petrol (EBP) programme. The Minister observed that against a requirement of 100 crore litre ethanol per year, the oil marketing companies have so far finalised procurement of around 40 crore litres of ethanol for next twelve months. The government seems to be seriously working towards encouraging the production within the county as the oil ministry had already rejected bids from foreign suppliers. Against an annual requirement of 105 crore litre, the domestic sugar industry committed 55 crore litre while the rest was supposed to come through imports. However, Moily had rejected global tenders to supply 80 crore litres of ethanol because suppliers quoted
22 • August 2013
Year
Ethanol Production
Ethanol Blending P e t r o l Requirement for Demand Transport Sector
Molasses Cane Total Industry Potable Balance 2001ă 1775 02 2006ă 2300 07
0
1775 600
1485 3785 711
2011ă 2300 12
1485 3785 844
2016ă 2300 17
1485 3785 1003
648
527
765
2309
887
2054
1028
1754
5%
448.03
10%
896.05
8960.52
20%
1792.10
5%
638.14
10%
1276.27
20%
2552.54
5%
814.30
10%
1628.61
20%
3257.22
5%
1039.27 20785.36
10%
2078.54
20%
4157.07
12762.72
16286.09
Projected Demand and Supply of Ethanol (Million Liters), Source: Planning Commission
exorbitant rates. „I canÊt allow petrol prices to go up because of Âethanol blended petrolÊ (EBP) programme,‰ he said. Ethanol Production to Increase A number of companies have already started investing in setting up new manufacturing
and expanding existing facilities to meet the demand of ethanol in the country. Recently, Praj Industries has emerged as the first company in South Asia to set up an integrated 2 nd Generation (2G) Cellulosic ethanol plant. The organisation Chemical Engineering World
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Chemical Engineering World
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CEW News Features “We will float fresh tenders and encourage Indian sugar industry to supply ethanol at much cheaper rates compared to international suppliers.”
has associate with VAAIL, an existing ethanol producer located in Western Maharashtra and a long term client of Praj. VAAIL will provide the land and allied services for the smooth operation of the project. The 2G Cellulosic ethanol demo plant will operate on different variety of biomass with a capacity of 100 dry tonnes of biomass per day, which includes agricultural wastes such as corn stover, cobs and bagasse. The demo plant will enable Praj to consolidate its 6 years of R&D efforts, starting with laboratory trials to pilot scale trials. The same plant will also enable Praj to develop various biochemicals and bioproducts. The new investments are mainly driven by the hope that the blending ratio will be raised to 20 per cent by 2017 as indicated by the government. Chempolis Ltd, a Finnish company, is also eyeing to tap Indian market with its patented third generation (3G) technologies for biorefining of non-food biomasses. Earlier, in an e-interview with CEW, Pasi Rousu, President, Chempolis Asia & Pacific had revealed that the company is negotiating for establishing a commercial-scale biorefinery projects in India in co-operation with leading Indian companies from sugar, oil and petrochemical industries. Feasible locations are especially in Uttar Pradesh, Maharashtra, Karnataka, Gujarat, Punjab and Haryana. The size of biorefinery can be adjusted based on the raw material availability starting from 100 000 tonnes of biomass (on annual dry basis). „A biorefinery of that size would produce approximately 25 000 tons of cellulosic ethanol and biochemicals per year. In addition, over 50 000 tpabiocoal would be co-produced. This will directly employ 150 people. Indirectly the biomass value chain may influence positively on income of thousands of people,‰ Rousu said. It is important to realise that currently India is importing petroleum but when using 3G biorefining technology for the production of biofuels and chemicals, this currency would remain in India for the benefit of Indian people, he added further. According to Rousu, „Recent changes in government regulations will be boosting setting up biorefineries in India. As our solution is combining all sustainability components; economic, environment and social we are confident the first projects will be established this year. Industry is ready and willing to move onwards.‰ Particulars
Amount (` crore)
Price (`/litre) paid by OMC @ 46.11 per litre ` 59.49/$ Savings at 40 crore litres of ethanol 1844.4 blending upto October 2013 Saving at 105 crore litres of ethanol 1841.5 between November 2013 ă October 14 Total savings between August 2013 - 6686.0 November, 2014 Savings in foreign exchange @ USD1124 million = USD ` 59.49/USD 1.13 billion Economics of Ethanol Blending, Source: ISMA
24 • August 2013
Veerappa Moily, Minister of Petroleum & Natural Gas, the Government of India
“Domestic industry is in a comfortable position to supply balance ethanol amount from November if the oil companies float a supplementary tender.”
Abinash Verma, Director General, Indian Sugar Mills Association (ISMA)
Pasi Rousu, President, Chempolis Asia & Pacific
“The fundamentals of driving forces for advanced biorefining have remained the same: depletion of oil resources and increased oil price, mitigation of CO 2 emissions and climate change, and reduction of dependence on imported oil and petroleum products.”
Economics of Ethanol Blending Sugarcane is most important feedstock in India for ethanol production, and for successful implementation of EBP in the nation, the supply chain of the crop will play a vital role. There is dire need to streamline the entire process so that the programme is implemented to a tee. Recently, the Indian Sugar Mills Association (ISMA) has explained the economics of the ethanol blending and stated that if there is 400 mn litres of ethanol blending with petrol, there would be a saving in foreign currency of ` 1,844 crore. If the entire annual requirement of 1,050 mn litres of ethanol (between October 2013 and November 2014) for blending is sourced, the government can save ` 4,841.5 crore. In the period from August this year to November 2014, it has said, Indian distilleries are set to produce 1,450 mn litres of ethanol. If utilised fully, these can save about USD 1.1 billion in foreign exchange. - Harshal Y Desai Chemical Engineering World
Chemical Engineering World
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CEW Features
Positive Displacement and Centrifugal Compressors in the Middle East A new analysis from Frost & Sullivan, Analysis of the Middle East Centrifugal and Positive Displacement Compressors Market, finds that the Centrifugal Compressors market earned revenues of over USD 868.6 million in 2011 and estimates this to reach USD 1,312.1 million in 2016; while the Positive Displacement Compressors market earned revenues of USD 450.5 in 2011 million, and is estimated to reach USD 669.5 million in 2016.
Non-Oil and Gas Sector to Fuel the Demand for Positive Displacement and Centrifugal Compressors in the Middle East The growth story of the Middle East is well known, attracting global companies, technology and talent to help exploit the vast natural resources. Historically, the growth of oil and gas exploration, production, transportation and downstream refining was coupled with burgeoning power generation capacity and large-scale infrastructure projects. This provided a very attractive market, with major oil companies, technology/ license providers, global Engineering, Procurement and Construction ( E P C ) c o n t ra c t o rs a n d e q u ip m e n t manufacturers making a beeline for the Middle East since the middle of the 20 th century. Over the past few decades, the Positive Displacement (PD) and Centrifugal Compressors market has reached a stage of moderate growth. However, the years preceding the global economic downturn witnessed numerous expansions and Greenfield projects being commissioned ă due, in large part, to the soaring oil prices. Raw material prices and project costs exceeded previous estimations, peaking in 2008. Subsequently, crashing of oil prices and the sweeping effects of the crisis in the West were soon felt across the Middle East, leading to abandonment of numerous projects and shelving of future growth plans. However, despite the debilitating effects of the economic downturn on manufacturing output, the large after-sales demand and 26 • August 2013
backlog of projects buoyed the PD and centrifugal compressors market. Industrial Compressors: A USD 1,432.7 Mn Opportunity Frost & SullivanÊs research on the PD (includes Reciprocating and Rotary Screw Compressors) and centrifugal compressors market in the Middle East suggests that a paradigm shift is expected in this market; over the next 10 years. While oil and gas installations will continue to be a recurring source for the demand, this change is largely attributed to the surge in demand from the non-oil and gas segment (especially, the Petrochemicals, Chemicals and Fertilisers (PCF) sector). As per Frost & Sullivan research, in 2012 the Middle East market for centrifugal compressors was estimated at USD 946.2 Million (Mn) while that of PD compressors was at USD 486.5 Mn. Overall, the Middle East Market for compressors, is forecast to become a USD 1,981.6 Mn opportunity by 2016. Regional and Global Factors Compound Market Dynamics There are numerous dynamics associated with the PD and centrifugal compressors market in the Middle East. Key among the market drivers is the economic diversification initiative (specifically in the GCC) to reduce dependence on oil and gas. The regionÊs burgeoning population has led to rapid and diversified industrialisation and infrastructure growth. The subsequent introduction of several non-oil and gas based projects, besides continued investment in the oil and gas industry has further heightened the demand for compressors.
Total Industrial Compressors Market: Market Size: Middle East, 2012 Centrifugal Compressors
66.0%
PD Compressors
34.0%
Source: Frost & Sullivan Analysis
Escalating energy requirements have necessitated the construction of gas-fired plants that need compressors. Growth in non-oil and gas-based projects such as petrochemicals, power, desalination, water and wastewater, infrastructure, metals and mining will increase the overall demand for compressors, and moderately reduce the dependence of compressor manufacturers on any particular industry. Furthermore, this is expected to particularly benefit compressor manufacturers with a limited range of American Petroleum Institute (API) certified compressors in their product portfolios. Non-oil and gas sector presents significant opportunity for the installation of non API certified compressors. Meanwhile, factors such as the rising average price of oil continue to encourage additional investment in capital-intensive exploration and production activities, as well as value added processing and refining. In the aftermath of the economic downturn, there has been significant pressure to Industry Challenges Ć Ć Ć Ć
Delay and complexity in qualifying as an approved vendor. Adherence to stringent testing/quality requirements. End-usersÊ reluctance to adopt new technology. Intensifying competition; specifically for the standard off-the-shelf compressors. Chemical Engineering World
Chemical Engineering World
July 2013 • 9
CEW Features reduce overall project costs, which are constraining margins all along the value chain (from end-user, through the contractor / Original Equipment Manufacturer (OEM) to the compressor supplier). Although the tendency to reduce costs has always been prevalent, recent events have exacerbated the situation to the point that entire project scopes are being reconsidered and, in certain cases, being significantly downsized. According to recent Frost & Sullivan research, most suppliers cite competitive pricing as the most significant challenge, along with increasing competition caused by new entrants (Asian manufacturers) for off-the-shelf products.
sectors). Lastly trade sanctions against Iran and the economic instability of Iraq, raise concerns about the steady growth of the compressors market. Growing Market and Intensifying Competition As the predominant compressors market demand is from the oil and gas industry, most of the global manufacturers who cater to this industry are present in the Middle East. Most of the high value projects (especially oil and gas) and those involving compressors for critical applications are restricted to major manufacturers that specialise in tailor-made engineering solutions and have robust product portfolios.
Possible restraints in the long term are reduced investments in Middle East projects due to significant build-up of regional overcapacity, discovery of major oil and gas sources in other countries (includes recent major gas finds in the US and globally increasing investment in shale gas, deepsea oil production, and other alternative sources) as well as the globally growing impetus to develop renewable energy sources. Also, countries in the Middle East are in a state of political uncertainty and unhealthy contagion. Political tensions over succession in the Kingdom of Saudi Arabia (KSA), sporadic political unrest in Kuwait, and the effects of the Arab spring in Bahrain, Jordan, and Lebanon (among others) have dampened investor sentiments. Political instability along with a weak global economy has a diminishing effect on investor confidence and end-user businesses, which is expected to impact the compressors market.
As is the case globally, the Middle East market for compressors is dominated by major multi-nationals like General Electric Company, Siemens, Atlas Copco, Elliott Group, and Dresser-Rand. These companies have gradually built-up extensive solution portfolios suiting local requirements, and their presence in the Middle East spans across pre-sales and sales support, marketing, and comprehensive after-sales support. Local engineering value-add is minimal, and investments targeted at manufacturing / assembly of these compressors in the Middle East are being explored.Earlier compressor installations in the Middle East showed a strong preference for American and European manufacturers. However, with the recent coup of EPC contracts by Asian (mainly Korean) companies, a growing acceptance of compressors from their respective countries has intensified the competition in the Middle East market.
