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Chemical Engineering World
CEW Industry News KSB Introduces New Range of Solar Powered Pumps Pune, India: KSB Pumps Ltd, has launched a new product called KSBSol which is a submersible pumpset with high energy efficiency and reliability suitable to run using Solar power. KSBSol pumpsets are centrifugal pumps in radial and mixed flow type construction coupled with AC motors and are specially designed and matched to the requirements of solar pumping applications like drip irrigation, sprinkler irrigation, water supply etc. Pumpsets are capable to work under low sun intensity. Motors are suitable to work with VFD / MPPT controller. These pumpsets are suitable for borewells of sizes 100 mm and above. These pumpsets are designed using the proven German technology and are manufactured in its ultramodern plant located at Sinnar, near Nashik in Maharashtra State.
Godavari Biorefineries Limited Launched Its New Chemical Plant Mumbai, India: Godavari Biorefineries Limited inaugurated its new MPO plant with a capacity of 4,000 tons per annum, at Sakarwadi in Maharashtra. Godavari Biorefineries Ltd is a biorefining company producing sugar, biofuels, chemicals, power, compost, waxes, and related products, using sugarcane as the primary feedstock. The company has manufacturing plants at Sameerwadi, Bagalkot district in Karnataka and Sakarwadi, Ahmednagar district in Maharashtra. Inaugurating the plant, Prakash Mehta, Minister of Housing, Labour and Mines, Guardian Minister of Raigad District, Government of Maharashtra, said, “The development of this plant will contribute to the socio-economic development of the area. The commitment of the company for this region began with Karamshibhai Somaiya when he founded the company here and this became his Karmabhoomi. From the past 76 years, the company has worked for the development of this area”. Samir Somaiya, Chairman and Managing Director said, “The new unit will allow us to offer customised chemicals and solutions for the global markets. It is part of our strategy to meet the growing demand for chemicals manufactured from renewable feedstocks using sustainable practices”.
KEPL Commissioned First API Turbine in Indonesia Pune, India: Kirloskar Ebara Pumps Ltd (KEPL) has successfully commissioned its indigenously-developed first API 611 Steam Turbine ‘K-TUR’ at PT Pemukasakti Manishindah, Indonesia. Having immense experience in manufacturing, KEPL designed and developed API 611 compliant steam turbine up to a power rating of 3000 Kw for the global API industry. This turbine is capable of variable speed/ power operation from 30 per cent to 110 per cent of the boiler load and has been designed in a way that it has the best operational efficiencies over its designed life of 20 years. Being the first KEPL turbine in the international market, the erection and commissioning had its own set of challenges. However, the rich experience and in-depth expertise in commissioning API turbines for its customers in India and the availability of expertise from KBI global operations, KEPL was able to plan and execute the commissioning activities smoothly. 6 • November 2015
STEER Aims Transform Jute Industr y with Jute Polymers Bangalore, India: Bengaluru-based STEER announced the development and availability of technology to process jute-filled polypropylene compounds (jute polymers), that will have the capability to replace minerals and fibres and help reduce product cost, density and carbon footprint, while improving product performance. The popularisation of jute polymers is expected to help provide a major thrust to the government’s Make in India campaign, by popularising new usage of jute in other sectors, thus stimulating industrial activity. Jute polymers are certain to greatly benefit the jute industry with its ability to transform the traditional use of jute for modern day products, thus, touching human lives. Nearly 75 per cent of jute goods are used as packaging materials, burlap, gunny cloth (hessian), and sacks. Speaking about the advancement, Dr Babu Padmanabhan, Founder and Managing Director, STEER said, “Through years of constant innovation and reinvention, scientists at STEER have now developed jute-filled polypropylene (PP) compounds, by incorporating up to 50 per cent by weight of jute, utilising advanced corotating twin-screw platform technology with special patented fractional-lobe elements. The new material has formidable advantages – it is strong, flexible, and heat-resistant, not to mention that it is also an economical, lighter and eco-friendly reinforcing agent for plastics.” Jute filled PP composites are today being successfully used for various components and materials. India is still largely an agrarian economy, which needs to generate massive employment in rural areas for a rapidly growing population. Technological breakthroughs such as jute-filled PP compounds show the way for economic development of the masses by marrying stateof-the-art technology and research with cash crops to create rural and industrial prosperity.
Ecolab Launches a New Sanitizing Wash ‘n Walk Pune, India: A recent Ecolab study found that 49 per cent of floors and 66 per cent of floor drains in commercial kitchens are contaminated with pathogens. The study also showed that regular floor and drain cleaning is not enough to reduce these pathogen levels. Routine restaurant activities, such as moving a box from the floor to a counter, can potentially transfer these pathogens onto food-contact surfaces and onto food. In response to these studies, Ecolab reformulated its industryleading Wash ‘n Walk floor cleaner by adding sanitising chemistry that lowers pathogen levels on commercial kitchen floors. Recently launched in India, Ecolab’s new Sanitizing Wash ‘n Walk is the first one-step, no-rinse floor cleaner and sanitizer registered with the EPA as effective at killing 99.9 per cent of Listeria, E. coli, Salmonella and Staphylococcus on non-food contact areas with a five-minute contact time. Like the original formula, Sanitizing Wash ‘n Walk also helps reduce slips and falls, saves energy and water (no rinse needed), and makes the cleaning process quick and easy. Chemical Engineering World
CEW Industry News Siemens, TÜV Rheinland Set Up Global Skill Centre for Occupational Safety
Bentley Solutions Offers Analysis & Design of Wastewater & Stormwater Systems
Mumbai, India: Siemens India, in collaboration with TÜV Rheinland India, has together set up the Global Skill Centre for Occupational Safety in Mumbai. TÜV Rheinland India, headquartered in Bengaluru, is a subsidiary of TÜV Rheinland Group, Germany, a worldwide leader in Testing, Inspection, Certification and Training. The training centre has been specifically designed by Siemens and TÜV Rheinland to provide practical training on the latest safety equipment and techniques and thus taking the first step towards the ‘Zero Harm Culture’ that enables individuals to work responsibly and run projects without accidents. The Centre will conduct certified training courses that develop ‘Safety Leaders’ in the project-based businesses and industries. The flagship program of the Centre – SITRUST or Siemens and TÜV Rheinland Unique Safety Training – is a 3-day program that includes extensive practical training using a simulated construction site environment. The course provides an experiential learning of Hazard and Risk Identification, Safety Planning, Risk Mitigation and Implementation of Controls. The unique feature of the practical training program is the concept of Story Boards – a case study-based learning on safety management at the workplace. In addition, the training modules also include specialised training based on real-life scenarios of an operational nature in project or construction sites, such as Electrical Safety, Fire Safety and Working at Height. The target audience for the program includes Occupational Safety Practitioners, Project / Site Managers, Construction Managers, Construction Site Supervisors, Safety Marshals and Site Engineers. This TÜV Rheinland-certified course will set a benchmark in the field of safety in India.
Mumbai, India: Bentley Systems, Incorporated, announced the general access of its new SewerGEMS, SewerCAD, StormCAD, and CivilStorm V8i (SELECTseries 5) products for the analysis and design of wastewater and stormwater systems. In addition to being available as stand-alone applications and to running on CAD and GIS platforms, the V8i (SELECTseries 5) sewer and stormwater products can now be used from within the V8i (SELECTseries 4) versions of OpenRoads-based products – combining 3D design and hydraulic analysis capabilities in the same platform. The resulting comprehensive civil solution eliminates the need for extra import/export steps or file conversions. Commenting on the new releases, Chris Haines, senior civil engineer and PAR-BIM technical lead, Drainage and Utilities, Parsons, said, “The integration of Bentley’s OpenRoads civil design functionality with the advanced capabilities of Bentley’s storm and sewer analysis products will be a huge benefit to productivity and quality for our highway drainage design workflows.” Gregg Herrin, Bentley Systems director of product management, hydraulics and hydrology, said, “With these new releases, the automated hydraulic design functionality of our sewer and storm products can be effortlessly combined with the 3D physical design and terrain modelling capabilities of Bentley’s other civil products. From an information mobility standpoint, this has a direct and substantial positive impact on roadway, site, and municipal work where hydraulic engineering is just one part of a much larger project.”
Affordable Optical RDO Technology from Cole-Parmer Mumbai, India: Cole-Parmer recently introduced new range of waterproof por table metres. Its optical RDO technology is a cost-effective option for dissolved oxygen metre users. The new Oakton GLP complaint Waterproof DO 450 and pH/DO 450 Metres from Cole-Parmer are optical metres—with the convenience of no membrane replacement, no electrolyte replacement, no incoming flow requirement, and no hydrogen sulphide interference. The metres also offer a short response time, minimal drift, and minimal maintenance. Users gain more accurate readings on these DO metres with automatic and manual temperature compensation, which adjusts for fluctuating temperatures. They can see more data at a glance by viewing measurements with temperature and calibration data on a large, backlit display. Up to 500 data sets can be stored and easily downloaded with USB or RS-232 cable. The Oakton DO 450 metre features manual barometric pressure and salinity corrections. It also includes an annual sensor cap replacement. The Oakton pH/DO 450 meter offers six-point calibration—either USA, NIST, DIN, or custom buffers. Convenient auto buffer recognition automatically identifies the correct pH metre buffer for rapid calibration. 8 • November 2015
NORD India Has Won ‘Best HR Practices’ Award 2015 Mumbai, India: NORD Drivesystems Pvt Ltd has been honoured with the first place in ‘Best HR Practices’ Award from Genius Consultant in association with The Times of India. Directors from Economic Times were also present during the event. Genius Consultancy is a 22 years old company with a turnover of ` 550 crores and they are successfully conducting HR Excellence Award since last 5 yrs. In 2015, they included 15 Award categories in two groups ie, companies having turnover up to ` 500 crores and ` 500 crores and above. They have received more than 500 nominations including companies like Piaggio, Mahindra, JK Papers, MSP Steels, Simplex, Coromandel, Britannica and various other software and logistics companies. The ‘Best HR Practices’ award was presented to PL Muthusekkar, Managing Director and Pankaj Vohra, Branch Manager (Sales) from NORD India, also it was the first award announced during the Award Presentation. Among all 38 Awards, 9 Awards were given to Women HR Professional. “It was difficult to choose the winners, however determining factor was to recognise less-known companies who are following excellent HR practices” mentioned one of the Jury members. Chemical Engineering World
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CEW Industry News BASF Begins Specialty Amines Production Ludwigshafen, Germany: BASF in Ludwigshafen has started up a world-scale plant for the production of specialty amines. The multi-product plant can manufacture approximately 12,000 metric tons per year of a product range of about 15 amines for different applications. Owing to its high flexibility, the plant can also be used for the production of new specialty amines. The major applications are currently in the construction, automotive, crop protection and pharmaceutical industries. With the new facility, BASF expands its global production network for amines with plants in Ludwigshafen and Schwarzheide in Germany; Antwerp, Belgium; Geismar, North America; and Nanjing, China. With about 200 different amines, BASF has the world’s most diverse portfolio of these chemical intermediates. In addition to alkylamines, alkanolamines and alkoxyalkylamines, the company also offers heterocyclic and aromatic amines as well as specialty amines. The range is completed by an expanding portfolio of chiral amines with high optical and chemical purity. The versatile products have proven their effectiveness above all in the manufacture of crop protection products and pharmaceuticals, as well as in cosmetics, detergents and process chemicals. They are also needed to produce coatings, special plastics, composites and special fibres.