The KSA faces a situation where there has been an overcapacity of oil production and limited success in exploration for commercially viable non-associated gas reserves (when there is an urgent need for natural gas to fuel power generation, as well as to be used as feedstock for petrochemical plants). In the past few years, Kuwait has been experiencing sluggish growth, with previously-shelved refining and exploration and production projects struggling to be brought back on track. Furthermore, the UAE is seeing low demand post-recession (especially in the utilities sector) and also due to the numerous projects that were completed / awarded in the past few years (as with the Petrochemical and Fertiliser
Industrial Diversification Vital for Market Growth End-users are opting for one stop solution providers to mitigate issues that arise due to handling of multiple suppliers. Companies with vast product portfolios therefore have a competitive advantage. They also benefit from replacement demand stemming from their large installed bases. In fact, as a means of market share expansion or even market penetration, addressing replacement demand is a key strategy and at times more challenging than a new installation. The ability to deliver differentiated services drives solution providersĂŠ competitiveness and can be a key decisive factor for customers during vendor selection. Manufacturers develop
28 • August 2013
Total Compressors Market: Competitive Landscape, Middle East, 2012 Product
Major Supplier
C e n t r i f u g a l GE, Siemens, Atlas Compressors Copco, Elliott Group, Dresser-Rand PD Compressors
Atlas Copco, DresserRand, Neuman and Esser, Gardner Denver, GE
Source: Frost & Sullivan Analysis
a range of services such as preventive maintenance, remanufacturing compressors, and aid in reducing downtimes and lifetime costs for end-users. The future outlook for the PD and centrifugal compressors market is optimistic, with a moderate growth rate of around 8.0 per cent from 2012 to 2016. Various impediments to market growth of which the fluctuating progress in the oil and gas industry is a key factor, will affect the compressors market in the short term. However, the need for a stable source of oil revenues (in the face of depleting/ageing fields), creating value added products (through increased downstream activities), alleviating unemployment and economic disparity, and the need for economic diversification will be instrumental in fuelling industrial growth. The untapped potential for downstream activity in countries such as the UAE, Kuwait, and Qatar for various reasons (such as the moratorium on Gas projects in the North Field, Qatar), provide opportunities for substantial growth in the future. Additionally, new modern cities in the Middle East, growing population, increasing industrialisation and international mega events (as planned in Qatar) will provide the next industrial boom for the compressors market. In the short term, the resurgence of industries across the region is expected to create opportunities for established and new market entrants. However, given the dynamic nature of this region, compressor suppliers planning to expand or enter the Middle East market might need to periodically re-examine their strategies in accordance with the changing regional dynamics in order to maintain a competitive edge. Courtesy: Industrial Automation & Process Control Practice, Frost & Sullivan Email: tanu.chopra@frost.com Chemical Engineering World
Chemical Engineering World
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CEW Features
Mechanical Grooving and Flanging Many piping systems including chemical, industrial and plant utility piping systems, building services and water treatment, use flanges in pipe runs to join pipe, and to allow pipe sections to be assembled and disassembled if a piping system has to be modified or maintained in the future. An effective alternative to flanging is the use of grooved mechanical joints that offer faster installation and disassembly when maintenance is required, as well as other performance and design benefits. The article compares the flanged and grooved pipe-joining methodologies and the advantages they deliver. Flanged joints in a mechanical room: flanges are roughly twice the width of the pipe they are attached to.
T
raditional Flanging is one of the more ÂÊtraditionalÊÊ pipe joining methods and has been around for many years. Because of this tradition many piping components ă such as pumps, valves and chillers ă are supplied with flanged connections. Flanging is commonly used in certain scenarios where speed and a degree of flexibility is required although it is not a system that allows for easy system contraction and expansion. Depending on the pipe joining system employed, installation and maintenance time will increase reducing system efficiencies. A flanged pipe joint is a good example of this. Flanges are bolted together, compressing a gasket to create a seal. The bolts and nuts of a flanged union and gasket absorb and compensate for system forces and, over time, the bolts and nuts can stretch due to surges, system working pressure, vibration, and expansion and contraction. When these bolts yield, the gasket can „slip‰ which can result in a leak. 30 • August 2013
Depending on the location and service of the piping system, subsequent leaks can be costly and hazardous, resulting in downtime and exposure to risk. Gasket replacement may be required, particularly when the flange is taken apart. Also, over time, the gasket can bond to the flanged pipe ends. When the joint is disassembled, the gasket will need to be scraped off the flanged pipe end and replaced, again increasing downtime due to maintenance. Because of system expansion and contraction flange gaskets can also take on compression over time, resulting in leakage, as well.
groove, the gasket, the coupling housings, and the nuts and bolts. A pipe groove is formed by cold forming or machining a groove into the end of a pipe ă using a variety of grooving tools, it is possible to do this onsite or offsite in a workshop enabling prefabrication. The coupling gasket is pressure responsive and is encased by the coupling housing when it engages in the groove around the circumference of the pipe. The gasket then creates a seal unified joint that is enhanced when the system is pressurized.
Robust and Safe A solution for these common problems is to use grooved couplings in place of flanges. In fact mechanical connections are becoming more common as they can offer practical as well as economical advantages.
With both rigid and flexible style couplings available, couplings can be used in virtually every application instead of a flange. Rigid grooved mechanical couplings are designed to provide a rigid pipe joint connection, permitting neither linear, angular nor rotational movement at the joints.
A mechanical joint, or coupling, is comprised of four basic but robust elements: the pipe
Flexible grooved mechanical couplings on the other hand are designed to allow Chemical Engineering World
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CEW Features controlled linear and angular movement at each joint that can accommodate pipeline deflection. They offer security whilst also accommodating potential misalignments without the need to install the expensive and delicate specialised equipment that are necessary with flanged or welded systems. A third benefit can be derived from the use of three flexible couplings used near a source of vibration. Flexible couplings reduce noise and vibration and eliminate the need for specialised noise reduction components. Flanges, a rigid pipe joining method, are not ideal for environments in which there is pipe movement, such as thermal expansion, vibration or building settlement. Expansion and contraction can stress the flange and piping, which can compromise the gasket over time. When this occurs, the joint is at risk of leaking. Grooved flexible couplings can provide pipe movement in the form of axial movement or angular deflection, and can accommodate thermal pipe movement. In many ways, mechanical pipe joining can offer a more efficient solution than flanging and is a widely accepted method for joining pipe based on the simple system access they provide and their proven reliability - couplings can match the pressure ratings of flanges with no significant difference in flow dynamics. Grooved couplings also reduce the weight of a system and only require two bolts to complete a joint, versus eight bolts in a like size flange.
to be connected to the unit. With only one of a number of fixed positions determined by the number of holes in a flange, a fitting or valve can only be rotated to match the bolt holes. All this results in an increased risk of misalignment issues in the field. Grooved systems do not have this problem and allow much more convenient installation with a full 360-degree rotation. There is no bolt-hole pattern to line up, and a coupling can be oriented at any angle around the joint. The coupling can be „free floated‰ around the pipe in the field to provide easy access to the bolts, and in turn, simplify access to the equipment. In addition to eliminating misalignment issues during installation, a couplingÊs 360-degree orientation capabilities coupled with its smaller profile, compared to a flange, makes the installation of grooved systems ideal for confined spaces. Flanges are roughly twice the width of the pipe they are attached to. On average, grooved couplings are only half this size. The size advantage of the smaller design makes the grooved system ideal for jobs where space is limited ă such as mechanical rooms and refurbishment of existing buildings ă and any jobs that demand additional flexibility. Speed of Assembly Because couplings also have fewer bolts and typically no torque requirements, grooved piping is up to six times faster to install than flanging. Couplings
32 • August 2013
So for example, to flange a 6‰/150mm joint on Schedule 40 Carbon Steel pipe requires eight bolts and would take approximately 1.5 man hours to complete. This could be completed in just 20 minutes using a grooved solution, or around 10 minutes using a Installation-Ready coupling, since these do not require disassembly prior to installation. Both grooved solutions require just two nuts and bolts. These time savings only increase with larger diameter piping systems. For example, a 36‰/900mm flange joint on Standard Wall (3/8‰/9.7mm) carbon steel pipe would require 32 nuts and bolts and around 10 man-hours to complete, but only four nuts and bolts and around two hours with a grooved coupling. In addition, flanges require time consuming star pattern tightening with specialised wrenches to measure and ensure that correct torque ratings are achieved. Grooved technology allows couplings to be assembled by simple hand tools and the joint is properly installed once bolt pads of the coupling housings meet metal-to-metal. Ideal grooved systems are designed for visual inspection to ensure complete assembly. When the bolt pads are metal-to-metal this indicates a properly installed coupling. Flanges, on the other hand, do not provide visual confirmation and the only measure to ensure proper assembly is to fill and pressurise the system and check for leaks.
Flexible Install On initial installation, boltholes of a flange must be precisely aligned, and then tightened to hold the joint. Also the bolt-hole index on equipment inlets and outlets must line up perfectly with the flange on the piping
Figure 1: The mechanical grooved joint is comprised of four elements: grooved pipe, gasket, coupling housings, and nuts and bolts
require just two bolts and for larger sizes (over 26‰/660mm) just four bolts. For comparison at this higher size range a flange would require a minimum of 20 nuts and bolts.
Figure 2: A mechanical coupling has 360-degree orientation capabilities and a low profile - making it ideal for installation in confined spaces.
Maintainability The same characteristic of grooved systems that accelerate installation·fewer bolts and no torque requirements · also makes system maintenance a quick and simple task. When piping needs to be moved, rotated, changed or added, the two or four bolts of a coupling make these maintenance tasks much more efficient than a flange, which can have up to eight times as many bolts. Chemical Engineering World
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CEW Features To gain access to a pump or valve, for example, the two bolts of the coupling are loosened, and the housings and gasket are removed from the joint. In a flanged system, multiple bolts need to be removed. The same time-consuming bolt-tightening sequence required upon initial installation is also required upon reassembly of the flange. Couplings eliminate a lot of the regular maintenance associated with flanges, decreasing maintenance downtime, because they do not require regular retightening. Unlike a flange that puts variable stress on the gasket and nuts and bolts, a coupling holds the gasket in precise compression from the outside of the pipe joint. Additionally, coupling gaskets do not need to be replaced on a regular maintenance schedule, while flange gaskets need to be replaced when the system is disassembled for maintenance. Better Vibrations Over the life of a system, flanging can require quite a bit more work to maintain joint integrity. Pumps and other equipment frequently create vibration and noise in a piping system. For example, oscillatory forces can be generated due to the lack of balance of rotating components such as from pump vanes. Although field balancing can reduce this, it requires specialized equipment, which can become difficult, expensive and impractical. System vibration and other forces can lead to joint problems in a flanged system. Flanging employs a series of bolts and nuts to compress a gasket between two flat-faced, flanged pipe ends. The torque on the bolts employs a high compressive load on the internal gasket, which can cause the gasket to adhere to one or both of the flanges. When the joint is disassembled, the gasket can tear, resulting in failure upon reinstallation if not replaced.
have a comparable performance to twin-sphere neoprene connectors and a superior performance to braided metal hoses. Victaulic couplings dampened the overall vibration amplitude by 80 to 90 per cent. Each successive joint creates a further reduction in vibration. Independent test laboratory Nutech Testing Corporation/ SE Laboratories used Victaulic mechanical couplings in its testing, and concluded that, for any given pipe diameter, less vibration is transmitted with each additional Victaulic coupling, regardless of whether Victaulic flexible or rigid couplings are used. The gasket absorbs the vibrations, not the bolts and nuts. Over the life of the system, the nuts and bolts do not require regular retightening and will not slip or relax, thus maintaining a leak-tight seal. The gasket of a grooved coupling has a C-shaped cross section seal that is very durable and can handle significant compressive and cyclical loading. A system can be pressurized and depressurized repeatedly without fatiguing the rubber. Gaskets from Victaulic are rated for life-of-the-system service. Conclusions In summary, grooved piping systems can offer significant advantages over their flanged equivalents because of their speed of installation, maintainability and alignment ease. These characteristics, coupled with additional benefits such as design versatility, safety and reduced total installed costs, are leading many installers, engineers and owners to choose grooved mechanical systems instead of flanges.
In order to accommodate system vibration and reduce noise, flanged systems employ specialised and expensive rubber bellows or braided flexible hoses to accommodate this vibration. Over time or due to overextension, these products can wear out or fail, requiring replacement. Furthermore, the bolts and nuts of a flanged union absorb system forces, and over time, can relax due to surges, system working pressure, vibration, and expansion and contraction. When the bolts lose tension, the gasket can „slip,‰ which can result in a leak. Flange gaskets can take on compression over time, also resulting in leakage. To prevent or stop leaks, routine bolt and nut tightening is required. The ability of high-end grooved couplings to accommodate system vibration reduces the risk of joint issues. Grooved systems can accommodate vibration without the need for speciality products that require periodic repair or replacement. The resilient elastomeric gasket contained within both flexible and rigid couplings aids in dampening noise and vibration. Recently, acoustical consulting firm SSA Acoustics, in Seattle, Washington, undertook a field measurement that showed three Victaulic couplings, placed in series in a pipe section, 34 • August 2013
AuthorÊs Details Andy Carter Product Engineer Victaulic Email: andy.carter@Victaulic.be
Chemical Engineering World
Chemical Engineering World
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CEW Features
Pump Materials for Harsh Environments Pumping corrosive fluids containing abrasive solids is a challenge. Sulzer can adapt pumps to such requirements by making the ideal choice of hydraulics and seals and by improving the materials used to produce the pump. Because i t h a s i t s o w n f o u n d r y, S u l z e r can offer materials that are not easily available on the market. The company has developed a specific heat treatment procedure for steel that improves wear resistance, while leaving corrosion resistance nearly unchanged.
Sulzer’s foundry in Karhula, Finland, manufactures stainless castings for pumps, mixers, and agitators.
S
ulzer supplies a variety of pumps that can operate in corrosive and abrasive environments, such as chemical or metal processes and demanding wastewater treatment. To ensure high reliability, research and development in the fields of fluid mechanics and materials technology as well as detailed knowledge of the applications and operating conditions are essential. Hydroabrasive wear and corrosion can significantly reduce the lifetime of pump components. One possibility to optimise operational life in such aggressive surroundings is the use of specially adapted hydraulics or seals. Furthermore, the selection of appropriate materials is the key to substantially extending the service intervals of a pump. Specialised Foundry Cast duplex stainless steels, as defined by ASTM International (the international standards organisation formerly known as American Society for Testing and Materials), are the materials mainly used today under corrosive and erosive conditions. When sourcing from commercial foundries, pump 36 • August 2013
manufacturers are required to use these standard grades for their components. By contrast, Sulzer operates its own foundries in Karhula (Finland) and in Jundiaí (Brazil). This gives the company the option of developing alloys and methods for material treatment that commercial foundries do not offer. The foundry in Karhula supplies high-quality, corrosion-resistant steel and special cast-iron castings primarily to the companyÊs own factories. Of the total annual production of some 30,000 castings, almost 90 per cent are made of corrosion-resistant duplex and super duplex cast steel grades. Making a Standard Material Better Even though duplex steel offers outstanding wear properties along with its corrosion resistance, some demanding applications require an enhancement. Precipitation hardening is a specific heat treatment that can improve the characteristics of duplex steel without the need for expensive additional alloying elements. This heat treatment strengthens the material by allowing the controlled release
of constituents that form precipitated nanoscale and microscale intermetallic clusters. However, it is not applicable to all duplex grades and bears the risk of impairing the corrosion resistance and the toughness of the respective material. Sulzer has examined several procedures for the precipitation hardening of duplex steel containing copper. By varying the copper content and the parameters of the heat treatment, Sulzer engineers have succeeded in improving the wear resistance of the material without undermining its corrosion properties and toughness. Proprietary Testing Knowledge Various process parameters, such as heating rate, heating temperature, dwell time, and cooling rate, influence the size and the distribution of the precipitates. The optimal control of these two characteristics provides the balance between the resulting increase in strength and the loss of ductility and toughness. Methods for the testing and characterisation of the material developed by the experts at the research unit Sulzer Innotec were used to optimise the parameters. The Chemical Engineering World
Chemical Engineering World
August 2013 • 37
CEW Features What is Duplex Stainless Steel? The corrosion resistance of stainless steels is based on the presence of a substantial amount (>12 per cent) of chromium in the steel. It forms a protective film of chromium oxide on the surface that inhibits corrosion. By alloying other elements like nickel, molybdenum, nitrogen, titanium, and manganese, it is possible to achieve a wide range of mechanical and chemical properties in the stainless steels. Stainless steels are categorised into four groups according to their crystal structure: Ć Austenitic stainless steels (face centered cubic structure) Ć Ferritic stainless steels (body centered cubic structure) Ć Martensitic stainless steels (body centered tetragonal structure) Ć Duplex stainless steels (mixture of austenite and ferrite phases) Figure 1: The hardness and the toughness of the steel can be controlled by varying the precipitation hardening temperature and the dwell time.
goal was to adapt the ASTM material A 890 Grade 1B (duplex steel containing some copper) to make it usable in challenging pump applications. During the materials development project, the several parameters were varied such as Copper content, Solution annealing temperature of the base material, Heating rate, Treatment temperature for precipitation hardening, Dwell time and Cooling rate Improved Hardness The testing clearly showed that there is only a small temperature range where hardness and toughness can be optimized. This temperature range is limited on both sides by the precipitation of harmful intermetallics (brittle metallic structures). However, within that process window, hardness and toughness can be tuned over a wide range by choosing the appropriate dwell time (Figure 1). Measured with a high-velocity slurry jet, precipitation heat treatment leads to a significant improvement in wear resistance compared with the reference material, which was only solution annealed. Corrosion testing of the precipitation hardened steel also showed only minor relative changes. Extending Pump Lifetime Sulzer has successfully used this heattreated material in cases where the pumped 38 • August 2013
media are corrosive fluids that contain moderately abrasive solids such as pure salt crystals. For these applications, typically an Ahlstar process pump type WPP with wearresistant hydraulics is selected. The special material is used for pump impeller and side plate·because these parts are normally the most exposed to wear·or for all wetted cast parts. An exemplary application of a pump made from this new material is the second step of absorption in the fluor salts production, which is part of the production process of phosphoric fertiliser. As for most chemical processes, the performance of these pumps is critical for the production, and the requirements relating to their reliability are high. The pumped liquid is both corrosive and contains fine, abrasive particles. Improving Process Reliability A client who operates a fertiliser production plant wanted to replace the original pumps, which had an insufficient lifetime. These machines were sealed with gland packings. This type of seal works with a lubricating fluid and failed to seal the aggressive fluid dependably. Because the customer had had a positive experience with the Sulzer pumps being used in the first step of absorption, he entrusted Sulzer again with the replacement of the second-step pumps.
The austenitic grades are most popular, but the duplex grades are the most important for industrial pump applications. Owing to their two-phase microstructure consisting of austenite and ferrite grains, duplex alloys combine the advantages of both steel groups. They are roughly twice as strong as purely austenitic stainless steels. They have significantly better toughness and ductility than ferritic grades. They exceed austenitics in their resistance to stress corrosion cracking. And these advantages are not associated with higher costs. Because of the increased yield strength, it is often possible to reduce the section thickness of components compared with designs based on austenitic grades. Furthermore, duplex stainless steels have a lower content of expensive nickel and molybdenum than their austenitic counterparts do, making them a cost-effective and weight-saving choice for many applications. Duplex steel combines two different phases: austenite (white areas) in a ferrite matrix (grey areas).
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CEW Features
Sulzer examined several procedures for the precipitation hardening of duplex steel.
Based on their experience with the pumps in first step of the absorption in the fluor salts manufacturing process, the Sulzer experts selected a WPP (wear resistant) pump with an open impeller and a dynamic seal. These seals operate very reliably with corrosive and abrasive fluids. The pumps are made from precipitation heattreated material with a hardness of 300HBW. The chosen pumps operate close to their duty point, which is essential for efficient hydraulic operation. In this case, the combination of pump, fabrication material, and seal type·all well suited for the application·led to increased reliability of the overall process. This improvement reduced outage and increased the time between repairs. Following the successful installation of the first pump, several pumps·all made from specifically heat-treated steel·are now running in same fertiliser production line.
AuthorsÊ Details Raimo Arola Material Specialist Sulzer Pumps Finland Oy Email: raimo.arola@sulzer.com Thomas Kraenzler Manager Core Technology Materials Sulzer Pumps, Winterthur, Switzerland. Email: thomas.kraenzler@sulzer.com
40 • August 2013
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CEW Features
Ultrasonic Flowmeters In the last decade, ultrasonic flowmeters have grown in popularity in laboratory and process areas as a cost-effective, noninvasive alternative for measuring the velocity and flow rates of liquids and gases. With highly accurate and flexible ultrasonic flowmeters, users can choose from various electronics packages, and also use the devices in areas that require explosion-proof devices. These value-added benefits provide a striking contrast to turbine or variable-area flowmeters, which are less accurate, offer fewer output capabilities, and are invasive to the process media Handheld Ultrasonic Flowmeter, Image Courtesy: Cole-Parmer
hile ultrasonic flowmeters are now cost effective, their most significant benefit may be their ability to measure flow without interfering with any process liquids or gases. The noninvasive measurement is taken from two or more transducers attached to the piping exterior. The frequency shift of an ultrasonic signal that is sent through the fluid or gas is measured, then a signal is sent via cable to the electronics housed in the flow computer.
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that uses particles or aeration in the fluid as a reflective mechanism to gauge the velocity of the fluid, and second transit-time technology relies on a frequency difference in forward and reverse signals sent through a clean liquid to gauge the velocity of the fluid; this fluid must not contain solids or aeration as they will distort the sonic pulses. Both of these technologies are ideal in creating flow profiles through an existing process when modification of piping or a process line is not possible.
According to a 2006 Frost and Sullivan report 1, the replacement rate for ultrasonic flowmeters is 12 to 15 years, producing a solid return on investment. This longevity may account for an expanding market for ultrasonic flowmeters when many other flow technologies are shrinking. By 2012, the report projected, the market is expected to grow to an estimated $1 billion in sales.
Selecting a Ultrasonic Flowmeter Style To determine what style of ultrasonic flowmeter will be most effective for any specific application, consider how it will be used. The three primary styles are handheld, portable, and dedicated.