LAUDA Acted as a Successful General Contractor Lauda-Königshofen, Germany: For a large chemicals company in Switzerland, the task was to develop an optimised temperature control concept in the temperature range from 50O to 360O°C for controlling the temperatures of various reactors and catalysers. Electrical heating was excluded on the grounds of the required 3.0-Megawatt heating capacity and the resulting high cost of electricity. The specialists of LAUDA heating and cooling systems therefore decided to use two gas-fired, thermal oil heaters, with a power of 1.5 Megawatt each, as the central heating system. LAUDA acted as general contractor for the complete temperature control system. This also included the manufacture of the two gas heaters with double-flue chimney and heat recovery system. This made LAUDA directly responsible for the complete project management as well as for the welding supervision and quality assurance of all suppliers. Consequently, throughout the whole project period, the Swiss chemicals company had just one, central point of contact; an important prerequisite for continuously smooth communication and successful project completion. For the open-air installation and for cooling, air coolers with a capacity of around 250 kilowatt proved to be optimal, since the thermal oil must be cooled from 350O to 50O°C. This meant it could do without a complex water cooling system. This decision led to another advantage: the risk of the cooling water freezing in winter was eliminated. As usual, before delivery, LAUDA carried out a complete Factory Acceptance Test (FAT) of all plant components with thermal oil in their main factory, Lauda-Königshofen, in the presence of the customer. Commissioning in Switzerland was carried out by staff of the LAUDA Service Center in close collaboration with the LAUDA suppliers. 10 • November 2015
Hankuk Chooses Solvay’s Virantage Polyethersulfone for Automotive Application Georgia, USA: Solvay Specialty Polymers announced at the 2015 Composites and Advanced Materials Expo (CAMX) that Hankuk Carbon Co selected Solvay’s high-performance Virantage polyethersulfone (PESU) to improve the toughness, heat resistance and processing consistency of a thermoset composite prepreg. The prepreg is intended for use by a major US automotive OEM for a commercial automotive fender and roof application. Solvay’s broad offering of such light-weighting solutions underscores the company’s proactive support of the industry’s growing adoption of carbon composites. According to the Institute for Advanced Composites Manufacturing Innovation (IACMI), fibre-reinforced polymer composites could help reduce the weight of conventional passenger cars by 50 per cent and improve fuel efficiency by nearly 35 per cent without compromising performance or safety. Fabricated using advanced polymer technologies, composites also eliminate corrosion and improve weather resistance vs metal. They also require lower maintenance. Solvay’s Virantage PESU tougheners can increase the impact strength of thermoset composites parts by nearly 40 per cent and provide a step-change improvement in heat resistance. Because Virantage PESU micropowders are compatible with a range of epoxy systems, they disperse more quickly vs conventional impact modifiers, thereby improving processability and consistency in high-volume composite production. Already widely used in prepreg production for commercial and military aircraft applications, Virantage PESU tougheners are attracting increasing interest from automotive engineers as an integral part of their vehicle lightweighting strategy as they seek to meet emerging CO2 emission standards.
Versalis Provides KBR with Licence for EB/SM Technology Houston, USA: Versalis (Eni) and KBR Inc, have entered a cooperation agreement for KBR to license Versalis’ proprietary Ethylbenzene and Styrene Monomer Technologies (EB/SM). These technologies are used for productions in a large variety of applications including industrial and food packaging, household appliances, building insulation, electronic equipment, car components and toys. Through this agreement, KBR and Versalis will offer competitive and flexible EthylBenzene and Styrene Monomer production technologies using Versalis’ innovative zeolite-based catalysts and expert design capabilities. KBR will provide engineering support to deliver the license packages to clients. Ethylbenzene is an organic compound used to produce Styrene, the main raw material to produce Styrenic Polymers, and for production of high performance Elastomers. Styrenics are exceptionally versatile plastic materials that are light, durable, highly insulating and provide good mechanical properties. Chemical Engineering World
CEW Industry News Wärtsilä Power Plants Capable of Running on Propane
Celanese Expands Acetic Acid Capacity
Helsinki, Finland: Wärtsilä is expanding its Smart Power Generation portfolio by introducing the capability of using propane as fuel for power generation. “Shale oil and gas production has substantially increased the availability of propane in the market. Many of Wärtsilä’s customers see an opportunity for using propane now for power generation,” says Thomas Hägglund, Vice President, Technology and Solutions, Wärtsilä Energy Solutions. Hägglund points out that the multifuel capability is one of Wärtsilä’s traditional strengths. Now the marketleading Wärtsilä 34SG engine can be used not only with natural gas, but also as a dual-fuel engine that can run on natural gas or propane without physical modifications to the engine. Propane is the main component in liquefied petroleum gas (LPG), which is commonly used in cooking appliances and vehicles, and increasingly offered for power production. LPG is a by-product of natural gas processing and crude oil refining. By replacing heavy fuel oil with propane, carbon dioxide and other emissions from a power plant can be significantly reduced. Wärtsilä’s first propane-fired project using two 20V34SG gas engines is currently under construction in El Salvador and will be operational by the end of 2015.
Dallas, USA: Celanese Corporation will expand acetic acid and vinyl acetate monomer (VAM) capacity in North America. Celanese will implement a series of low capital debottlenecks in its Clear Lake, Texas, acetic acid facility and expects up to 150kt more product. The current nameplate capacity of the facility is 1,350kt per annum. The debottlenecks will happen in stages over the next several years with the expectation that total US output will have a nameplate capacity of more than 1,500kt per annum by 2016. Celanese has also begun work on a 150kt expansion of its Clear Lake, Texas, VAM facility raising plant capacity to 450kt – making it the largest and most efficient VAM plant in the world. The expansion will be complete in 2018.
Air Liquide Develops News CO2 Capture System Paris, France: Air Liquide inaugurated Cryocap, a unique industrial installation that enables the capture of CO2 released during hydrogen production via a cryogenic process. Connected to Air Liquide’s largest hydrogen production unit in France, located in Port-Jérôme, NotreDame-de-Gravenchon (Normandy), Cryocap represents an investment of around Euro 30 million that was decided by the Group in 2012, and which received an additional public financial support of close to Euro 9 million. Developed jointly by Air Liquide R&D and Engineering and Construction teams, Cryocap is being rolled out for the first time in PortJérôme, on the SMR (Steam Methane Reformer) of Air Liquide which produces hydrogen for the neighbouring refinery, Esso Raffinage SAF (ExxonMobil group). Hydrogen is used to remove the sulphur content of the automotive fuels the refinery produces, in order to bring them into compliance with environmental standards in the transportation sector. Cryocap is the first CO2 capture technology using a cryogenic process. Cryocap enables the capture of CO2 emissions resulting from the production of hydrogen by natural gas reforming, while improving efficiency, leading to an increased hydrogen production. The Cryocap unit has an annual capture capacity of 1,00,000 tonnes of CO2 at this site. Recently, Air Liquide has reached an agreement to acquire Airgas in a game-changing combination that strengthens Air Liquide’s global leadership position, offers new opportunities to Airgas’ customers and delivers significant value to shareholders. Combining Air Liquide and Airgas will bring together two highly complementary businesses to deliver greater value, service and innovation to customers in North America and around the world. It builds on Air Liquide’s longstanding track record of successfully operating in the US and will benefit from Airgas’ unmatched national presence and its more than 1 million customers in the US, as well as its leading customer-facing platform including e-commerce and telesales capabilities. 14 • November 2015
Simultaneously, Celanese also announced that it will expand the high end of its engineered materials product portfolio with the initial introduction of two premium industrial grades of Polyether Ether Ketone (PEEK) in the second half of 2016. “With the addition of this ultra-high performance polymer to one of the world’s broadest, most technically proven materials product lines, Celanese will be able to deliver greater value to moulders, extruders and end users in key industries including automotive, electronics, electrical, industrial and medical. This is highly complementary for our customers to the current offering that Celanese has in the high performance polymer space including Vectra LCP and Fortron PPS that can enable growth for our customers,” said Scott Sutton, President - Materials Solutions, Celanese.
Veresen Announces $140 Million Ethane Storage Facility Development Calgary, Canada: Veresen Inc, will build and operate a new wholly-owned ethane storage facility located near Burstall, Saskatchewan, approximately 20 kilometres north of the Empress natural gas liquids (NGL) complex. The salt cavern facility will have capacity to store approximately 1 million barrels of ethane, and will be connected via pipeline to Veresen’s Alberta Ethane Gathering System. The expected capital cost of the storage facility and related infrastructure is approximately USD 140 million. “Veresen is committed to building the best connected network of natural gas and NGL infrastructure within our geographic footprint and delivering on this opportunity demonstrates our strategy in action,” said Don Althoff, President and CEO, Veresen. Veresen and NOVA Chemicals Corporation have entered into an agreement where NOVA will use the majority of the storage capacity under a 20-year arrangement. Subject to final regulatory approvals, the facility is expected to be in service in the second half of 2018. Once operational, Veresen expects the storage facility will contribute annual EBITDA in the range of USD15 million to USD18 million, comprised largely of fixed payments which are not dependent on utilisation levels. Chemical Engineering World
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CEW Industry News MHPS to Supply H-25 Gas Turbine & Generator to KPIC Yokohama, Japan: Mitsubishi Hitachi Power Systems, Ltd (MHPS) has received an order for a gas-fired H-25 gas turbine and a generator from Korea Petrochemical Ind Co, Ltd (KPIC). The turbine and generator will be installed in an in-house power generation plant at KPIC’s Onsan Plant, which produces ethylene, in Ulsan-Metropolitan City, an industrial city in southeastern Korea. KPIC is expanding power generation capacity at the plant in order to increase ethylene production. The power generation system on order is scheduled to go on-stream in June 2017. MHPS received a previous order for the H-25 gas turbine for the Onsan Plant in 2006. The high-efficiency H-25 is capable of using the methane off-gas derived from the ethylene plant as fuel to operate the plant. Once the new power generation system goes on-stream, it will supply power mainly to help meet in-house demand, and also provide high-temperature exhaust gas to Naphtha Cracking Heaters as fuel air for energy saving. Plans call for the Onsan Plant’s ethylene production capacity to increase from the current 470,000 metric tonnes per annum (mtpa) to 800,000 mtpa. Itochu Machine-Technos Corporation is handling the trade particulars.
Axalta Starts Construction on Technology Centre Shanghai, China: Axalta Coating Systems has commenced construction of its Asia Pacific Technology Center (APTC) that will develop coating technologies designed to provide customers in China and the greater Asia-Pacific region with the best and latest products and services. Scheduled to be operational in third-quarter 2016, the regional technology centre will be equipped to undertake fundamental research and develop new coating applications, including the latest generation paint formulations, colours, resin development, dispersion technology, spray application and analytic evaluation of paint performance. The centre will have technical support capabilities to serve light vehicle OEM, commercial vehicle and refinish customers as well as those in the industrial and architectural sectors. With a workforce capacity of up to 500 employees, the centre is poised to support all Axalta businesses with high quality paints, lean processes, and sustainable applications. The technology centre will be part of Axalta’s global network of global innovation centres in North America, Europe and Latin America. The facility will house Axalta’s Refinish Color Development Center, a new Refinish Training Center for customers, and extensive laboratories. Dr. Barry Snyder, Axalta’s Senior Vice President and Chief Technology Officer said, “As part of Axalta’s global network of technology centres, the APTC will combine our global expertise and next-generation tools with local talent and market knowledge of China and the larger Asia Pacific region to provide customers with innovative coating solutions and applications.” 16 • November 2015
I N E O S h a s L i c e n s e d i t s Te c h n o l o g i e s t o PTTGC America Rolle, Switzerland: INEOS Technologies announced that it has licensed its Innovene S Process for the manufacture of medium density and high density polyethylene to PTTGC America LLC at its new cracker complex to be located near Dilles Bottom, Ohio, USA. The Innovene S HDPE plant will consist of two lines having a total capacity of 700 KTA, producing a wide range of polyethylene grades to serve the growing demand for high performance products in the US and export markets. Peter Williams, CEO, INEOS Technologies, said, “INEOS is delighted to have been selected by PTTGC as its licensing partner for the HDPE plant in Ohio. We look forward to working with the PTTGC team to deliver an asset that will meet fully both the current and future requirements of PTTGC’s customers.”
Idemitsu Kosan Will Acquire Showa Shell Sekiyu Tokyo, Japan: Idemitsu Kosan will be acquiring Showa Shell Sekiyu and has signed a definitive binding agreement for USD 46 billion. Both the companies will have equal representatives on the new company’s board. The companies wish to secure a stable supply of energy all over the country with this move. This decision taken by the two companies is a result of the domestic oil market experiencing problem of oversupply for some time now. Both the companies rank second and fifth in Japan with regards to oil distribution; last July the companies announced plans of a merger that will be executed in the next two years. Both the companies would have a combined capitalisation of USD 5.8 billion.
Technip Receives Technology & EPC Contract from CHS Paris, France: Technip was awarded a significant contract by CHS Inc, to provide proprietary technology and EPC for a 40 thousand normal cubic metres per hour grassroots hydrogen plant at the CHS Refinery in Laurel, Montana, USA. The plant is part of the company’s ongoing upgrades to boost efficiency, increase diesel production and process additional crudes at its refinery. The design will utilise Technip’s high efficiency top-fired steam reforming technology to produce high purity hydrogen and export steam as well as the latest nitrogen oxide reduction technology to ensure minimum emissions. Technip’s operating centre in Claremont, California, USA, will execute the project, which is scheduled for completion in 2017. Chemical Engineering World
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CEW Industry News Clariant to Build Multi-purpose Facility in JIIPE
thyssenkrupp with New Brand Identity
Muttenz, Switzerland: Clariant announced its latest double digit million investment at the groundbreaking ceremony held at the Java Integrated Industrial and Por t Estate (JIIPE) in Gresik, Surabaya, where construction has officially commenced to develop the first phase of a multi-purpose facility that would allow Clariant to establish its presence even further in Indonesia and Asia. With already 5 production sites and 3 technical centres established in Indonesia, Clariant’s new site in East Java — the upcoming chemical industry hub in Indonesia, is going to further reinforce Clariant’s commitment to opportunities in the emerging Asian market.
Essen, Germany: In the future thyssenkrupp will use one common brand the world over. The redevelopment of the brand reflects the transformation of the Essen-based technology company to a diversified industrial group. “thyssenkrupp has changed in recent years. We are a different company today. We have become more diversified and as a result more stable,” says Dr Heinrich Hiesinger, CEO, thyssenkrupp. The new brand puts a stronger focus on customers. It communicates the company’s positioning as a diversified industrial group and its aspiration to work in an integrated way, leveraging internal synergies and creating added value for customers, employees and shareholders. The new brand identity builds on this image and at the same time puts an even stronger focus on customer requirements. The new brand condenses what thyssenkrupp stands for in a logo, a slogan, and new colours. Wilke said, “But these are only the visible elements of our brand. At its core is our brand promise - because it places the focus on customers and says how we want to advance them.” “The new brand does not mean that we have reached the end of our transformation. But it is designed to give a further boost to our change process both inside and outside the company,” Hiesinger continues. That is why thyssenkrupp will use one common brand in the future. Over 180 different brand identities currently exist side-by-side within the Group. That results in complexity and an inefficient use of resources. The single brand will create a unified image among customers and employees. The Thyssen and Krupp signets, previously separate, now form a single element. The new slogan ‘engineering. tomorrow. together.’ condenses the brand promise “and describes in three words who we are, what we do and how we do it,” says Wilke. The new brand deliberately represents an evolution. thyssenkrupp will be introducing the new brand gradually and in accordance with the company’s financial situation. Overall thyssenkrupp is investing a mid-single-digit million euro amount in the new brand.
By establishing its new site at the JIIPE, Clariant is taking advantage of the industrial park’s first-class support in many aspects of its operation. For instance, the deep sea port, toll roads and the international airpor t located in the vicinity of JIIPE will offer strong logistics support for shipments destined for both domestic and international markets. The first facility to start operation at the new site is going to be a new bleaching earth plant for Clariant’s Functional Minerals Business Unit. It is expected to come on-stream early 2017 with facilities from other Clariant Business Units that could join and co-develop the new site in becoming a multi-purpose facility for Clariant in the future.
Dürr Strengthens Cleaning Technology Business in India Bietigheim-Bissingen, Germany: Dürr is investing in the expansion of its cleaning technology business in India. In November 2015, the group acquired Indian supplier Mhitraa Engineering Equipment based in Chennai. Mhitraa is a leading local specialist for industrial cleaning systems. The company has close supplier relations with automotive and motorcycle manufacturers as well as engine suppliers in India.
Shandong Luqing Chooses UOP’s Oleflex Technology
The automotive industry uses industrial cleaning systems to clean workpieces such as engine and transmission components in the production process. With the Dürr Ecoclean Group, Dürr’s Measuring and Process Systems division is the world market leader in cleaning technology, achieving sales of around Euro 200 million in this market segment. The acquisition of Mhitraa rounds off its cleaning technology portfolio: Dürr Ecoclean mainly serves the mid to high-end price and technology segment.
Illinois, USA: UOP LLC announced that Shandong Luqing Petrochemical Co, has started up a new production unit in just 20 months, leveraging Honeywell UOP technology and a pre-engineered, fast-to-market design. Located in Shandong Province on China’s East Coast, the new unit will use Honeywell UOP’s C4 Oleflex process to produce 170,000 metric tons per year of isobutylene, a key ingredient for making high-octane fuel and synthetic rubber used in tires, healthcare supplies and other consumer products. In addition to licensing, UOP provided the engineering design, catalysts, adsorbents, equipment, staff training and technical service for the project.
Mhitraa, on the other hand, offers systems for the entry-level segment, which is particularly important in India. Mhitraa has around 60 employees and achieves sales in the single-digit million euro range. Since its foundation in 1988, the company has installed more than 500 cleaning systems in India. Experts predict that automotive production in India will grow by an average of 10 per cent per year until 2019. In 2015 car production volumes are expected to reach the 4 million mark for the first time.
“UOP’s fast-to-market solution with key, pre-engineered components enabled this project to go from kick-off to start-up in just 20 months – about 10 to 12 months earlier than a typical project of this size – allowing Shandong Luqing to start producing isobutylene sooner. With the lowest cash cost of production and the highest return on investment, Oleflex technology makes Luqing a more competitive player in the market for isobutylene,” said Mike Millard, Vice President and General Manager - Process Technology and Equipment business unit, UOP.
18 • November 2015
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CEW Technology News
Evonik & Par tners Launch the ROMEO Research Project
R e s e a rch e rs C r e a t e C h e a p e r, H i g h Performing LED
Essen, Germany: With the ROMEO (Reactor Optimization by Membrane Enhanced Operation) research project, which started up in fall, Evonik Industries will be working with eight partners in pursuit of an ambitious goal: the aim of ROMEO is to reduce energy consumption by up to 80 per cent and emissions by up to 90 per cent in industrially important, catalytic gas-phase reactions. ROMEO revolves around a new reactor concept that utilises membranes in order to carry out chemical synthesis and processing in a single step—something of a 2-in-1 reactor, in which the product is continuously removed from the reaction mixture as soon as it is formed. The EU is providing Euro 6 million in funding for the research program as part of its Horizon 2020 project.
Florida, USA: A team of Florida State University materials researchers has developed a new type of light-emitting diode, or LED, using an organic-inorganic hybrid that could lead to cheaper, brighter and mass produced lights and displays in the future. Assistant Professor of Assistant Professor of Physics Hanwei Gao and Associate Professor Physics Hanwei Gao, left, of Chemical Engineering Biwu Ma are using a and Associate Professor of Chemical Engineering Biwu class of materials called organometal halide Ma, right, look at their new perovskites to build a highly functioning LED. Credit: Bruce Palmer/ LED. They lay out their findings in the journal Florida State University Advanced Materials. “Early work suggested perovskites could be a promising material to build LEDs,” Gao said. “But, the performance was not up to their potential. We believed there was significant room for improvement.” Perovskites are any materials with the same type of crystal structure as calcium titanium oxide. Other researchers experimented with perovskites to build LEDs in the past but could not build particularly effective ones. Gao and Ma believed this organic-inorganic hybrid could perform better, if the formula could be appropriately tweaked. “When we thought about this class of material, we knew it should perform better than this,” Ma said. “We came up with our novel approach to solve some critical problems and get a high-performance LED.” After months of experiments using synthetic chemistry to fine-tune the material properties and device engineering to control the device architectures, they ultimately created an LED that performed even better than expected. Read more about the research on www.newswise.com
Over the course of the next four years, the nine partners intend to demonstrate the technical feasibility of the reactor concept test using systems for two industrial gas-phase processes—hydro-formylation and the water-gas shift reaction. “If we succeed, it will be a small revolution for chemical process engineering and a huge step toward more sustainable processes,” says Professor Robert Franke, who works in the Performance Materials Segment of Evonik, where he leads innovation management for the hydroformylation process. “Not surprisingly, the project immediately landed in the top 15 percent of all of the projects submitted,” notes Dr. Frank Stenger of Evonik’s Process Engineering Business Line, which will be carrying out Evonik’s end of the project.
Chemists Create Adaptable Metallic-Cage Gels
MIT chemists have created a new type of gel by linking metal organic cages with long polymer strands (blue). The red polymer strands, which loop back to the cages, can be used to further customise the gels by adding other molecules.
Massachusetts, USA: MIT chemists have created a new material that combines the flexibility of polymer gels with the rigid structure provided by metal-based clusters. The new gels could be well-suited for a range of possible functions, including drug release, gas storage, or water filtration, the researchers say.