Ultrasonic Measurement: Doppler and Transit-Time Two main technologies distinguish ultrasonic measurement: First, doppler technology 42 • August 2013
Handheld Ultrasonic Flowmeters are exactly what they seem to be. They generally include a case for transporting the meter between locations within a factory, process area, or facility. While they are priced lower as compared to other ultrasonic flowmeters, their functionality is limited to basic flow
rate measurement. Typical accuracies are Ο2 per cent full-scale or better. On average, the handheld models are battery powered or rechargeable. Most will have a four- or five-digit display and will show flow in Gallon Per Minute (GPM) or Liter Per minute (LPM). The unit is easy to use¡simply turn on the flowmeter and holds the transducer (which sends and receives radar signals) to the pipe to take a reading. Most Handheld Ultrasonic Flowmeters use Doppler technology. Some are now capable of datalogging and employ RS-232 output for recordkeeping needs (if required for ISO compliance). Handheld flowmeters are most commonly used to measure slurries and dirty fluids Advantages of Using Ultrasonic Flowmeters Improved accuracies No pressure drop High turn-down ratio No moving parts Minimum maintenance Long-term cost savings Chemical Engineering World
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CEW Features operation of the meter. Proprietary software is usually included with these flowmeters. A portable unit can be programmed through its integrated keypad allowing control of operating parameters. Many portables can also be programmed via a PC or laptop. Dedicated Ultrasonic Flowmeter The displays on portable Ultrasonic Flowmeters are usually much larger than handheld meters, enabling the user to see more data at a glance. Because the flowmeter cases are NEMA 4X rated or better, these units are suitable for continuous outdoor use. Also, they can be used in wide temperature range applications. Dynasonics, GE Sensing, and Thermo Scientific are the leading manufacturers for portable ultrasonic flowmeters. Portable Ultrasonic Flowmeter, Image Courtesy: Cole-Parmer
in the chemical industry, food processing, and water treatment plants where basic flow measurement is required from time to time. Facility engineers working in office buildings or small-scale process plants frequently need to monitor HVAC-R systems. Typically, these engineers will use a handheld unit to accomplish this task. Portable Ultrasonic Flowmeter Portable Ultrasonic Flowmeters are more advanced than the handheld models and also more expensive. These larger units use both Doppler and transit-time technologies to measure flow and velocity. Most high-end Portable Doppler and Transit-Time Ultrasonic Flowmeters employ digital signal processing (DSP), digital cross-correlation, and a proprietary time expansion algorithm·producing outstanding accuracy as compared to handheld models. The design of the transducer set enables the flow to be measured in a broad range of pipe sizes and materials. Transducers used with ultrasonic doppler flowmeters do not operate well with concrete, clay, or fiberglass pipes as the transducers donÊt have the capability to „see‰ through such dense materials. Many portable systems are suitable for survey work in remote locations. For example, fisheries need to monitor the input and output of water flow on a daily basis to confirm filtration is at adequate levels. Large petrochemical facilities also measure and monitor flow regularly. These facilities can extend over a wide area, requiring an engineer to employ a portable system if dozens of locations are measured. A waterproof enclosure can protect the transmitter from accidental immersion or splashes. When wired power is not available, most portable meters will operate from eight to 24 hours on an integrated, rechargeable battery. If operating in a wired installation, a 4 to 20 mA or voltage output can be used for continuous monitoring of flow rate. Several portable models are available with a datalogger that can be unplugged for data downloading without disrupting the 44 • August 2013
Dedicated Ultrasonic Flowmeters are designed to be installed and operated in one location. They are used almost exclusively in plants and process areas. These flowmeters operate well in HVAC-R, potable water, ultrapure water, petroleum products, sludge and slurries, and liquefied gases applications. As with portable units, Dedicated Ultrasonic Flowmeters use both doppler and transit-time technologies. Unlike portable units, though, dedicated units deliver unique benefits and options. Many manufacturers (including GE Sensing and Thermo Scientific) offer intrinsically safe and ATEX-rated units for the petrochemical markets. They also have units that are DC or AC powered and operate with digital communications. Dedicated units have electronics housed in enclosures rated NEMA 4X and contain NEMA 6-rated transducers. They are typically waterproof, preventing damage in case of accidental immersion. Some manufacturers offer 30,000-point datalogging and accuracies to μ0.5 per cent full-scale. Easily installed, the transducers clamp onto pipes that range in size from 1 to 200 inches and offer bidirectional flow measurement. Conclusion In summary, with prices dropping and benefits increasing, it may be an optimal time for users to upgrade from older technologies and invest in an ultrasonic flowmeter. It just makes sense to buy an instrument with high accuracy and flexibility. For those in the market, choose the best model by assessing the following criteria: ultrasonic measurement technology, application usage, and option efficiencies. Use the Ultrasonic Flowmeter Application Guide to help determine typical applications for each type. Added features and options (such as finer precision, advanced datalogging capabilities, etc.) may tip the balance toward one or two models. References: 1. Frost & Sullivan, World Flow Sensors and Transmitters Markets (Palo Alto, California: Report, 2006), Section 5-3, 5-7
Courtesy: Cole-Parmer Chemical Engineering World
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CEW Features Case Study
Handling Tricky Situation with Ball Sector Valve When an expensive control valve breaks down after three months only, a remedy is needed badly. But engineering resin producer Ticona had been having to live with this situation for considerable time due to their extraordinary producing process. Thinking outside the box was the way out. Using an “exotic” ball sector valve not only solved the problem, but also saves money.
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h e c o n t r o l va l ve w a s r e a d y fo r scrapping after only three months. We are not talking about some cheap plug valve made from low-quality steel, but rather a valve made from high-quality Hastelloy C. This situation could not be tolerated for long, but the harsh conditions in fiber enforced plastic production at Ticona in Kelsterbach in Germany meant that abrasion and corrosion occurred on the body, tapered seat or plug after only a short time, leading to total failure. Lift valves of the type used until in the 1980s could not be considered because of the emissions regulations in „TA-Luft‰. Thomas Labahn, the person responsible for plant planning and EMC at Ticona in Kelsterbach, took a long hard look at the problem. This explains why he was very interested in a ball sector valve that he saw during a plant tour of the valve manufacturer Schubert & Salzer Control Systems. „As soon as they explained the control valve
46 • August 2013
to me, a light went on in my head,‰ is how Labahn describes his Eureka moment. The fiber enforced plastics manufacturer conducted a parallel test of a ball sector valve from Schubert & Salzer and one from another manufacturer. The latter valve lasted precisely three weeks before seizing up. The Schubert & Salzer valve on the other hand, lasted the course: „The very first attempt was a major success.
why it is significantly less expensive than the previous valve made from Hastelloy. Furthermore, the damaged valve can be repaired and even costs a good deal less to buy than does the plug valve made from Hastelloy. Considering the numerous control functions in which these valves a r e u s e d a t T i c o n a u n d e r ex t r e m e l y challenging conditions, the saving potential is quite considerable. A small actuator is sufficient.
The valve lasted nearly ten months, almost three times as long as before,‰ explains Labahn. The trick: The valve is made from standard material (stainless steel) and only has hard chrome-plated (stellited) ball sector surfaces. This is the reason
After ten months in operation, only the holder of the seat ring had come loose, and the manufacturer is already working on a solution to this problem with an improved variant. „We found there was abrasion on the parts that were not stellated but came
The valve is made from standard material (stainless steel) and only has hard chrome-plated (stellited) ball sector surfaces. This is the reason why it is significantly less expensive than the previous valve made from Hastelloy Chemical Engineering World
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CEW Features 1
2
(1) The ball sector valve opens the entire pipe cross section when it is open, (2) The actuator of the ball sector valve is relatively small
into contact with the medium,‰ describes Labahn. As far as the client is concerned, the reason for the longer ser vice life is principally to do with the geometr y: „The media flows through the ball sector element in a totally different way than in the plug valve,‰ explains Labahn. In future, completely stellated valves are expected to offer even greater improvements. Other impor tant aspects in favor of using ball sector valves are their comparably light weight and relatively low actuator thrusts. The friction against the stuffing box seal in plug valves means they have a very high break-loose torque and this explains why they need powerful actuator thrusts. The torque with the ball sector valve, on the other hand, is relatively low and the actuators can be correspondingly smaller. A single action Wirematic actuator with a safety position is used on the valves. F u r t h e r m o r e , t h e va l ve d o e s n o t g e t
blocked because the entire pipe cross section is left unobstructed when the ball sector is fully open. The fibre enforced p l a s t i c s m a n u fa c t u r e r i s a l s o h a p py when it comes to the control response: „In our case, the control accuracy that h a s b e e n a c h i eve d i s c o m p a r a bl e t o that of the plug valve we used to use,‰ reports Labahn. „We are planning to test using the ball sector valve as a manual valve as well soon,‰ declares operations assistant Volker Gatzer t. The client anticipates this will result in greater ease of movement at the same time as saving space and weight. „ThereÊs not much room available where we use the valve,‰ describes Gatzert. However, it is a disadvantage that the unit is not built as a flange valve. Gatzert: „I think the manufacturer should consider designing a flange valve to open up a new and wider range of applications for its valves.‰
The modified equal-percentage operating characteristic (in operation, the differential pressure increases as the valve closes) combined with the outstanding rangeability of 300:1 mean that that valve can be used for most control tasks. 48 • August 2013
COMPACT - Principle of the Ball Sector Valve The ball sector valve consists of a hemispher ical shell - the ball sector that is held securely in the valve body u s i n g t w o l a r g e b e a r i n g s t e m s . Pa r t of the hemispher ical shell is used for isolating, while the other has a hole with a diameter corresponding to about 80 per cent of the nominal size of the valve. The ball sector is turned through about 90Ĉ from fully open to closed. The shape of the opening cross section changes from completely round to elliptical in this case. This practically round shape for the flow opening reduces the r isk of blockage when small control settings are made. The valve characteristic maintains almost the same percentage value with constant differential pressure. The modified equal-percentage operating characteristic (in operation, the differential pressure increases as the valve closes) combined with the outstanding rangeability of 300:1 mean that that valve can be used for most control tasks. The special connection of the valve body ensures that the differential pressure on the valve has little effect on the actuating torque. Ball sector valves are used as isolating and control valves for fluids, gases, turbid m e d i a a n d s l u d g e s, e s p e c i a l l y i n t h e pulp and paper and chemical industr y. Abrasive slurries of iron ore, coal, lime and fly ash are also controlled with this type of valve.