These new gels, known as polyMOCs, are a hybrid of two materials called metallogels and metal organic cages. Metallogels, which consist of metals bound to polymer chains, are similar to regular polymer gels in that they are soft and viscoelastic. Metal organic cages (MOCs), on the other hand, have a rigid structure and tend to form crystalline materials. “One can imagine a class of materials that borrows from both of those, and so has the well-defined, self-assembled structures of the MOCs, but also has the viscoelastic properties of a polymer gel. That’s what we’ve tried to make,” says Jeremiah Johnson, the Roger and Georges Firmenich Assistant Professor of Natural Product Chemistry and the senior author of a paper describing the gels in Nature Chemistry. Read more on the research at http:// news.mit.edu/
20 • November 2015
Concepts Emerge For Generating Clean, Inexpensive Fuel From Water Chicago, USA: An inexpensive method for generating clean fuel is the modern-day equivalent of the philosopher’s stone. One compelling idea is to use solar energy to split water into its constituent hydrogen and oxygen and then harvest the hydrogen for use as fuel. But splitting water efficiently turns out to be not so easy. Now two scientists at the Institute for Molecular Engineering and the University of Wisconsin have made an important contribution to the effort, improving the efficiency of the key processes and offering new conceptual tools that can be applied more broadly in the quest to split water with sunlight. In the research, Giulia Galli, the Liew Family Professor of Electronic Structure and Simulations at the IME, and Kyoung-Shin Choi, a professor of chemistry at the University of Wisconsin, found a way to increase the efficiency with which an electrode used for splitting water absorbs solar photons—while at the same time improving the flow of electrons from one electrode to another. Simulations allowed them to understand what was happening at the atomic level. “Our study will encourage researchers in the field to develop ways to improve multiple processes using a single treatment,” said Choi. “So it’s not just about achieving higher efficiency, it’s about providing a strategy for the field.” Read more on news.uchicago.edu/ Chemical Engineering World
CEW Technology News Super Environmentally Friendly: The ‘Fool’s Gold Battery’
Better Catalysts Will Remove Carcinogenic Chlorine Compounds From Water
Dübendorf, Switzerland: Highperformance lithium ion batteries face a major problem: Lithium will eventually start to run out as batteries are deployed in electric cars and stationary storage units. Researchers from Empa and ETH Zurich The key to success: pyrite (fool’s have now discovered an alternative: the gold) as a cathode material. photo: ‘fool’s gold battery’. It consists of iron, JJ Harrison/commons.wikimedia. org sulphur, sodium and magnesium – all elements that are in plentiful supply. This means that giant storage batteries could be built on the cheap and used stationary in buildings or next to power plants, for instance.
Warsaw, Poland: The Institute of Physical Chemistry of the Polish Academy of Sciences in Warsaw has just unveiled two new catalysts developed in close cooperation with the Jagiellonian University in Cracow and the Jan Kochanowski University in Kielce. The catalysts have been designed with the effective treatment of tap water in mind, eliminating harmful chlorine compounds.
There is an urgent need to search for low-priced batteries to store electricity. Intermittency of green electricity is affecting the power grids, calling for stationary storage units to be connected into a smart grid. Electric cars are of increasing popularity, but are still too expensive. Efficient lithium ion batteries we know are not suitable for large-scale stationary storage of electricity; they are just too expensive and precious lithium is too scarce. A cheap alternative is called for – a battery made of inexpensive ingredients that are highly abundant. But electrochemistry is a tricky business: Not everything that’s cheap can be used to make a battery. Read more on www.empa.ch
World’s First ‘Porous Liquid’ Invented Belfast, Ireland: Scientists at Queen’s University have made a major breakthrough by making a porous liquid – with the potential for a massive range of new technologies including ‘carbon capture’. Researchers in the School of Chemistry and Chemical Engineering at Queen’s, along with colleagues at the University of Liverpool, UK, and other, international partners, have invented the new liquid and found that it can dissolve unusually large amounts of gas, which are absorbed into the ‘holes’ in the liquid. The results of their research are published today in the journal Nature. The three-year research project could pave the way for many more efficient and greener chemical processes, including ultimately the procedure known as carbon capture - trapping carbon dioxide from major sources, for example a fossil-fuel power plant, and storing it to prevent its entry into the atmosphere. Professor Stuart James of Queen’s School of Chemistry and Chemical Engineering said: “Materials which contain permanent holes, or pores, are technologically important. They are used for manufacturing a range of products from plastic bottles to petrol. However, until recently, these porous materials have been solids. What we have done is to design a special liquid from the ‘bottom-up’ – we designed the shapes of the molecules which make up the liquid so that the liquid could not fill up all the space. Because of the empty holes we then had in the liquid, we found that it was able to dissolve unusually large amounts of gas. These first experiments are what is needed to understand this new type of material, and the results point to interesting long-term applications which rely on dissolution of gases. Read more on www.qub.ac.uk 22 • November 2015
In 2008, in the village of Srebrna Gora in Lower Silesia, trichloroethylene was unexpectedly detected in the tap water. This is a carcinogenic compound conducive to the development of, among others, leukaemia and lymphoma. The source of contamination turned out to be a factory which, 20 years earlier, had been used for the production of paints and solvents. In Poland alone, post-industrial pollution with chlorine compounds occurs several times a year. One method of preventing such a hazard – or the rapid elimination of its effects – may be the use of the catalysts developed by the research groups from the Institute of Physical Chemistry of the Polish Academy of Sciences (IPC PAS) in Warsaw, Poland, the Jagiellonian University (UJ) in Cracow, and the Jan Kochanowski University (UJK) in Kielce. New catalysts, that are cheaper and more efficient than those used up to now, will enable a wider use of the hydrodechlorination reaction to effectively purify water, removing organic compounds containing chlorine. Read more on http://ichf.edu.pl/
New Class of Materials for Organic Electronics Berlin, Germany: Polymeric carbon nitride is an organic material with interesting optoelectronic properties. As an inexpensive photocatalyst, it can be used to facilitate water splitting using sunlight. Joint research by Helmholtz-Zentrum Berlin, the University of Rostock, and Freie Universität Berlin as well as other partners has now investigated for the first time how light creates charge carriers in this class of materials and established details about charge mobility and lifetimes. They discovered surprising characteristics in their investigations that provide prospects for new applications, in conjunction with graphene for example. Polymeric carbon nitrides are organic compounds synthesised to form a yellow powder of a myriad of nanocrystals. The crystalline structure resembles that of graphite because the carbon nitride groups are chemically bound only in layers, while just weak Van der Waals forces provide cohesion between these layers. It was already known that light is able to create an electron-hole pair in this class of materials. So there have already been numerous attempts to employ polymeric carbon nitrides as cost-effective photocatalysts for solar-powered water splitting. However, the efficiency levels so far have remained comparatively low. Now a team headed by Dr Christoph Merschjann (HZB and Freie Universität Berlin) and Prof. Stefan Lochbrunner (University of Rostock) have for the first time precisely probed the processes occurring during light-induced charge separation. Read more on http://www.alphagalileo.org/ Chemical Engineering World
CEW News Features
Soda Ash Demand Reasonable Growth
Will
Continue
to
Witness
In the coming 2-3 years, GHCL Ltd (GHCL) is expecting to invest approximately ` 500 crores across all its verticals namely soda ash and textiles segments. The investment in soda ash is approximately of the value of ` 350 crores and for textiles it is around ` 150 crores, says R S Jalan, Managing Director of GHCL Ltd.
C
urrently our soda ash plant of GHCL has a production capacity of 8.50 Lacs MTPA against the total Indian manufacturing capacity of 30.76 Lacs MTPA. In 2014-15, the company had produced 7.39 Lacs MT against 7.12 Lacs MT in the previous year, reveals Jalan. “Our capacity utilisation was 87 per cent against the industry average of 85 per cent. We have also achieved highest domestic sales of 6.74 Lacs MT against 6.44 Lacs MT in the previous year. It is expected that on the back of further pick-up in economic growth, demand for soda ash will continue to witness a healthy growth.” Jalan says that the new investment in soda ash will witness a capacity expansion in the production. In the textiles division, it will be used for debottlenecking of processing capacity and implementing energy conservation measures by installing Green Energy (Wind Mills) to reduce carbon footprint. Growth of Soda Ash Industry The major consuming sectors for Soda Ash in India are Detergent and Glass (Flat and Container) industries, Jalan comments while explaining the driving element for the industry. “The growth of detergent is based on increasing Urbanisation and the subsequent growth in rural income. The driving factors for growth in glass industries are Construction (Real Estate), Automobiles, Conversion of Food and Medical supplies from Plastics to Glass Containers etc. All these factors are currently active in the Indian economy and shall remain major drivers for growth of Soda Ash in India,” he adds further. According to Jalan, it is expected that on the back of improved GDP growth projected and the growth in Glass (Constructions/
26 • November 2015
Au t o m o b i l e s ) a n d D e t e r g e n t ( F M C G penetration and growth) manufacturing industries, Soda Ash demand will continue to witness a reasonable growth. And Jalan believes that the Indian manufacturers will be able to meet the demand themselves. “The domestic market size is around 3.3 million MT which is projected to be around 4 million MT by 2019 and to cater to this projected increase in demand, a number of projects are under implementation or consideration to address the situation,” Jalan comments. He further elucidates that other than the expansion of GHCL which is around 100000 MT in the first phase, Nirma is expanding around 200000 MT and RSPL’s Greenfield project is going to add another 500000 MT in the quantum of soda ash production. Tata Chemicals is also waiting for regulatory clearances to expand its capacity. Going forward the Indian manufacturers will be capable of meeting the demand growth in the country; however, as is currently the case any small deficits will be made up by imports. Challenges for the Industry Cheap import from China has always been an issue with Indian manufacturers. However, Jalan says that the Chinese volume of import in India has actually reduced this year. He further explains that in 2014-15 the total imports from China were 1.38 Lac MT. In the period between April-September 2015, the quantity was 45000 MT against 70000 MT during the same period previous year. The growth in terms of volume is far below what was expected. However, the prices of Chinese Soda Ash are currently soft and if it remains to be same then we need to see what shall be the impact of it in near future. Jalan also talks about other challenges and mentions that in view of the non-allotment of limestone mines in the last 5-6 years, the
availability of limestone is a major concern for the soda ash manufacturers in India. “Salt prices are consistently going up as majority of salt produced in the coastal belt of Gujarat is ‘Solar Evaporated’ and hence production can get adversely affected by vagaries of weather. Also export options to countries like China, Japan etc, who offer higher price creates a periodic shortfall in salt availability.” Commenting on the viability of HOU’s process, Jalan reveals that the process is very popular in China since it produces a by-product ie, Ammonium Chloride (NH4Cl) while manufacturing soda ash. This is a cheap fertiliser which has a number of end uses in China. In India, however, the use of this product is not encouraged as most of the agriculture is using Urea, which is a superior fertiliser. Hence HOU’s process is not a viable option in India. Expectation from the Government Currently the Indian chemical industry is fighting hard in the Global market against its Chinese counterparts. Support from the government in earnest is required to enable Indian chemical industries to compete with China. We also wish to see some reduction in the taxes which are levied on the purchase of raw materials for this industry to enable them to stay afloat with competitive pricing.
- Harshal Y Desai Chemical Engineering World
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CEW Features Guest Column
Strategies to Reap Operational Benefits from Smart Manufacturing or Industrial IoT Globally, the transformation of the manufacturing sector has begun. The emergence of the Industrial Internet of Things (IIoT), Industrie 4.0, Smart Manufacturing, and other new approaches and initiatives have the potential to uproot traditional ways of doing business. In a connected and collaborative environment the entire manufacturing and supply chain ecosystem becomes agile, flexible and performs better. The impact of these new technologies is being felt across all industries, including the downstream chemical industry.
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s Smart Manufacturing Or Industrial IoT a Smart Strategy? Before the shale oil and gas boom in the US, and in Europe after the financial crisis of 2008, the industry GDP was declining. The European Union started issuing manufacturing competitiveness reports to guide policy makers to stimulate the economy. The studies found that manufacturing contributes over-proportionally to exports, a way of bringing liquidity to the region, and increases the resilience to crises and capacity to recover after them. Benchmarking with countries such as Germany with a higher than average industry GDP demonstrated that the average level of industry GDP could be increased. Finally, the fact that innovation in manufacturing is proven to stimulate manufacturing growth made the EU innovation program Horizon 2020 receive a focus on manufacturing. Both the program for the discrete and the process industries are set up as private-public partnerships to increase ownership by industry, and multiply the public investment. Europe’s strategy
Figure 1. Industrie 4.0, a government initiative. Source Presentation by Dr. Achatz, ThyssenKrupp, Orlando 2015
28 • November 2015
inspired the member countries to set up their own programs in line with national needs, the most well-known being Germany’s Industrie 4.0; however the UK’s Catapult program and France’s Industrie du Futur are also likely to create economic impact. For the so-called innovation-driven economies as the World Economic Forum calls them, initiatives that impact product value are the most effective to boost growth; however, cost-related improvements in the domain of process and productivity innovation are also useful. All initiatives mentioned aim to affect these economic factors. Some initiatives, mostly government initiated, such as Horizon 2020 or Industrie 4.0, but also Smart Manufacturing Leadership Coalition (SMLC) are concerned with environmental footprint; and the European initiatives also have social sustainability goals, such as well-being at work, jobs, quality of life, etc. We do then conclude that these initiatives are a smart strategy for growth and societal well-being. Other major initiatives New information technologies have been applied to optimise individual unit processes in factories, but Smart Manufacturing (SM) systems that integrate manufacturing intelligence in real-time across an entire production operation are rare in large companies, and virtually non-existent in small and medium size organisations. The SMLC was founded as an industry initiative in the US to overcome the costs and risks associated
with commercialisation of Smart Manufacturing (SM) systems, primarily oriented towards the process industries. A few years later, the Industrial Internet Consortium was founded to accelerate the development, adoption and widespread use of interconnected machines and devices and intelligent analytics. Also China and India started their initiatives. Vocabulary To create clarity we make the following distinction between smart manufacturing and Industrial IoT: Smart Manufacturing is more encompassing and includes all methodologies, processes and technologies that substantially improves the outcome of manufacturing, be it in the form of product value, quantity or quality, or in the form of productivity or reduced environmental footprint. There are two main sources of improvement: advanced manufacturing that involves improvements in fundamentals, such as physics, or chemistry, such as photonics, or chemical nanostructures – engineering science, such as modular production technology and intensification, additive manufacturing or advanced forming. The second group is related to IT, communication or automation related technologies, among which we find internet enabled applications, often referred to as Industrial IoT. For example, advanced or model-based process control, often applied in refining and petrochemicals, could be applied to a larger degree in smaller chemical processes. Industrial Data Analytics have a great potential for the industry. Chemical Engineering World
CEW Features A supply chain operating network such as Elemica could perfectly play its role in such a scenario to make the link between supplier and manufacturer to find the raw material that could arrive earliest at the production site, when the supplier has IoT connectivity with its logistics network. The latter could then directly coordinate via Industrial IoT connectivity with the manufacturer to reserve a docking station and create an unloading appointment.
Figure. 2 Industrial IoT; Strategy Report by Greg Gorbach, ARC Advisory Group
Figure. 3 A snapshot of supply chain management; Smart Manufacturing Leadership Coalition
Application Examples Current manufacturing processes and technologies can be augmented with smart manufacturing or Industrial IoT, and create incremental value quickly. In Europe, ThyssenKrupp is one of the integrated companies that consistently implements Industrie 4.0 across domains and operations. The company was able to increase the throughput of a plant producing intermediate products (transforming steel slabs into rolled steel), by applying pull manufacturing and coordinating manufacturing and logistics with real-time information. While pull manufacturing is not new, it a great opportunity for many industry sectors to apply it. Fortunately Industrie 4.0 creates momentum to do this. In specialty and performance chemicals as well as life sciences, the NAMUR organisation is well known for their vision and standards, mostly in automation and IT for manufacturing. In supply chain coordination, the contribution by Dr Poetter from Bayer Technology Services in 2013, anticipated the use of wireless and/ or internet connectivity to faster order raw materials to variable production orders. 30 • November 2015
In the near future, modular production technology - miniature chemicals plants in a container - will make supply chains much more agile than today’s. But to plan and optimise them, they become also more complex. Manufacturing capacity can then be very fast and flexibly scaled up and down, and production units can be shipped to sites close to raw material production or consumers. Early examples today are on-site production of liquefied air and dangerous gases as feedstock for downstream production. As a result of these developments, ARC Advisory Group expects that supply chains will become far more agile, dynamic and complex over the coming years. Not only will the number of permutations of possible routings become orders of larger magnitude, also the tighter supply chain network integration will cause important supply and demand volatility that should be damped with high quality supply chain coordination and professional operation of supply chain operation networks (SCON). New developments in discovery, predictive and prescriptive analytics applied to supply chain network regulation and optimisation are very promising to assist the operators. As these can operate in-memory and in the cloud, they take out ‘latency’ of previousgeneration applications and can compensate for supply chain volatility. Industrial data analytics, in combination with the internet is particularly powerful. When data scientists add their complex event processing techniques and statistical methods to process structured (eg, timeseries) data and unstructured data such as operator logs, to the modelling techniques based fundamental and engineering science, great results can be obtained in the domains of production, quality, energy or assets. Production analytics at Dow or Sabic UK have proven to create several millions of dollars
in operating efficiency. Other companies use quality analytics to monitor maintenance needs of quality testing techniques, or to determine the useful life span of rotating equipment before maintenance, resulting in improved uptime, increased first-quality production and major cost reductions. Engineering humans into the system Industrial IoT, supply chain optimisation and analytics can help the operators best, when they allow them to focus on problem solving by providing easily interpretable analyses within context and free them from repetitive tasks. Then the operator can work at his best, and assess, delegate, interpret, judge and decide with consciousness and skill. As each decision involves emotional processing in the brain, for example when it concerns ethics, we will continue to need operators as part of our systems. Recommendations ARC recommends users to take time for planning the future and set radical improvement targets in product, process and supply chain performance, as Industrial IoT solutions have shown to be able to provide those. These goals should be aligned with the users’ strategies, and a roadmap should include quick wins - as incremental solutions are available today - as well as a long term plan. Since the smart manufacturing landscape changes quickly these roadmaps must be updated regularly.
Author’s Details Valentijn de Leeuw Vice President ARC Advisory Group E:VdeLeeuw@ARCweb.com Chemical Engineering World
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CEW Features Technical Article
Digitalisation Playing A Major Role In The Process Industries
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rocess industries are constantly looking for increasing their efficiency and productivity, and thereby, their competitiveness. Higher efficiency and productivity is possible only through higher level of transparency across the whole life-cycle of the plant. Transparency is enabled only through digitalisation. Digitalisation helps in prediction of the plant behaviour and better planning and optimisation of the whole process. Digitalisation enables the integration of individual process steps over the entire plant lifecycle, from engineering and operation to continuous optimisation. Industries should look for the right automation partners who will help them achieve this continuous optimisation rather than looking for one-time low-cost process automation systems. Thus, the selection of the automation partner is very crucial for the success of the plant. Data integration and data interchange is the need of the time. We have to ensure that the industry has the right tools to achieve this â&#x20AC;&#x201C; for example, with the integration of planning for electrical engineering, process engineering and automation. The challenge that the Indian industry faces is the dependency on the legendary engineering consultancy that follows the traditional automation rather than focusing on proven futuristic technologies. Integrated engineering provides higher transparency - right from the day-one of the idea to end-of the plant life cycle. It ensures higher data integrity between the consultants, the EPCs, the end-customers and all other stake holders of the process plant. 32 â&#x20AC;˘ November 2015
The EPCs embracing the integrated engineering will succeed faster than the other EPCs. This enables EPCs to better control their margins and plan their schedule more effectively and deliver higher value to their end-customers.
networks that meet the needs of today and tomorrow. The education systems should take the lead in integrated engineering and start practicing this by setting up integrated engineering labs in collaboration with these companies.
Process Industries ensuring the integration of operations through the digitalisation of automation and electrical world is going to have a better control than anyone else. In addition to these software solutions, these process industries need a strong industrial communications network that transfers the necessary information and data between all the areas of the company. This forms the base for Industry 4.0, the Fourth Industrial Revolution. It is wise to select an automation partner who has all the necessary building blocks for digitalisation, ranging from industry software to industrial identification to industrial communication. These should enable the implementation of an integrated, high performance data
Authorâ&#x20AC;&#x2122;s Details Thirumalai Kumar Process Automation Promoter Southern Region, Siemens Ltd E: m.thirumalaikumar@siemens.com Chemical Engineering World
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CEW Features Guest Column
The Golden Age of Control The term industrial automation involves automation of processes related to manufacturing, quality control and materials handling. Automation offers multiple benefits such as saving labour, saving energy and materials as well as improving quality, accurary and precision. This article presents before you the concept of industrial automation based on having one centralised ‘brain’ to facilitate production.
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eal-time process control has been effectively applied across industrial operations to improve operational efficiency for decades. The primary purpose for automation systems is as delivery vehicles for real-time control. I find it fascinating that as the number of control engineers has been in decline as the number of automation engineers has been on a continual increase. That is, there are more engineers focusing on the technology of the automation platforms while there are less and less focusing on the functions automation systems provide – realtime control. To this point in time, most process control, whether manual or automatic or whether feedback or predictive, has been applied to improve the efficiency of industrial operations. Efficiency improvement is important but is only one area in industrial companies requiring real-time controls. As the speed of industrial business has continually increased over the last decade, triggered by the deregulation of electric power grids, a number of business variables that had been stable for months at a time have started to demonstrate realtime variability. Traditional approaches to try to manage the profitability of industrial operations on a monthly basis just do not work anymore. Improving the profitability of industrial operations is a real-time control problem requiring good, business-oriented, control engineers. Automation projects are often categorised as greenfield – new automation systems going into new plants or plant expansions, or brownfield – new automation systems going into existing plants to update or upgrade 34 • November 2015
existing systems. The value proposition for greenfield automation projects is pretty clear and significant. The automation system is simply required to get the plant or plant expansion up and running making it essentially a binary value proposition. If the plant is operating, the automation system has done its job and the company is making money. If not, and the automation system is the cause, the negative value is huge. With this in mind the primary value proposition for automation systems in a greenfield environment is to minimise the risk of on-time delivery of a working system and an operating plant. The value proposition for brownfield automation projects should be focused on the incremental value the automation system provides. In fact, when industrial companies are trying to justify the capital expenditure for an automation system upgrade they typically have to project an expected return on investment (ROI). If the projected ROI is above a threshold limit set by the company’s financial management team the capital investment has a reasonable chance of being approved. This focus on ROI would seem to imply that the industrial company would evaluate the different potential automation solutions on the basis of which of the alternate solutions might maximise the ROI by driving the most incremental business/ financial value at the most reasonable cost. Profitability is one of a number of industrial domains that had been effectively managed on a daily, weekly or monthly basis 10 years ago, but require real-time controls today. Other domains include reliability, safety risk, environmental risk and security risk. All of these domains, including efficiency of course, require the skills only found in
control engineers. This situation presents a huge problem for industrial companies and industrial automation suppliers. Industrial companies are typically not getting the value they should, and could be realising from their automation investments. Automation suppliers find themselves in the position of having a hugely valuable capability that is perceived as providing little of no value. This may be one of the reasons that industrial companies are waiting longer and longer to upgrade installed automation systems. Why would you update a system that is working pretty well if the new system offers little or no incremental value. This may also be the reason that automation systems, which can provide value, are becoming commodities at an ever increasing rate. Automation systems are simply not seen by industrial executives as adding value. This has to change! Industrial companies can benefit greatly through the effective utilisation of automation technologies, but, for the most part they are not benefitting to the degree they should be. Automation systems can be highly valuable if applied and measured effectively. Perhaps it is time to question the traditional business processes and perspectives that are diminishing the value of automation.