AuthorsÊ Details Volker Gatzert Schubert & Salzer Control Systems GmbH Email:marketing@schubert-salzer.com
Thomas Labahn Schubert & Salzer Control Systems GmbH Email: info.cs@schubert-salzer.com
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CEW Market Insights
Rise in Sustainable Pumps and Valves Market
Ashish Gurnani, General Manager South Asia, Dixon Asia Pacific Private Limited
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ith the growing globalisation, organisations are not only opting for expansion but are changing their arenas in the industrial sector. Expanding from outsourcing to manufacturing units is one of the biggest change, we can identify in the growing industry horizons. Established in 1916, in the United States by Howard W Goodall, Dixon Valves grew widely during the countryÊs thriving progress in mining, construction, railroads and oil drilling sectors. Designing customised hose and couplings according to the individual clientsÊ requirement became one of their fortes and has largely contributed to their success. They are gearing to achieve its century in the Pumps and valves market across the world and have marked their footprints across most of the countries. Dixon Valves, after marking their presence in almost all the continents, arrived in India in 2006 as major Hose assemblies, connectors and valves trader. The company has now started moving in manufacturing sector to expand their horizons within the country. Retaining the legacy of 97 year old prestige, Dixon ValveÊs mission is to solidify their feet in the manufacturing sector of Indian market. It has a manufacturing site at Rabale Industrial Area, which will be used for manufactures of Hose Assemblies and Test facility for the Dixon Bayco range. The capacity is further planning to produce more products and systems there. It also has a 3500 sq ft 3PL warehouse at Bhiwandi with good inventory of Industrial Hose and Fittings, QRC, Camlock products etc. The completion of manufacturing set up has encouraged the team to aggressively pave the way for promotion of their inhouse products. According to Ashish Gurnani, General Manager - South Asia, Dixon Asia Pacific Private Limited, India is a bright and emerging market wherein, the company has decided to penetrate the market strategically and raise the flagship of Dixon Valves. By and
India is a bright and emerging market wherein, the company has decided to penetrate the market strategically and raise the flagship of Dixon and Valve. 50 • August 2013
Sources Mcllvaine Company
large, a majority of the Dixon Products are highly utilised in the varied end- users industries of power generation, oil and gas and heavy industries. The Indian market has been blooming in this sector due to countryÊs wide spread oil and gas exploration and manufacturing activities along with refineries and various other core energy sectors. Evaluating the vastness of Indian end- user Industry and the range of applications involved in each of the sector, the demand for fluid transfer products is extremely high. Thus, it has accelerated the growth rate which is good sign for Dixon Valves to put their foot into manufacturing segment. However, he also added that if IndiaÊs expanding infrastructural systems will be a great advantage for the company. Companies nowadays are inventing remarkable products that ease out the production work and increase the lifecycle of machines. Sustainability is one of the pillars for the growth and development for various industrial sectors. In adherence to market scenario, he mentioned that India and China are growing 5 per cent on GDP front. With immense growth opportunity in India, the company is looking at Energy, Steel, mining, pharmaceuticals and food processing industries as the key market segments. Dixon Valve Asia Pacific Limited is in full fledge swing to upraise their market positioning in the country. - Namrata Tanna Chemical Engineering World
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ColeParmer.in/3125 August 2013 • 51
CEW Products Seal-less Drive Eccentric Disc Pumps Mouvex offers SLC4 and SLC8 models of its seal-less drive eccentric disc pumps for use in general industry applications, as well as the handling of numerous chemical-based compounds, including isocyanates, polyols, additives, solvents, glues (starches and latex), paints and coatings (inks and resins), methacrylates and detergents.The major technological advancement in the SLC4 and SLC8 pumps is the incorporation of double-wall bellows into the design, along with monitoring that is done by pressure switch. By mounting the pressure switch on the bellows flange, the bellows becomes an independent sub-assembly within the pump, making for safer and easier operation. Other improvements in the SLC4 and SLC8 pumps includes the ability to handle differential pressures up to 10 bar (145 psi) in the SLC4 and 6 bar (87 psi) in the SLC8, and high-quality sand castings that are integrated into the manifold flange and bracket, which are compatible with ISOPN16 and ANSI150 flanges. For details contact: Dover India Pvt Ltd - PSG 40 Poonamallee By-pass Senneerkuppam, Chennai 600 056 Tel: 044-26271020 E-mail: sales.psgindia@psgdover.com or Circle ReadersÊ Service Card 1
nXDS Dry Scroll Pumps EdwardsÊ turbopumping stations feature a choice of nEXT turbopumps with speeds from 42 to 400 l/s, enabling the most appropriate pump for the application to be selected. T h e r e i s a l s o a c o m p r e h e n s i ve range of backing pumps to meet specific needs, from low priced oil-sealed rotar y vane pumping options to totally dry systems, now including the nXDS dry scroll pumps. The nXDS dry scroll pump offers a unique, oil-free, robust va c u u m s o l u t i o n . I t s a d va n c e d s c r o l l - fo r m a n d q u i e t operation, <52 dB(A), deliver best-in-class performance. The unique tip-seal design doubles the tip-seal life compared with EdwardsÊ previous XDS scroll pumps and it is easily field serviceable with a minimum of special tooling, giving class-leading maintenance intervals, less down time and a lower cost of ownership. For details contact: Edwards Group Ltd Crawley Business Quarter, Manor Royal, Crawley West Sussex RH10 9LW, U.K. Tel: +44 1293 603103, Fax: +44 1293 534149 E-mail:rebecca.walder@edwardsvacuum.com / pr@edwardsvacuum.com or Circle ReadersÊ Service Card 2
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Intellig ent Transmitters for pH/ORP and Conductivity SensorexÊs TX2000 pH/mV transmitter and CX2000 conductivity/ resistivity transmitter monitor changes in process fluids for more accurate control in a wide range of water, chemical, electronics, food production, environmental and wastewater processing applications. Both transmitters include Multi-Cal calibration with automatic buffer recognition, two assignable isolated analog (0/4-20 mA) current outputs, two alarm/control relays with an additional wash feature, and a universal 100-240 V AC power supply. CE certified, the compact NEMA 4X/IP65 enclosures can be wall mounted, installed in a panel or conveniently pipe/handrail mounted. The TX2000 has a pH measurement range of -2.00 to 16.00 pH and an ORP measurement range of -1999 to 1999 mV. The CX2000 has a conductivity measurement range of 0.000 uS/cm to 200.0 mS/ cm and a resistivity measurement of 0.00 to 20.00 MÃcm. Both are compatible with a number of probes and sensors to fit most application requirements. For details contact: Ion Scan Instruments & Services India Pvt Ltd 23, Mahalakshmi Street, B-16, Shanthi Flats, T Nagar, Chennai Telefax: 91-044-24349998 E-mail: sensorex@ionscanindia.com / Sales@ionscanindia.com or Circle ReadersÊ Service Card 3
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CEW Products Nitrile Rubber for Oil and Gas Industries
Krynac 4955 VP is a high-ACN nitrile rubber (NBR) for oil and gas industries thanks to its outstanding resistance to non-polar media. The new material also features improved flow properties for fast and reliable filling of large moulds, without the need to add large quantities of plasticizers. Further it includes optimized vulcanization properties and increased metal adhesion. The chemical component acrylonitrile (ACN) gives this elastomer its excellent oil resistance. LANXESS has a number of these grades, including Krynac 4975. Although LANXESSÊ Krynac 4450 and 4045 are high-ACN NBR grades with enhanced flow properties, their oil resistance cannot quite match that of the 4975 grade due to their lower ACN content. Krynac 4955 VP contains 49 per cent acrylonitrile, which makes it highly resistant to oil. With a Mooney viscosity (ML (1+4) 100 o C) of 55 μ5, however, it boasts far better flow properties than Krynac 4975 F. For details contact: LANXESS India Pvt Ltd LANXESS House Plot No: A 162-164 Road No: 27 MIDC Wagle Estate Thane (W), Maharashtra 400 604 Tel: 022-25871000 or Circle ReadersÊ Service Card 4
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Laboratory Temperature Controllers Oven Industries Inc offers laboratory temperature controllers with ramp/soak capabilities. The 5R6-900 benchtop controller can be plugged into the wall as a self-contained temperature control system, which has its own power supply. As a solid-state MOSFET bidirectional compact unit featuring an internal power supply, it is also capable of loading currents up to 10 A. The electronic controller easily connects to a computer through the electrically isolated RS232 communications port. The computer can be utilized as a connector and the unit can stand alone, once the desired parameter settings are in place. These settings are kept in the non-volatile memory. The controller features an easy-to-read digital display for controlling functions. For details contact: Oven Industries, Inc 5060 Ritter Rd, Bldg C, Suite 8, Mechanicsburg, PA 17055, U.S.A. Tel: (717) 766-0721, Fax: (717) 766-4786 E-mail: sales@ovenind.com / r.wescott@ovenind.com or Circle ReadersÊ Service Card 5
Test Strip-based Water Analyzer and Dosing System Blue I Water Technologies has been granted yet another patent for the PRIZMA water analyzer and controller, a technology for residential swimming pools, water tanks and wells. The patent is based on an innovative electro-optic test strip technology that has introduced automation to the litmus paper test for monitoring chemicals in water. The system assures chemical balancing for the poolÊs water, features automatic calibration and provides real-time online reports. The new Canadian patent, entitled „Indicator Strip and a Device for Automatic Testing of Liquids‰, further protects the technology that is already patented in many other countries. PRIZMAÊs system is particularly suited for use in residential and private swimming pools and spas, ensuring pool sanitation and clear water. It works by applying electro-optic capabilities to accurately analyze test pads that automatically monitor water quality at regular intervals. A continuous indicator strip is run across a series of individual test sections, each providing analysis for a different chemical, such as chlorine and pH. Pool owners and pool service companies benefit from the simpleto-use, probe-less (no calibration) and low maintenance technology that helps to significantly reduce workload and unnecessary pool maintenance, and are updated with online reports. For details contact: Blue I Water Technologies 23 Hamelacha St, Rosh HaÊayin 48091, Israel Tel: 972-9-768-0004 Fax: 972-9-765-2331 E-mail: Amilo@blueitechnologies.com or Circle ReadersÊ Service Card 6
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CEW Products Injection Moulding Processes
Recent Sanner developments include the desiccant capsule „360 Capsule‰ and „TabTec‰ tablet packaging. Operating in compliance with GMP standards, the companyÊs main plant is certified according to DIN EN ISO 15378:2007, DIN EN ISO 9001:2000 and DIN EN ISO 13485:2003. The 360 Capsule absorbs moisture both through an outer cardboard disk and also through a special grid in the capsule no matter how it is positioned within the filled container. The 360 Capsule solves two practical problems associated with desiccants and sachets: reduced moisture absorption when the desiccant capsule is in a disadvantageous position in the container, and the danger of being mistaken for medication. It is available with one gram of desiccant as the first member of a new product family. The TabTec container is a safe and simple solution for tablet removal. The flip-top closure with a thumb tab can be opened and tablets removed one at a time. The remaining contents of the box stay clean and protected in the packaging, thereby reducing the risk of product contamination. TabTec is available with or without integrated desiccant, providing an alternative for less moisture-sensitive capsules and coated tablets. For details contact: Communication Harmonists GmbH & Co KG Poststraße 48, 69115 Heidelberg Germany Tel. +49 (0)6221 90574-20 Fax +49 (0)6221 90574-11 E-mail: sanner@commha.de or Circle ReadersÊ Service Card 7
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Bursting Strength Tester MangalÊs bursting strength tester is designed to find bursting strength of fabric/leather/paper/paper board. Different models are available in the range. A test specimen is held between two annular clamps under sufficient pressure to minimize slippage. The upper clamping surface which is in contact with the test specimens has continuous spiral grooves. A circular diaphragm of pure gum rubber is clamped between the lower clamping plate and pressure cylinder so that before the diaphragm is stretched by pressure underneath its upper surface is below the plane of the clamping surface. The equipment is fitted with a motor driven cam mechanism, which increases fluid displacement on the lower side of the diaphragm at a specified rate. The equipment is fitted with an arrangement, which automatically brings down the pressure and stops the motor on completion of the test cycle. A max reading type pressure gauge gives the bursting pressure. For conducting tests on material where one pressure gauge does not cover the full range of loads encountered with the desired accuracy in measurement, a special model fitter with two pressure gauges with an isolating valve can be offered. Digital type pressure gauge type instruments and with pneumatic clamping models are also available. For details contact: Mangal Instrumentation 134 Apna Bazar,Nehru Nagar, Ring Road, New Delhi 110 065 Tel: 011-65845192, 29842634, 29843129, Fax: 91-011-29841033 E-mail: mangal_india@vsnl.com or Circle ReadersÊ Service Card 8
Electromagnetic Flowmeter FlowtechÊs electromagnetic flowmeters are intended for measuring flow of electrically conductive liquid in closed pipelines where the magnetic flux permeates the entire cross-sectional area of the liquid flow. Electromagnetic flowmeters measure electromotive force to determine liquid velocity using FaradayÊs Law of Electromagnetic Induction and computes the flowrate using the equation of conductivity. It operates with electrically conductive liquids having minimum conductivity of 5 micro Siemens/cm and is relatively immune to the effects of temperature, pressure, viscosity and density of the flowing liquid. For details contact: Flowtech Measuring Instruments Pvt Ltd 900/2/B, GIDC Estate Nr Pakona Engg Makarpura, Vadodara Gujarat 390 010 Tel: 0265-6508171, Telefax: 91-265-2636795 E-mail: flowtechinstruments@yahoo.com / flowtech01@gmail.com or Circle ReadersÊ Service Card 9
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SAMARTH ENGINEERS
Manufacturers & Fabricators of: Industrial Pressure Vessels Process Vessel & Heat Exchanger Our Products: Chemical Process Equipments Process Vessels Chemical Process Equipment Parts Fabrication Unit I : J-415, M. I. D. C., Bhosari, Pune - 411026. Maharashtra, India. Tel. No. : +91 20 66300305, 66146033 Mobile: +91 98600 98706 / 97663 26240 Email: sanjayraut21@hotmail.com Website: www.samarthengineers.com
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CEW Products Glass and Plastic Packaging Gerresheimer also has innovative and safe solutions for new parenteral drugs with different pH ranges or toxic pharma. The new MultiShell vials unite the best properties of plastic and glass in a high quality container for liquid medications. They are made of COP/polyamide/COP (cyclic olefin polymer) in a sandwich structure. The COP ClearJect syringes are also one of GerresheimerÊs flagship products. Heavy metal-free COP is perfect as a primary packaging for sensitive medications for oncology, ophthalmology and other fields of medicine. Gerresheimer is renowned for its pre-fillable RTF syringes made of tubular glass. Pre-fillable syringes are available as bulk products and in ready-to-fill format. Gerresheimer tubular glass is the input material for a comprehensive range of high quality pharma vials, ampoules and cartridges in numerous filling sizes and design variants. The Duma OneLiner is a twist-off closure specifically for the US market with the mandatory foil seal. For details contact: Gerresheimer AG Benrather Strasse 18-20, 40213 Düsseldorf, Germany Tel: +49 211 6181-250, Fax: +49 211 6181-241 E-mail: j.kuerten@gerresheimer.com or Circle ReadersÊ Service Card 10
E-Series Plastic AODD Pumps AlmatecÊs E-Series plastic AODD pumps provides the safe pumping option caustics-handling operators require due in par t to its solid-block construction with abrasion-resistant PE and chemicalresistant PTFE materials. It meets ATEX requirements, The availability of unique accessories improves safety aspects and makes the E-Series ideal for handling dangerous chemicals. The E-Series also features no mechanical seals, utilizing SS ring technology instead to increase protection from leaks by creating a consistent compression around the ring for higher torque.The E-Series not only ensures operator safety, but it lowers energy costs thanks to the exclusive Perswing P air control system, which offers superior efficiency when comparing flow rate and air consumption needed. The E-Series is available in seven sizes from 6 to 76 mm with maximum temperatures to 120oC. The pump also features maximum flows to 800 L/min (210 gpm); suction lift to 5 m dry, 9.5 m wet; and maximum solids size to 15 mm. For details contact: Dover India Pvt Ltd ă PSG 40 Poonamallee By-pass, Senneerkuppam, Chennai 600 056 Tel: 044-26271020 E-mail: sales.psgindia@psgdover.com or Circle ReadersÊ Service Card 11
58 • August 2013
Measuring Instruments The CombiView display is impressive with its presentation of all necessary and desired information at a glance. In terms of the displayÊs visual mode, the user can choose from several different types: analog, digital or illustration. The background colour of the display works like a traffic light system (red/green), depending on whether the measurement results have reached a critical value that requires user intervention. The respective housing completes the impressive functions of the new product series. With its protection class IP 69 K and entirely SS design, the hygienic version can withstand even the toughest conditions. In addition, its ability to pivot around two axes facilitates even more installation flexibility. Reliable and precise measurements are provided by the CombiPress pressure transmitter between -1 and 400 bar and by the CombiTemp temperature gauge between -50 and +400 degrees Celsius. For details contact: Baumer India Pvt Ltd 201, C3-Bldg, Saudamini Complex, Bhusari Colony Paud Road, Kothrud, Pune, Maharashtra 411 038 Tel: 020-25286833, Fax: 91-020-25286835 E-mail: sales.in@baumer.com or Circle ReadersÊ Service Card 12
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CEW Products New High-speed Liquid Filling Machine The Macofar LF 200 FC was specifically developed for filling pharmaceutical syrups of almost any viscosity. The systemÊs maximum filling speed is 4,500 bottles an hour with a filling volume of up to 250 millilitres. The intermittent filling process is recommended, amongst other things, for cough and fever medicines or nutraceuticals. The machine is suitable for filling glass and plastic bottles with a maximum volume of 500 millilitres. The containers are sealed with pilfer-proof or screw caps. With its compact design and length of just 2,200 millimetres, the Macofar LF 200 FC has a remarkably small footprint and is very economical in use. It requires only minimal maintenance and is readily accessible, allowing convenient operation as well as quick format or product changes. For details contact: Romaco Group Am Heegwald 11, 76227 Karlsruhe, Germany Tel: +49 (0) 721 4804 0, Fax: +49 (0) 721 4804 225 E-mail: susanne.silva@romaco.com or Circle ReadersÊ Service Card 13
GSM Gateway
LiquiSonic Analyzer
GSM solution is not just a Modem. It is actually a Cellular Wireless Gateway that works on GSM technology to enable user to connect any serial device to GSM network for data transmission and receiving in most convenient way. It is a data monitor/sharer for devices like PLCs, inverters, controllers, DCS, energy meters, PID controllers and others.