Author’s Details Dr Peter Martin Vice President - Business Value Solutions Schneider Electric Chemical Engineering World
CEW Features Technical Article
Developments in Instrumentation Calibration Tools The process sector is probably the main industrial user of plant instrumentation and this is used for the measurement of a wide range of parameters, such as pressure, temperature, flow, level and various electrical measurands. This accurate and reliable measurement is essential for continuing plant performance, efficiency, quality, safety and compliance. To ensure this accuracy and maintain reliability, it is vital that all measuring instruments are regularly and correctly calibrated.
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alibration? What, Why and When? Calibration involves comparing, at intervals, the value measured or set by the plant instrumentation with a known reference standard, which is traceable to national or international standards, to establish the accuracy of the plant instrumentation. It is important that calibration is carried out on a regular basis, because all measuring instruments drift in accuracy over time. Having established the need to calibrate, it is then important to decide when to calibrate. Sometimes calibration strictly follows manufacturersâ&#x20AC;&#x2122; recommendations. Some organisations prefer to calibrate on a regular frequency basis, such as annual shut-down. The safest bet would seem to be to calibrate more frequently, but this entails increased time and cost, both in lost production and in calibration resource. Historically, calibration often
Figure 1: A Technician carrying out calibration
38 â&#x20AC;˘ November 2015
meant taking an instrument out of service and sending it to a standards laboratory, or sometimes to an on-site laboratory, equipped with the necessary quality of calibration equipment. This is still done for some specialised instruments but with the introduction of the latest generation of smart, portable calibration instruments, which can integrate with todayâ&#x20AC;&#x2122;s sophisticated calibration and maintenance management software, it is now possible to automate the calibration process for some measurands and often even possible to increase calibration intervals while still meeting standards relating to process and product quality and safety. How to Calibrate? If it is decided to calibrate in situ, it is first necessary to consider the ambient conditions of the various calibrations. Working in potentially explosive atmospheres, for example, presents real challenges, particularly for technicians who need a multitude of test tools and ancillaries, including gas bottles and regulators, to cover electrical, temperature and pressure applications. The difficulties are further complicated because of the regulations governing working practices in potentially explosive atmospheres. Even with suitable equipment, technicians are required to follow strict procedures and safety guidelines documented in text documents, drawings, data sheets, spreadsheets etc. It is simply not practical to carry all this material into the field in paper form. In addition, all
calibration and maintenance actions and data have to be documented, often with pen and paper. Errors result and time is wasted transcribing the data and then up-dating the maintenance systems. It is an unfortunate fact that, even when calibration has been carried out correctly, poor documentation can be the difference between a forced shut-down and a safety approval. Selecting the Right Tools Selecting the right calibration tool can be confusing. Many tools are dedicated to one measurand so that an instrument technician often needs to carry a number of calibrators to meet all the challenges he faces in a typical working day. Fortunately, multi-function calibrators, which combine a standard multimeter and with additional capabilities such as loop testing and pressure calibration, are now available. The latest hand-held, multi-function/ calibrator is operated by a touch and swipe screen, similar to a smart phone. It can measure and simulate the electrical parameters, temperatures and frequencies associated with the majority of process instrumentation but is significantly more accurate (eight to 16 times) than a typical multimeter. As a modular tool, its duties can be expanded by the addition of a uniquely flexible pressure system. This comprises a range of 32 high accuracy pressure measurement modules and three pressure generating stations so that pressure can be generated pneumatically Chemical Engineering World
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CEW Features Hand-held calibrators operate essentially like a multi-meter (although today, they are between 8 and 16 times more accurate than a standard multimeter). As such, they measure the electrical parameters of instruments. measured and sourced without the need for secondary calibration equipment. Genii also provides its own 24V loop supply and contains an integral 250 ohm HART resistor.
Figure 2: The swipe screen of the latest type multi-function calibrator
from 95 percent vacuum up to 20 bar to 100 bar, and hydraulically up to 1000 bar. Its broad range solves the transportation and EHS issues of using gas bottles and regulators. Such a calibrator also allows instrument engineers to view written procedures, safety notes permits, drawings, diagrams and datasheets and has sufficient memory to store a massive plant instrument database. Consequently, results can be recorded automatically, enabling full historical analysis in the field, without the need for a PC, so that automated procedures / work orders can be downloaded remotely and results up-loaded to anywhere in the world, enabling timely completion of audit records, service invoices and calibration certificates etc. In addition, the latest calibrator also offers HART and Fieldbus communication capability, so that instrumentation can be configured and commissioned as well as calibrated. It features a built-in library of all 1300 registered HART and 600 Foundation Fieldbus device descriptions (DD), with virtually unlimited memory for future updates. It can view, change, clone and store device configurations, even off-line. Analogue variables can be 40 â&#x20AC;˘ November 2015
Compatible Calibration Maintenance Software A typical process plant can contain 1000s of instruments and the analysis of all the calibration data is not a simple task. It involves scheduling, resource management and cost analysis, as well as the challenge of storing all the data and documentation to meet audit requirements. However, the latest software developments combine calibration and maintenance management and provide a comprehensive solution for streamlining maintenance workflow by improving data integrity, scheduling work activity, automating calibration and maintenance and correcting deviations. For example the latest software platform from GE interfaces seamlessly with the latest calibrator, enabling the automatic download of procedures and the direct upload of results, ensuring paperless calibration and maintenance, with total integrity of data and no chance of transcription errors. Scheduling can be automated and worksheets sent directly to the appropriate operators. The system generates alarms for overdue activity and will highlight deviations that require action and provides compliant audit-ready data. A major advantage of the GE software package is that it is web-based and can be installed on a companyâ&#x20AC;&#x2122;s server and accessed through a PC and web browser from anywhere in the world. Alternatively, the software can be hosted by a third party as a service on an external server, so that there is no need
for software installation and IT support at the company itself. Calibrating Temperature Sensors Hand-held calibrators operate essentially like a multi-meter (although today, they are between 8 and 16 times more accurate than a standard multimeter). As such, they measure the electrical parameters of instruments. With temperature instruments, such as RTDs and thermocouples, they are used to simulate the electrical output from the device to see if this agrees with the value displayed. For general purposes, this is sufficient, as the mechanical components of RTDs and thermocouples are themselves inherently stable, the greatest source of drift being in the associated electronics. Consequently, to calibrate the sensor itself, it is necessary at intervals to simulate the temperatures the sensor will measure in practice. Todayâ&#x20AC;&#x2122;s multi-function calibrators have the capability to simulate pressure, as explained earlier, but the simulation of temperature requires a separate piece of hardware and, generally, this takes the form of a calibration bath. Temperature Calibration Baths There are two kinds of calibration baths: liquid baths and dry blocks. Both require an electricity supply and both generate real heat to simulate the conditions under which temperature sensors operate. The temperature generated has a known accuracy, so these devices can be used with great confidence to calibrate various temperature devices. However, with some calibrators certain sources of inaccuracy must be taken into account. A typical liquid bath can generate temperatures from -35 0 C to 165 0 C and from ambient to 255 0 C, depending on the heating fluid. The latest baths, such as those from GE, incorporate Chemical Engineering World
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CEW Features
Figure 3: A selection of the latest multi-function and temperature calibrators
the latest heating and electronic control technology, combined with continuous agitation of the fluid bath, providing high accuracy and stability throughout the large homogenous measuring zone. They are factory-configured as liquid baths and are provided with a cover to hold up to five temperature devices, of various geometrical form and size, while reducing heat loss from the surface of the heating fluid. A leak-proof cover also prevents spillage during transportation around a site. The latest liquid baths are also versatile and feature additional interchangeable baths to suit different temperature ranges. They can also be converted into dry block calibrators by the insertion of a dry block insert. Dry blocks are simple to use and are very robust for field use. Essentially, they rely on the heating up of a metal block and can, typically, simulate temperatures from -350C to 6500C. Compared with liquid baths, they heat up and cool down much more quickly. To ensure homogeneity of heat around the sensor to be calibrated, Dry Blocks offer a range of precision-bored inserts with diameters to suit a wide range of sensors. Although not quite as accurate as liquid baths, dry blocks can offer significant benefits in terms of ease of use in the field. Conclusions Process instrument calibration is vital to the continuing operating efficiency and safety of any process plant. However, the selection of the right tools for the job can sometimes be confusing. Fortunately, developments in calibration technology are now helping to make a task, which is often still considered as a chore, increasingly productive, reliable and user-friendly.