The LiquiSonic analyzer from SensoTech is manufactured with modern electronic components. Particularly in the chemical industry, it is being used in diverse applications, such as the determination of the concentration of bases and acids, but also for polymerization and crystallization monitoring. In order to further improve the functional reliability during operations, the LiquiSonic analyzer now complies with the increased electro-magnetic compatibility (EMC) requirements proposed by NAMUR under NE21.
GSM Gateway uses SMS to offer convenient, easy to configure and very low cost M2M solution. The GWY-900 unit can be connected to any supported serial device using standard serial protocols such as Modbus RTU (Master/Slave), DF1, SNP-X, HostLink, ASCII and many more. The other end of GWY-900 is an antenna that functions as a transceiver. The data from Serial device/s is collected and then transmitted over GSM network and vice versa. GWY-900 supports GSM Quad Band frequencies 850/900/1800/1900 MHz. User can now receive alarms and data on cellular phones (single or multiple) at the same time send set-points, etc, using SMS to the field devices. The user can also exchange Data between 2 or more different make of field devices supporting different communication protocol. GWY-900 also supports ladder logic that is used for sending conditional alarms/messages based on events, data change, etc. User can send generic alarms to specific cellular number and escalation alarms to multiple cellular numbers. For details contact: Renu Electronics Pvt Ltd Survey No: 2/6 BanerRoad, Pune, Maharashtra 411 045 Tel: 020-27292840, Fax: 91-020-27292839 E-mail: anant.kulkarni@renuelectronics.com or Circle ReadersÊ Service Card 14
62 • August 2013
The NAMUR recommendation under NE21 requires, that the devices used in laboratory and process control are immune to interference. The abbreviation EMC stands for electromagnetic compatibility and characterizes the ability of an electrical device to function satisfactorily in its electromagnetic environment, without itself causing any inadmissible effect on the other devices in the surroundings. Thus, with the EMC conformity the function of the LiquiSonic analyzer is neither influenced by electromagnetic sources of interference from other devices nor the analyzer turns into a source of interference to other devices. For details contact: SensoTech GmbH Steinfeldstr 1 D-39179 Magdeburg-Barleben Germany Tel: +49 39203 514100 Fax: +49 39203 514109 E-mail: info@sensotech.com or Circle ReadersÊ Service Card 15
Chemical Engineering World
Products CEW Comprehensive Lines of Metering and Peristaltic Pumps NeptuneÊs Series 7000 pumps is designed with water and wastewater applications in mind. It eliminates the use of contour plates on the liquid side of the diaphragm while the simple, straight-through valve and head design allows for improved flow characteristics. The Series 7000 is self-priming, provides superior performance and has a max capacity range up to 300 gph (1,135 L/h) at 150 psi. NeptuneÊs PZ Series electronic diaphragm pumps have numerous designed in features, making them ideal for various product applications at flow rates from 0.01 to 20 gph and operate on a manual control that produces speed ranging from 15 to 300 strokes per minute with variety of liquid-end materials available. In addition, the Series 500 hydraulically actuated metering pumps feature EZE-CLEAN valve cartridges that can be removed for cleaning without disturbing the piping to the pump. Series 500 pumps have capabilities to 100 gph (302 L/h) simplex and 160 gph (605 L/h) duplex at pressures up to 3,000 psi (210 kg/ cm). NeptuneÊs industry-proven line of Abaque peristaltic (hose) pumps is available in 9 different models/sizes from the AB10 to the AB100, with flow rates ranging from 0.07 to 211 gpm (0.015-48 m 3/hr). Ductile-iron and steel construction enables the pump to offer max discharge pressures as high as 217 psi (15 bar). In addition to the peristaltic and diaphragm metering pumps, Neptune offers multiple products used in the water and wastewater market, including portable mixers, chemical feed systems and related accessories such as injection quills, corporation stops, back pressure valves and relief valves. For details contact: Dover India Pvt Ltd - PSG 40 Poonamallee By-pass, Senneerkuppam, Chennai 600 056 Tel: 044-26271020 E-mail: sales.psgindia@psgdover.com or Circle ReadersÊ Service Card 16
Accurate Flowmeters
Fluid Bed Dryers Aero Therm Systems Pvt Ltd offers fluid bed dryer having batch capacity of 15 to 500 kg. The digital temperature indicator c o n t r o l l e r w i l l g i ve a c c u r a t e temperature control. Control action can be On-Off or PID as per control accuracy required. Construction of dryer can be made of MS/aluminium/SS-316/ SS-304 as per the requirement. Flame-proof and spark proof version is also available. Heating can be electrical/thermic fluid or steam radiator/oil fired hot air generator. For details contact: Aero Therm Systems Pvt Ltd Plot No: 1517, Phase III GIDC, Vatva, Ahmedabad, Gujarat 382 445 Tel: 079-25890158, 25834987 Fax: 91-07925834987 E-mail: contact@aerothermsystems.com or Circle ReadersÊ Service Card 17
Chemical Engineering World
Its correlated variable area is available in 65or 150-mm scales and can be used with gas or liquids and available in choice of materials, with or without control valves and range of flow tube sizes. The 65-mm models are for tight measuring areas and 150-mm for applications demanding high resolution. Aluminum body flowmeters are for use with non-corrosive gases and liquids. Brass body flowmeters are for use with water. SS-316 body flowmeters feature excellent chemical compatibility. High-precision valve flowmeter for low-flow applications or for precise flow control. Correlated flowmeters use a universal millimeter scale to be used with a number of different fluids, at changeable pressure and temperature conditions, by cross-referencing the scale against a correlation data sheet. Variable area flowmeters are for applications requiring visual indication of flow or flow rate. For details contact: Cole-Parmer India Pvt Ltd B 403-404 Delphi Hiranandani Business Park, Mumbai 400 076 Tel: 022-67162209, 67162222 E-mail: response@coleparmer.in or Circle ReadersÊ Service Card 18
August 2013 • 63
CEW Events
INDIA India Chem Gujarat Dates: 24-26 October 2013 Venue: Mahatma Mandir, Gandhinagar, Gujarat About: A prominent event on chemical industry Organiser: FICCI Contact: +91 11 2373 8760 Email: manoj.mehta@ficci.com Website: www.indiachemgujarat.com
INTERNATIONAL China International Chemical Industry Fair Dates: 4-6 September 2013 Venue: Shanghai World Expo Exhibition Centre, Shanghai, China About: Leading event in petroleum and chemical industry in China Organiser: China National Chemical Information Centre (CNCIC) Contact: 86-10-6422 2898; +86-10-6444 4135 Email: liuyan@ccpitchem.org.cn Website: www.chinaexhibition.com
Watertech Expo and Conference 2013
Speciality & Agro Chemicals America
Dates: 26-28 September 2013 Venue: Mahatma Mandir Convention Centre, Gandhinagar, Gujarat About: International trade fair for water and wastewater technology Organiser: Messe Frankfurt Contact: +91-22-6144 5900; +91 11 4132 6666 Email: anand.nair@india.messefrankfurt.com Website: www.watertechindia.com
Dates: 9-11 September 2013 Venue: Hilton Wilmington Riverside, Wilmington, USA About: leading event for agrochemical & specialty chemical markets Organiser: American Chemical Marketing Contact: +1-215-882-9100 Email: tom.leahy@chemicalsamerica.com Website: www.chemicalsamerica.com
2013 IHS DAY
Clean Coal Forum Indonesia 2013
Dates: 25 July 2013 Venue: Taj Palace Hotel, New Delhi About: High-level annual meeting for Asia Pacific senior executives Organiser: IHS Contact: +91 22 4090 7132 Email: annabelle.tok@ihs.com Website: www.ihsapac.com
Industrial Green Chemistry World Dates: 6-8 December, 2013 Venue: : Renaissance Mumbai Convention Centre Hotel, Mumbai About: One of the largest Industrial meet on green chemistry & engineering Organiser: Newreka Green Synth Technologies Pvt Ltd Contact: +91 22 2879 1835; 2879 1275 Email: krishna.dave@newreka.co.in Website: www.industrialgreenchem.com
Petrotech Dates: 12 - 15 January, 2014 Venue: Greater Noida, India About: Petrotech features among the most comprehensive oil, petroleum and natural gas sector trade fairs in India. Organiser: PETROTECH-2014 Secretariat (ONGC) Contact: +91-11-2331 2607/ 2330 1169/ 2330 1170 Email: exhibition@petrotech.in; secretariat@petrotech.in Website: www.petrotech.in 64 • August 2013
Dates: 4-5 December 2013 Venue: Jakarta, Indonesia About: AsiaÊs premier coal event Organiser: China Decision Makers Consultancy (CDMC) Contact: +86 21 6840 7633 Email: ccfi@cdmc.org.cn Website: www.cdmc.org.cn
ChemTECH South 2013 Dates : 10 ă 12 October 2013 Venue : Chennai Trade Centre, Guindy, Chennai Event : ChemTECH South 2013 will have display of state-of-the-art technologies, equipment, accessories and services from national and international players for various sectors. Concurrent International conferences - EPC Sourth, ChemPetro South, Industry Automation & Process Control South and WaterEX South will have deliberations on topical issues by industry leaders, experts and influencers, and offer high level networking opportunities to take the businesses to newer heights. For details contact: Chemtech Secretariat 26, Maker Chambers VI, Nariman Point, Mumbai 400 021 Tel: + 91 22 40373737; Fax: +91 22 22870502 Email: sales@jasubhai.com; conferences@jasubhai.com Website: www.chemtech-online.com Chemical Engineering World
Project Update CEW New Contracts/Expansions/Revamps The following list is a brief insight into the latest new projects by various companies in India. Ć CHEMICALS Resil Chemicals Private Limited is planning a specialty chemicals manufacturing project in Malur, district Kolar, Karnataka. As of July 2013, land has been partially acquired. The project is in conceptual stage. Other details are yet to be finalized. Macro Polymers Private Limited is planning a 15,000 TPM synthetic resin manufacturing project at a cost of ` 250 million in village Chacharwadi, district Ahmedabad, Gujarat. Land acquisition is in progress. The project is waiting for clearances and is planned for completion on 1 st April, 2014. Hindusthan Chemicals Company, formerly known as Cyanides & Chemicals Company is planning capacity expansion of its sodium cyanide manufacturing project from 5,400 TPA to 12,000 TPA in Olpad, district Surat, Gujarat. As of May 2013, the project is waiting for environmental clearance. Work on the project will commence in 2014 and is planned for completion in 2016. Ardex Endura (India) Private Limited, belonging to the Ardex Group, is planning a tile-fixing adhesive, flooring, water proofing and allied products manufacturing project at a cost of `100 million in Aerotropolis, Asansol, district Bardhaman, West Bengal. As of March 2013, the project is in planning stage and planned for completion in Q4 of 2014. The estimated land area is 3 acres. Ricela Health Foods is planning a nutraceutical plant for the manufacture of oryzanol concentrate in district Sangrur, Punjab. As of January 2013, the project is in planning stage. Work on the project is expected to commence in 2014. KPR Fertilisers, belonging to the KPR Group, plans to manufacture 50 TPD dimethyl sulphate, 40 TPD linear alkyl benzene sulphonic acid, 50 TPD alum (ferric/non-ferric) and 50 TPD chlorosulphonic acid at a cost of ` 200 million in village Biccavolu, district East Godavari, Andhra Pradesh. As of October 2012, work on the project commenced in January 2013 and is planned for completion in December 2013. The unit currently manufactures 500 TPD single super phosphate, 800 TPD NPK mixtures, 30 TPD di-calcium phosphate and 300 TPD sulphuric acid and has a 3 MW co-generation power project. JBF Industries is planning a 1.25 MTPA purified terephthalic acid manufacturing project in Mangalore, district Dakshina Kannada, Karnataka. As of August 2012, the land for the project acquired. The project will spread over 104 acres of land and is planned for completion in 2014. Ć MINING Sri Venkatesh Granites is planning a colour granite mining project in Kamanpur, district Karimnagar, Andhra Pradesh. As of December 2012, environmental clearance has been received. The project will come up on 4.56 hectares of leased area. Global Enviro Labs is the environmental consultant. Chemical Engineering World
Western Coalfields is planning the Penganga open cast coal mining project (coal (3 MTPA and peak capacity is 4.5 MTPA) on 781 hectare land in village Wirur, district Chandrapur, Maharashtra. As of November 2012, the project has been submitted in the 59 th EAC (Thermal & Coal Mining Projects) meeting held on 6 th November 2012. Central Coal Fields is planning the 0.3 MTPA Ray Bachra underground coal mining project in district Ramgarh, Jharkhand on 1215.45 hectare land. As of September 2012, the project has been submitted in the 57 th EAC (Thermal & Coal Mining Projects) meeting held on 17 th September 2012. Rajasthan Rajya Vidyut Utpadan Nigam is planning the open cast Parsa East & Kanta Basan coal mining project (10 MTPA) and a coal washery (10 MPTA) in Udaipur, district Surguja, Chhattisgarh. As of August 2012, the project has been submitted in the 55th EAC (Thermal & Coal Mining Projects) meeting held on 28th August 2012. Odisha Power Generation Corporation is planning the Manoharpur open cast coal mining project in district Sundergarh, Odisha. As of July 2012, the company is waiting for environmental clearance. Chhattisgarh Mineral Development Corporation is planning open cast and underground coal mining project in district Surguja, Chhattisgarh. As of July 2012, the company is waiting for environmental and forest clearance. Central Coalfields Limited plans expansion of its Churi Benti UGP coal mining capacity from 0.16 MTPA to 0.81 MTPA in district Chatra, Jharkhand. As of June 2012, MoEF clearance has been received and the project is planned for completion in 2 years from zero date. Zain Coke & Energy India is planning a 150,000 TPA metallurgical coke manufacturing project at a cost of ` 450 million to ` 500 million in Chickanthapura, district Bellary, Karnataka. As of May 2012, the project is waiting for revenue and statutory clearance and is planned for completion in 10 months from zero date. Jaiprakash Associates is planning limestone mining project in village Kothar, district Satna, Madhya Pradesh. As of March 2012, the project is waiting for environmental clearance and the project completion date is yet to be finalized. Ć NON-CONVENTIONAL ENERGY Favorich Sugars, belonging to the Favorich Group, is planning a 15-MW bagasse-based co-generation power project in Krishnarajpet, district Mandya, Karnataka. As of January 2013, the company is waiting for land approval from Karnataka Industrial Areas Development Board. The project is waiting for financial closure and is planned for completion in 18 months from zero date. The State government had allotted 250 acres of land for the sugar project, distillery and mega food park. August 2013 • 65
CEW Project Update
Vishwanath Sugar & Steel Industries is planning to expand its bagasse-based co-generation power project from 39 MW to 64 MW in Bellad Bagewadi, district Belgaum, Karnataka. As of October 2012, environmental clearance has been received and the project is planned for completion in 18 months from zero date. The project is coming up in the existing plant premises. The project is waiting for State Pollution Control Board clearance. Green Planet Energy Private Limited is planning a 11-MW biomass-based IPP in village Bir Pind, district Jalandhar, Punjab. As of July 2012, 30 acres of land for the project has been acquired. The project is awarded by Punjab Energy Development Agency on BOO basis. PPA has been signed with the Punjab State Electricity Board. Work on the project commenced in October 2012 and is planned for completion in the first quarter of 2014. Ć NON-CONVENTIONAL POWER IPL Sugars & Allied Industries, a group company of Indian Potash, is planning a 20 MW bagasse and rice husk-based IPP spread over 250 acres of land in village Motipur, district Muzaffarpur, Bihar. As of March 2012, the existing plant will be demolished and the new plant will be constructed. The project is planned for completion in 1 year from zero date. Ć THERMAL POWER Jayaswal Neco Industries Limited is planning a 50 MW waste heat recovery based IPP in villages Dagori, Ameri Akberi and Udgaon, district Bilaspur, Chhattisgarh. As of February 2013, public hearing for the project is over. MoU is yet to be signed with the State Government. The project is waiting for environmental clearance and is planned for completion in 20 months from zero date. Stork Ferro & Mineral Industries, belonging to the Stork Group is planning a 100 MW captive power plant in India. As of December 2012, the project is in a conceptual stage. Amrut Sugar & Distillery is planning a 18 MW bagasse-based co-generation power project at a cost of ` 2,000 million inclusive of the sugar project in district Jalgaon, Maharashtra. As of October 2012, 120 acres of land has been acquired. Work on the project commenced in January 2013 and is planned for completion in October 2014. Maharashtra State Power Generation Company is planning a 2ï660 MW coal-based thermal power project near Manora, at Tiroda, district Gondia, Maharashtra. As of September 2012, preliminary activity for land acquisition is in progress. SKS Power Generation (Madhya Pradesh), group company of SKS Ispat and Power, is planning a 2ï660 MW super critical coal-based thermal power project in village Rahiwada and Amarwada, district Chhindwara, Madhya Pradesh. As of August 2012, the project is waiting for environmental clearance and is planned for completion in 1 year from zero date. 66 • August 2013
Rajuri Steels is implementing a 30 MW coal-based captive power plant in Mul MIDC, district Chandrapur, Maharashtra. As of June 2012, civil work was in progress. The project is scheduled for completion in Q1 of 2014. Ć POWER GENERATION Sintex Power, belonging to the Sintex Group, is planning a 1,720 MW (1ï400 MW gas and 2ï660 MW) coal-based thermal power project in village Lunsapur, district Amreli, Gujarat. As of June 2013, the project is waiting for the Government approval and is planned for completion in 1 year from zero date. The estimated land area is 600 acres. The main plant will come up on 350 acre land 175 acres land will be for ash pond and 65 acres land will be for onsite utilities. 10 acres land will be required for staff colony. Another 50 acres of land will be required for laying 16 km long water pipeline corridor. The coal required for the plant will be 5.6 MTPA and will be imported from Indonesia and South Africa. 1.65 MMSCD Natural Gas will be supplied by GSPCL. Heidelberg Cement India Limited is planning a 12.15 MW waste heat recovery based power project at a cost of ` 1,450-1,500 million in Narsingarh, district Damoh, Madhya Pradesh. As of February 2013, the project is in planning stage and planned for completion in January 2015. The project has been approved by the Board. The plant will produce approximately 12.15 MW of power from available waste heat of pyro-processing system of all three clinkerisation lines at Narsingarh. BGR Energy Systems is planning supercritical boilers, turbines and generators manufacturing project in Madurantakam, district Kanchipuram, Tamil Nadu. As of November 2012, MoU has been signed with the Government of Tamil Nadu. The project will be executed in technical collaboration with Hitachi Japan and Hitachi Europe. Ambo Steel & Power is planning a coal based captive power plant in district Deogarh, Orissa. As of January 2012, the project is in a conceptual stage and the completion schedule is yet to be finalized. Ć FERTILISER TJ Agro Fertilizers plans an expansion of single super phosphate from 24,000 TPA to 34,000 TPA and granulated single super phosphate from 10,000 TPA to 20,000 TPA manufacturing unit in Khadsupa, district Navsari, Gujarat. As of July 2012, the project is waiting for environmental clearance and is planned for completion in 1 year from zero date. Aero Agro Chemical Industries Limited plans to set up 600 TPM agro chemicals manufacturing unit in Bharuch, Gujarat. As of August 2011, the project is waiting for pollution clearance. Chemical Engineering World
CEW Book Shelf Diffusion: Mass Transfer in Fluid Systems Authors Price Pages Publisher
: E L Cussler : USD 33.00 : 600 (Hardcover) : Cambridge University Press
About the Book : This second edition of a highly acclaimed text provides a clear and complete description of diffusion in fluids. It retains the features that won praise for the first edition-informal style, emphasis on physical insight and basic concepts, and lots of simple examples. The new edition offers increased coverage of unit operations, with chapters on absorption, distillation, extraction, and adsorption. New chapters on membranes and drug release broaden the bookÊs scope. The entire text is extensively illustrated, and many new worked examples and homework problems have been added.
H y d r a u l i c s o f P i p e l i n e s : P u m p s , Va l v e s , Cavitation, Transients Authors Price Pages Publisher
: J Paul Tullis : USD 122.81 : 288 (Hardcover) : Wiley-Interscience
About the Book : This comprehensive book addresses all hydraulic aspects of pipeline design. ÂHydraulics of Pipelines: Pumps, Valves, Cavitation, TransientsÊ incorporates many reallife examples from the authorÊs experience in the design and operation of pipelines. Topics covered include basic equations necessary to pipeline design, how to conduct a feasibility study and perform economic analysis, design considerations for pumps and valves, how to suppress cavitation, hydraulic transients, trapped air, and methods of numerical solution of governing equations (including applications to complex piping systems). The book includes twenty-five tables for easy reference, which are extensively illustrated.