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42 • November 2015
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CEW Features
CHEMTECH SOUTH SPECIAL Tamil Nadu – An ideal Investment Destination and Investors’ Paradise
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amil Nadu has always been one of the pioneering states in terms of industrial growth and development and under the able and under the able and dynamic leadership of Hon’ble Chief Minister Puratchi Thalaivi Selvi J Jayalalithaa, the state has reached higher growth milestones. The visionary leader is to take the state to a new era of peace, progress and prosperity. With the presence of over 50 Fortune-500 companies, Tamil Nadu state in India has been the ideal investment destination because of its several advantages on economic and social fronts. Tamil Nadu is one of India’s most industrialised and urbanised economies with 48.5 per cent of the population residing in urban areas and is ranked among the top three on several economic and social indicators. The state has been the manufacturing hub with the presence of many internationally renowned companies like Ford, Hyundai, Daimler, BMW, Renault, Nissan, Saint Gobain, Michelin, Toshiba, Dell, etc, who have chosen the state as their global manufacturing hub and the state contributes over 11 per cent of the industrial output in India. The state is an economic powerhouse for the following reasons • 2nd largest contributor (8.4 per cent) to India’s GDP. Tamil Nadu’s GDP is about USD 375 billion on PPP basis and is equivalent to the 49th largest economy in the world. • 3rd largest in terms of cumulative FDI flows in India – USD 17.6 billion from year 2000 to 2015 • One of the top three exporting states in India – USD 35 billion per year • Ranked first in terms of employment in factories – 2.23 million • Share of total largest factories in India 44 • November 2015
– 17 per cent - Ranked #1 • Second largest software exporter in India – USD 13 billion. The state has a strong footprint in both manufacturing and services sector with the presence of a robust industrial base and service sector eco system. • Contribution to India’s renewable energy capacity – 28 per cent (higher than any other state in India) Tamil Nadu offers investors the right mix of a mature industrial base, a stable political environment, excellent infrastructure connectivity, policy for ease of doing business and a hardworking and knowledgeable workforce, supported by a Government that proactively encourages investments in a wide array of opportunities. Growth Enablers and Strengths of Tamil Nadu The success of Tamil Nadu is attributed to the availability of skilled manpower, state of the art infrastructure and conducive business environment for investors. The enablers of growth in Tamil Nadu are, • Most urbanised state in India – 48.5 per cent of the population live in urban areas. • Robust industrial ecosystem and MSME base – Right mix of over 40,000 large industries supported by over 3 million Micro, Small and Medium Enterprises (MSMEs) • Presence of qualified and skilled man power – Tamil Nadu has the highest number of universities, 2267 colleges, over 550 engineering colleges and 450 polytechnics, making it a hub of knowledge creation and dissemination. • Tamil Nadu is the only state with 4 large
ports – handling about 15 per cent of the total cargo of the country • Tamil Nadu is the only state in India with 4 international airports – offering direct connectivity with over 20 international destinations. The presence of four international airports is an indicator of balanced and equitable development across the state. • Path breaking policy initiatives and investor facilitation framework – Composite approval through single window on a fast track basis within 30 days of application for setting up unit. With focus on attracting commitments from investors, the government has also introduced a number of sector specific policies • Industrial Policy 2014 • Automobiles and Auto Components Policy 2014 • Biotechnology Policy 2014 • Vision Tamil Nadu 2023, To take the state to a higher growth trajectory, Hon’ble Chief Minister of Tamil Nadu had unveiled the Vision 2023 for the state, which envisages investments to the tune of ` 15,00,000 crore (USD 250 billion) for infrastructure development. 80 per cent of these investments will be in the areas of energy, transport, water supply, industrial/ commercial infrastructure and urban infrastructure. More than 40 per cent of the investments are proposed to be under the Public Private Partnership (PPP) model providing more opportunities for private players/ developers in infrastructure development. Global Investors Meet It is noteworthy to mention that the state is focused on attracting commitment from investors in the form of tangible monetary Chemical Engineering World
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CEW Features investment in manufacturing facilities as well as in intangibles like technology tie-ups, knowledge collaborations, investments in socially desirable sectors like education and healthcare. Through this, the state intends to achieve sustainable higher growth in economic output and augmentation of intellectual capability to place the state’s economy on a strong pedestal for the future. With this background, and the Hon’ble Chief Minister’s commitment in maintaining the state’s position as one of India’s most preffered investment destinations, the Tamil Nadu Global Investors Meet was organised on 9 th and 10 th September, 2015 at Chennai Trade Centre, Chennai, Tamil Nadu, India. This event was a focused endeavour to realise the state’s vision of inclusive growth through investment inflows, growth in employment, balanced regional development and environmentally sustainable long term development. The meticulously planned event was a grand success and received accolades from all sections of the society and media. The total investment committed during the Global Investors Meet has been an unprecedented ` 2,42,160 crore which is more than double the target of ` 1,00,000 crore set by the state government. 98 MoU’s have been signed and documents exchanged during this Mega Event. The Hon’ble Chief Minister, during GIM also assured that necessary statutory clearances would be accorded within 30 days from date of application to the Guidance Bureau’s Single Window Clearance facility. In this context, she also mentioned that the government has appointed senior IAS and they will be responsible for liaising with the investor and the relevant Government departments to ensure that all the clearances are granted within 30 days. The Hon’ble Chief Minister also announced that the Event will hence forth be conducted every two years and that the next Global Investor’s Meet will be held in the year 2017. During the Global Investors Meet, the Government of Tamil Nadu brought the investor community together on a common platform and had focused discussion/ seminars regarding investment climate in Tamil Nadu, policies and procedures, key challenges, etc. All the developmental position and initiatives of Hon’ble Chief Minister are aimed at improving the welfare of the people of Tamil Nadu and making the state more prosperous. As a way forward, the state government is aligning its initiatives and policies for forging long term partnerships. For more details on the Global Investors Meet and investments in Tamil Nadu, please visit www.tamilnadugim.com or www.investingintamilnadu.com
46 • November 2015
Chemical Engineering World
B/102, Shubh Sarita CHS, Near Shrikirshna Nagar, Appasaheb Sidhaye Marg, Borivali (East), Mumbai 400066 Tel. 02228975275 Mobile 9820047858 E-mail:electromech.engg.entp@gmail.com
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Vac Enterprises India LLP, Mr. Jayant Joshi B 102 Shubh Sarita, Appasheb Sidhaye Road Shree Krishna Nagar, Borivali (East) Mumbai 400 066 Tel. 02228975275 | Mobile 9820047858 info@electromechengineering.com
CEW Features
CHEMTECH SOUTH SPECIAL Company Profile
Rittal India Pvt Ltd
R
ittal India Pvt Ltd is one of the world’s leading system suppliers for enclosures, power distribution, system climate control, IT infrastructure and software services. Customers from all sectors of the industry, from mechanical and plant engineering, as well as from the IT and telecom market are making use of system solutions from Rittal. Rittal’s broad product range also includes complete solutions for modular and energy-efficient data centres: from innovative security concepts for data systems through to physical data and system security for IT infrastructures. Founded in 1961, Rittal is now active worldwide with 10 production sites, 63 subsidiaries and 40 agencies. With 10,000 employees worldwide, Rittal is the largest company of the proprietor-run Friedhelm Loh Group of Haiger, Germany. Rittal’s system is based on three pillars: products offering system basis, software tools for system integration, and service for system support offered 24 hours per day, every day of the year. Rittal’s fully compatible system accessories, software and services allow modular components to be easily combined into one fluid system. Applications for this company’s services and products include the oil and gas, cement, power, renewable energy, steel, automotive, infrastructure and construction, information technology, machine building, food, pharmaceutical, and government and defense industries. The production site in Doddaballapur, Bengaluru, is a full fledged production facility offering large scale manufacture of terminal boxes, compact and industrial enclosures, as well as specialised modular, free-standing and workstation enclosures for the IT industry. This site also has a new climate control production
48 • November 2015
facility, which is one of the most modern plants in India. With more than10,000 square metres of production space and a fully automated line with robotic welding, Rittal India can deliver immediately. Establishing this manufacturing site in Bengaluru gave the company several key advantages including nationwide, distribution capacity, ex-stock availability, and maintenance and spare parts service, International and National standards and approvals, and local knowledge of the market. Rittal India produces on a large scale, which translates into more than 1,00,000 free standing enclosures and 2,00,000 small boxes annually. As part of the Friedhelm Loh Group, Rittal India has its Corporate office and manufacturing facility in Doddaballapur, Bengaluru, and 18 sales offices at Bangalore, NCR, Mumbai, Chennai, Pune, Hyderabad, Ahmedabad, Kolkata, Bhopal, Vadodara, Chandigarh, Ernakulam, Jaipur, Nasik, Jamshedpur, Trivandrum and Coimbatore. More than 10 service centres are located across India. Four modification centres, which also serve as showrooms in NCR, Kolkata, Pune, Ahmedabad and Bangalore contain over 9,000 square metres of storage capacity and offer modification of modern machines and immediate delivery. Rittal has 50 channel partners and currently has over 700 employees in India. Rittal chooses to be active in India due to the growing markets and opportunities across most sectors. Initial incentives such as the skilled labour availability, clear legal framework, English language and low cost manufacturing drove the company to begin investing in India in 1995 and to acquire the Doddaballapur plant site in Bengaluru. Rittal India Pvt
Ltd was established in 1997. Initially sales were set up at regional offices in Delhi, Mumbai, Bangalore and Chennai, and in 2005, facilities were expanded with a subsequent extension in 2008. At the end of 2010, Ajay Bhargava joined the company as Managing Director. Rittal has certified quality and environmental management systems in accordance with International Organisation for Standardisation (ISO) 9001 and 14001 and follows work safety in accordance with Occupational Health and Safety Assessment Series 18001:2007. As part of its corporate social responsibility plan, Rittal has donated play equipment to schools and planted trees in local communities. Rittal India utilises its success in industrial enclosures, power distribution, climate control and IT systems solutions to continue to serve customers in India, the South Asian Association for Regional Cooperation (SAARC), and globally.