Valve Selection Handbook, 5th Edition: Engineering Fundamentals for Selecting the Right Valve Design for Every Industrial Flow Application Editors Price Pages Publisher
: R W Zappe, Peter Smith : USD 96.67 : 399 (Hardcover) : Gulf Professional Publishing
About the Book : Valves are the components in a fluid flow or pressure system that regulate either the flow or the pressure of the fluid. They are used extensively in the process industries, especially petrochemical. Though there are only four basic types of valves, there is an enormous number of different kinds of valves within each category, each one used for a specific purpose. No other book in the market analyses the use, construction, and selection of valves in such a comprehensive manner. The book covers new environmentally-conscious equipment and practices, the most important hot-button issue in the petrochemical industry today, details new generations of valves for offshore projects, the oil industryÊs fastest-growing segment, and includes numerous new products that have never before been written about in the mainstream literature. 68 • August 2013
Valve Handbook 3rd Edition Authors: Philip Skousen Price: USD 52.76 Pages: 496 (Hardcover) Publisher: McGraw-Hill Professional About the Book : Revised to include details on the latest technologies, Valve Handbook, Third Edition, discusses design, performance, selection, operation, and application. This updated resource features a new chapter on the green technology currently employed by the valve industry, as well as an overview of the major environmental global standards that process plants are expected to meet. The book also contains new information on valves used in the wastewater industry, Applying emergency shutdown (ESO) valves, recent changes to shutoff classifications, valves specified for the nuclear industry, the procurement process for the Nuclear Stamp (N-Stamp), the emergence of wireless technology and its application to current smart technology and characteristics of high-performance hydraulic fluid. Valve Handbook, Third Edition, covers: Valve selection criteria • Manual valves • Check valves • Pressure relief valves • Control valves • Manual operators and actuators • Smart valves and positioners • Valve and actuator sizing • Green valve technology and application • Common valve problems • Valve purchasing issues •
Chemical Engineering World
Interview CEW
Riding High on the R&D
Research and Development (R&D) form an important division of any chemical company. If you don’t invest in R&D, you are less likely to succeed. Pravin S Herlekar, Chairman and Managing Director, Omkar Speciality Chemicals Limited (OSCL), in an exclusive interview with CEW, reveals how OSCL has come of age with great emphasis on research within the organisation and talks about company’s core strengths, new products, plans for future and more.
Please apprise us of the companyÊs performance in recent few years? What are the business strategies OSCL has adopted since 1983? Omkar Speciality Chemicals Limited (OSCL) is one of the leading innovation-driven Indian manufacturers of niche speciality chemicals and pharma intermediate, which find applications in veterinary and
Chemical Engineering World
human APIs, with a global footprint. The company is professionally managed by technocrats and professionals since over three decades. Currently, we have a diversified portfolio of over 200 products, including a range of organic, inorganic and organo inorganic intermediates, which are transformed into veterinary and human APIs as
a part of our forward integration strategy. Pharma intermediates & APIs contribute around 70 per cent of our overall revenues, rest 30 per cent is contributed by our pedigree of speciality chemical products, which find applications in cattle & poultry feed, glass & ceramics, water treatment and other chemicals user segments.
August 2013 • 69
CEW Interview We have a competitive edge over our peers largely on the back of our robust R&D backbone, operational flexibility and consistent launch of newer products with IPR filings. What is the core strength of the organisation? Our ability to unswervingly develop new niche value added organic and inorganic chemical products offer us an edge over our peers. During FY12-13, We launched about five new high value-added products with niche applications which helped our topline revenues grow at a whopping 47 per cent and clocked export growth of 28 per cent year-on-year. Overall, we have maintained consistent growth of 30-35 per cent year-on-year. Some of the new products find application in veterinary APIs, tyre manufacturing, brain tumour imaging and pharma intermediates. OSCL is also expanding its product portfolio into retroviral protease inhibitors (anti HIV) & oncology space. Further, we are increasing our product range through proposed capacity expansion, which would help us move ahead in various segments like pharma, glass, cosmetics, and ceramic pigments, to name a few. We continuously launch new high value added products, which find application in various end user markets, which will offer us significant growth opportunities in the domestic and emerging markets. The new launches will enable us to reduce our product concentration risk and drive our revenues and profits in future. Our credibility of meeting stringent quality requirements and delivering high-quality orders consistently has enabled us in building a strong goodwill with our customers, which has resulted in repeat business, especially from large pharma players. It has also crested high entry barriers for new players and has enabled us to stay ahead of our competitors. Some of our ÂnicheÊ high value-added products, including pharma intermediates like resolving agents face no competition globally, especially from China. 70 • August 2013
Similarly, our presence in multi segment operations makes us less susceptible to any global market downturn. Over the years, we have built a strong export foothold across 21 countries, including regulated markets such as Europe, Canada, Asia (China, Bangladesh, Pakistan, etc) and Latin America. We have a healthy revenue scale up which is supported by our strong utilisation levels and introduction of six to seven new products every year. How did the tie-up with Cipla boost your companyÊs growth? Cipla was our first client. It was in 1983 that Cipla was planning to launch an antiasthmatic product (Asthalin inhaler), for which it required Selenium Dioxide, which was then entirely imported as nobody was manufacturing it in the country. Cipla was facing several hiccups in importing it. Sensing an opportunity, I went ahead and developed Selenium Dioxide derivative in my makeshift kitchen lab through non-conventional innovative engineered route. It turned out to be an import substitute for the anti-asthmatic drug and marked the beginning of my entrepreneurial journey and the first breakthrough. Till date, Cipla has been one of our valued customers. How has the research and development process evolved over the years within the company since it developed the Âspecial moleculeÊ for Cipla? Innovation remains our hallmark since our inception over three decades ago. It was in the 80s, when there were stringent government norms and restrictions on the imports. With all my determination, I went ahead with the idea of developing couple of import substitutes and that too in my kitchen as I did not have a full-fledge lab. It was in my kitchen that I developed some molybdenum and selenium derivatives, which were then not manufactured in India and were completely imported. But over the years, our approach towards innovation took a 360 degree transformation.
Today, we have a robust R&D backbone with state-of-the-art R&D facility at Badlapur, Thane, recognised by the Department of Science & Industrial Research, Ministry of Science and Technology, Government of India. We have a team of about 25 qualified personnel in our R&D department, which is headed by my elder son Omkar P Herlekar. He holds a PhD degree in pharma chemistry and has over seven IPRs (process patents) up his sleeves. Besides, we have a stringent quality control management system across all our seven manufacturing units spread across Maharashtra. What is the current market share of OSCL? What are the key growth drivers for specialty chemicals and intermediates business? Please comment on the revenue mix. During Q1FY2014, our consolidated sales stood at ` 57.51 crore as against ` 51.67 crore in Q1FY13. During FY2013, our consolidated sales stood at ` 211.69 crore in versus ` 166.95 crore in FY2012, clocking year-on year growth of 26.80 per cent. Our EBITDA stood at ` 40.17 crore in as against ` 33.19 crore in FY2012, registering growth of 21.01 per cent. Our PAT stood at ` 20.56 crore in FY2013 as against ` 16.00 crore in FY2012, registering growth of 28.47 percent. Similarly, our consolidated exports stood at ` 59.76 crore in FY2013 as against ` 26.08 crore in FY 2012, registering growth of 129.14 per cent. In terms of the key growth drivers for the speciality chemicals sector, I sense that there is an increased consolidation in generic pharmaceutical industry and focus is more on higher value creating opportunities driv en b y in te lle c tu a l property. Stringent regulatory approval process in US/EU will lead to high switching costs. Similarly, there is likelihood in the increase in competition from Indian and Chinese API suppliers as a large number of products are
Our credibility of meeting stringent quality requirements and delivering high-quality orders consistently has enabled us in building a strong goodwill with our customers, which has resulted in repeat business, especially from large pharma players. Chemical Engineering World
Interview CEW Description
Unit-1
Unit-2
Unit-3
Unit-4
Unit-5
Location
Badlapur Badlapur Badlapur Badlapur Chiplun
Existing installed capacity
600
New Acquisition Chiplun
Urdhwa Chiplun
Lasa
Total
Mahad
1,025
75
0
0
0
2,800
120
4,620
Proposed expansion in 500 installed capacity (MTPA)
0
0
2,900
6,000
300
0
480
10,180
Proposed installed capacity 1,100 after expansion (MTPA)
1,025
75
2,900
6,000
300
2,800
600
14,800
Adjusted Installed Capacity
600
1,025
75
0
1,500
300
2800
120
6,420
Proposed Capex (` In lakhs)
500
120
80
1,400
400
800
200
1,500
5,000
Capacities of different manufacturing units of OSCL. 2013-14 E
set to go off-patent in the next 3-5 years. As many of the less-regulated markets are shifting towards stricter regulations, resulting in renewed competitions, we smell a strong opportunity in terms growing our business. To give you a holistic view of the industry, India is among one of the largest bulk drugs exporters, which represent one fourth of the total pharma markets. The pharma industry in India has witnessed a rapid expansion at a CAGR of 10.56 per cent since 2006-2012. The domestic pharma market is expected to grow by 12.96 per cent in 2013 and will reach USD 14.99 billion by 2015. Patented drugs today account for 9.60 per cent of the total demand, which is expected to reach 13.30 per cent by 2014. During 2012, pharma industry (domestic, import and export) by value reached USD 27.40 billion, clocking a growth of 13.22 per cent from previous year and the domestic market grew by 15.69 per cent. The export of pharmaceuticals, drugs and fine chemicals combined grew 16.07 per cent in 2012. In 2012, biopharmaceutical sector contributed almost 62 per cent in the Indian biotech industry. The bulk drug industry registered a growth of 6.41 per cent. This segment is further expected to grow at CAGR of 14.80 percent by 2016. On the other hand, the Indian generic drugs market is projected to grow at a CAGR of around 11.13 per cent during FY2016 from current 12.69 per cent. There is also a colossal growth opportunity in animal health care and medical feeds markets, Chemical Engineering World
such as Asia Pacific, Europe, North America and Latin America. In the Asia Pacific region, the animal health care market has grown remarkably over the past few years due to the growth in the emerging markets such as India, China, Indonesia, Thailand, Malaysia and Taiwan. The veterinary health care market in Asia Pacific has grown at a CAGR of 11.5 per cent. In terms of revenue mix, pharma intermediates & APIs contribute around 70 per cent of our overall revenues, rest 30 per cent is contributed by our pedigree of speciality chemical products, which find applications in cattle & poultry feed, glass & ceramics, water treatment and other chemicals user segments. We have about eight products in the veterinary API space (Anthelmintic) and six products in the human API space (oncology, anti HIV, diabetic, cardiac and anti-depressants, to name a few. Over 5 per cent of our revenues come from APIs and we expect to garner 10-15 per cent growth by 2015.
high volume products in a most cost effective manner. Do you face any threat from China in terms of cheap imports? Not at all! This is b e c a u s e we predominantly manu fa c tu r e n ic h e speciality chemicals and not commodity products. China mainly specialises in commodity products and not niche speciality chemicals. We are the only mid-cap company in India to export our high-value niche products to China. What are your plans for future? Our operations are backed-up by a strong R&D and we constantly launch about 5-6 molecules every year. Currently, we have over 15 new products in the pipeline. We intend to increase our export presence in developing markets with our patented products in the niche segment. We also intend to strengthen our value addition through forward and backward integrations in our operations, take up actionable expansion plans to augment our manufacturing capacity to meet the growing demand and improve our margins by moving up the value chain and enhance our operating efficiency.
Please brief us about the manufacturing units of OSCL. How the Urdhwa plant is going to boost companyÊs performance? Our Urdhwa plant at Chiplun has a capacity of 2,900 MTPA. The plant is designed to handle advance intermediates for pharmaceuticals. It is a model facility, which operates as a separate system for both, the parent company ă OSCL and Lasa Labs. The plant layout is designed in the most suitable manner to minimise material handling and processing. Urdhwa plant is also capable of handling August 2013 • 71
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