Rittal India Pvt Ltd 2nd floor, Old No. 25, New No.73 Velachery Road, Littile Mount saidapet, Chennai 600015 T: 044 4211 8656 W: www.rittal.com E: info@rittal-india.com Chemical Engineering World
custom duty Appasaheb Sidhaye Marg, Borivali (East), exempt B/102, Shubh Sarita CHS, Near Shrikirshna Nagar, Mumbai 400066 Mobile : 98600 98706, 97663 26240, 7776025551 Appasahebprices Sidhaye Marg, Borivali (East), Your vacuum drying specialist marketing@italvacuum.com Tel.400066 02228975275 Mobile 9820047858 E-mail : sanjayraut21@hotmail.com | sanjayraut22@gmail.com Mumbai marketing@italvacuum.com italvacuum.com Website : www.samarthengineers.com, www.samarthengg.in E-mail:electromech.engg.entp@gmail.com Request yourTel. FREE catalog today!Mobile 9820047858 02228975275 italvacuum.com E-mail:electromech.engg.entp@gmail.com
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South Special
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South Special
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Agent for vacuum pumps
Interview of Y S Prasad, Kakinada Seaport
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Interview of Y S Prasad, Kakinada Seaport
EMJAY ENGINEERS, Mr. Jayant Joshi B/102, Shubh Sarita CHS, Near Shrikirshna Nagar, Appasaheb Sidhaye Marg, Borivali (East), Mumbai 400066 Tel. 02228975275 Mobile 9820047858 E-mail:electromech.engg.entp@gmail.com
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CEW
CHEMTECH SOUTH SPECIAL Interview
Powerful and Trendsetting laserz welding systems for plastics Arunkumar D Managing Director Leister Technologies India Pvt Ltd
1. Please apprise us of company’s business operations in India? How has the company grown in recent few years in the country? LTIN is a wholly owned subsidiary of Leister Technologies AG, Switzerland Global Leaders in Plastic Welding and Air Heaters founded in 1949. Leister Technologies AG is a longestablished Swiss company belonging to the Leister Group that prides itself on lasting customer satisfaction. The highest product quality, continuous innovation, extensive experience among its employees and outstanding services are clear benchmarks for this. Leister has been a world leader in plastics processing with hot air and hot-wedge technology for over 66 years. Leister Technologies AG provides solutions for professional applications in its product portfolio. To make sure customers can always rely on the renowned Leister quality, the company develops and produces all products and accessory parts in Switzerland in compliance with the strict ISO 9001 standard. 95 per cent of its products are exported. Leister maintains a tight network of over 120 sales and service centres throughout the world. This network comprises independent sales partners and national companies belonging to the Leister Group. This ensures and guarantees consistent quality and competent services right through to the end customer. The classic product portfolio of the Leister Group is subject to continuous further development and has been extended by high-tech machines and components involving laser and micro-technology for
50 • November 2015
some years now. Leister Laser Systems produces powerful and trendsetting laser welding systems for plastics. Axetris AG develops and produces laser gas detectors, micro-optics and mass flow rate sensors for industry. Leister Technologies India Pvt Ltd presents itself as a company offering Products and Services in the field of Plastic Welding, a technology driven industry which is application oriented. The Young Team of Leister Technologies India consists of technically qualified Engineers who are trained at Leister – Switzerland and Ritmo SpA – Italy in Product/Application engineering and After Sales Service of the Machines. LTIN was founded in 2007 with its Registered office in Chennai and branches in 7 others cities Ahmedabad, Bangalore, Delhi, Mumbai, Kolkata, Pune and Indore. 2. Will you please share some numbers on the growth and revenue of the company in India? LTIN is a clear market Leader in both Plastic Welding Machinery and Air Heaters with clear leadership position on market share, technology, product quality, technical support and after sales service. Leister Technologies India Pvt Ltd has been steadily growing over the last five years with a CAGR of 53 per cent as it serves the needs of the infrastructure industry in a big way. This synergy with the demand from the infrastructure industry is expected to keep the company on a very aggressive growth path atleast for the next 10 years going by the plans of investment in the infrastructure industry. Chemical Engineering World
CEW With a very professional approach to every aspect of the business the company has been able to serve its customers effectively over the years 3. Which are the industries, Leister serves in India? LTIN is a clear market leader in all its chosen fields of business be it in Plastic Welding Machines used in Plastic Fabrication, Water Proofing, Roofing, Pond and Tunnel Lining, Vinyl Flooring, Bill Boards and Tarpaulins, etc, or Air Heaters and Blowers used for various Industrial Applications like Shrinking, Roasting, Drying, Packaging, etc. The company offers the entire range of Leister products like Hot Air Tools, Automatic Plastic Welding Machines, Heat Sources and Blowers. These products find application in varied Industries like Civil Engineering and Tunnel Lining Projects, Rail Coach manufacturing, Vehicle Repairs, Tarpaulins and Tent manufacturing, Signage and Banner manufacturing, Geo Membrane Welding, etc. 4. Please talk about the technologies Leister leverages to offer its plastic welding services to its customers. Have you tied up with other companies for technological collaboration? Leister Technologies AG is the owner of many patented technologies in the fields of Hot Air Plastic Welding, Laser Plastic Welding, Micro Optics and IR Sensors. LTAG works very closely with Technical Institutes in Switzerland on many Projects which help both the company and the technical institutes leverage their capabilities. 5. What are the challenges in plastic welding? The field of Plastic Welding is still a niche market and the challenge of reaching out to the different industries still remains, we have been constantly expanding our operations to different parts of India. Plastic Welding also has some challenges arising out of material compositions, construction and place of usage. Understanding of the application and providing all the accessories is the challenge, most often we are able to find answers to customer queries from our exhaustive global database. Whenever Chemical Engineering World
Whenever there is a new application for which there is no readymade solution, we may have to study the application in detail and work closely with our technical teams in Switzerland to develop or find the right machines and accessories to meet customer requirements. there is a new application for which there is no readymade solution, we may have to study the application in detail and work closely with our technical teams in Switzerland to develop or find the right machines and accessories to meet customer requirements. 6. How do you ensure prompt and precise customer support to the clients across India? We have an internal guideline in the company that any customer should be able to reach a Leister Engineer or branch office within a 12 hour train journey from any part of India. Bearing this in mind, we have set up branches in the Ahmedabad, Bangalore, Chennai, Delhi, Indore, Kolkata, Mumbai and Pune; Hyderabad has a Resident Engineer and that will be our next destination. Technical and Soft Skills Training have been a focus area for us in order to provide the best Customer Service to our Customers who have high expectations being the Global Leaders. Our Sales and Service Engineers are trained either at LTAG- Switzerland or our HQs at Chennai periodically to keep them abreast with the developments on the products and associated Technologies. Engineers from LTAG Switzerland regularly travel to India to organise Training Programs to our team here.
7. Do you plan to open a manufacturing or research unit in India and support the ‘Make in India’ initiatives? Currently all Leister products are manufactured only at our manufacturing plants in Switzerland in Sarnen and Kaegiswil wherein the highest quality standards are followed and tremendous investments into R&D have been possible. Plastic Welding as a skill is still not easily available in India, therefore we have taken it upon ourselves to provide Training on Plastic Welding as part of our Skill Development initiative. There is no organised course for Plastic Welding currently in India whereas it is an established industry in Europe and America. Our immediate goal is to offer Training Courses on Plastic Welding for periods ranging from 3 days – 14 days depending on the applications the customer wants his technicians to be trained on. 8. What are you plans for future? We are present in 8 locations in India and our plan for 2016 is to be in atleast 10 cities so that we become closer to our customers. Currently we provide customers with solutions in Plastic Welding through Hot Air and Hot Wedge Technologies, our goal is to introduce Laser Plastic Welding into the country in 2016 and also follow it with Micro Optics, Infrared Sensors and Laser based Gas Detectors.
Our engineers also travel to customers’ factories or job sites to conduct Operation and Preventive Maintenance Training programs so that the customers need not depend upon the company’s service engineer for simple repairs. We have a very good presence on the Internet and our engineers are reachable very easily as they are all connected to the Central Customer Support Team. November 2015 • 51
CEW Features
CHEMTECH SOUTH SPECIAL When Intelligent P&IDs are not Enough While legible and intelligent P&IDs have always been the touch stone of plant documentation in pulling up information that links that symbol to the real world, but unfortunately that much of this information is not always made available at the time these P&IDs are being created. The article urges to redraw P&IDs in a standard, legible and intelligent format to gather and disseminate information. It should have the ability to use as much of this information as it already exists.
T
he promise of legible and intelligent P&IDs has always been the touch stone of plant documentation. The sad thing is that you could ask one hundred plant owners what defines an intelligent P&ID and if you were really lucky you would get fifty answers. But at their base level all would agree that each entity on the P&ID would represent a physical entity, and there should be some way of pulling up information that links that symbol to the real world.
information is to be used. So when we look at owners’ drivers for information gathering and retrieval we can see that they generally fall into the following seven categories: • Safety • Emergency • Operations • Maintenance • Expansion/Decommissioning and Demolition • Asset Inventorying • Asset Transference
Having these goals for intelligence is a good start, especially if done from the start. This would mean that when information is created it would be retained and that retention would then allow those downstream to benefit from the information captured. But it is a sad truth that much of this information is not always made available at the time these P&IDs are being created. Like it or not, most of the information represented by a P&ID component is created long after the P&ID is completed.
Where safety is the most critical and the last, asset transference, while not critical for safety or operations, may none the less be extremely important when needed.
Reality Check What we in the software world often forget is that most information gathering is done to help someone make a decision, and hopefully the best possible decision at that moment. That being the case, it is important that the best information is made available at the point of need. We all have to take a deep breath and be realistic about how much information we need to collect and for what purpose this 52 • November 2015
Silos of Expediency Obviously personnel safety and emergency procedures are of paramount importance in a facility, that is a given. But the fact is that the need of safety and emergency information is not always planned, but is almost always urgent. This means that gathering, collating and indexing of this information in advance, and in a readily accessible form, would be ideal. But typically, that is not the case. If you visit any site, you will find one or two people that everyone knows who to turn to for information. It could be Jan for the information on the new compressor expansion or Bernie in maintenance, who may have been there for 30 years, and does not even have to look at a drawing to locate that leaky valve you were searching for.
The bottom line is that, although this may often be a convenient and expedient of gathering information, there is a danger in relying on employees’ great memories or their siloed knowledge for critical information. Likewise, we cannot risk pointof-need retrieval on anyone’s good health, an accident, poor adherence to standards or people leaving our employ – we need a better plan. “I Don’t Have a Problem” – Really? So are we even talking about a real problem? And if so, how bad is it? One owner operator, on recently acquiring a floating production, storage and offloading (FPSO) unit requested all of the information on the FPSO from the past owner, and its engineering support company. In answer to this request the new owner received 11TB (terabytes) of hard drives full of information (this is equivalent to 4.8 trillion typewritten pieces of information or approximately 36 million P&IDs!), which they were to find out was mostly unstructured. In one case, the owner enquired as to how many P&IDs covered the asset and were advised by the engineering support company that there were 150. During the capture exercise, it found that there were over 7,000 P&IDs distributed around the drives – clearly, there were many duplicates and at many stages of revision. After a full audit the new owner was finally able to determine that there were actually just over 300 master P&IDs for the asset. Double of what was expected and 4 per cent of what they originally received. Chemical Engineering World
CEW Features You are Not Alone The truth is that there are 1000’s of well operated functioning facilities that face the same challenges, and in an emergency situation could anyone be absolutely certain that they have the latest information that they require at their point of need? Out of the 7000 P&IDs we mentioned previously would anyone be able to find the right one at the right revision that would show which manual valve(s) needed to be shut down in an emergency? The bottom line is that, in an emergency, the information we deliver to the field ought to be better than ‘run!’ Dealing with the Realities of Information Creation At this point, there is little point in not dealing with the reality of plant owners’ situations. The truth is that owners are in possession of a vast quantity of existing electronic design information, from multiple engineering companies, that are using a variety of tools. These design systems are so varied and could include: Intergraph Smart 3D, Intergraph PDS, AVEVA PDMS, Intergraph CADWorx, Bentley AutoPLANT or Autodesk AutoCAD Plant 3D or P&ID – each with their own way of representing the ‘truth’. That means that whatever system is selected to gather and disseminate this information it should have the ability to use as much of this information as already it exists. Additionally, users should be able to navigate between the tagged assets inside the system, and the streamed 3D model representation of the plant, regardless of the format to which the information was originally created. Fake it Till You Make It Software vendors often speak about intelligent systems and information gathering and the downstream benefits that can come from having that information available to all stakeholders. On a positive note the truth is that those benefits are not only real, but can be quantified in hard cash. Then what is not to like? Well, for one, a plant owner, whose assets can range in age 54 • November 2015
from one week to sometimes one hundred years, would make the task of documenting and collating existing plant information daunting. This should be no surprise as information could be held on anything, from scanned and rastered drawings to fully intelligent 3D plant models. So is it possible to access this collateral and thereby leverage the investments already made in the creation of existing information? Well the answer is ‘yes’ to providing access, as even the oldest drawings can be scaled and made available electronically. The real challenge is not being able to view drawings, but in accessing the underlying information these drawings, documents, and files represent and the intelligent linking and grouping of common information. Biting the Bullet One approach on the road to recovery is to redraw P&IDs in a standard, legible and intelligent format. Does it take time? Yes, it does, but here is the thing, we are taking about developing a graphical information foundation upon which access to all of your site data will be based, so it may be worth it. In this case a solution like CADWorx P&ID Professional would help greatly as facilities can not only recreate these intelligent documents quickly, but they can also attach any related data or documents to any database-linked component on the drawings. Here readers may be justified in thinking “we have now moved from one silo, and created a better (shinier) one, where the creators and drafters of those P&IDs are now the ‘go-to’ persons for information.” Luckily that is not the case, as CADWorx P&ID Professional also allows P&ID projects, with all of their associated data, and linked documentation, to be published and accessed through a browser. But if you do not want to redraw your P&IDs, CADWorx P&ID Professional also allows the mapping of components in nonintelligent P&ID to and intelligent database, and from there the drawings and linked data can also be published and shared.
Aims of Existing and Ongoing Asset Capture What if the desire is to automatically capture and aggregate information that is already out there, without redrawing anything? That is also possible but for any system to be successful it would have to as painless, accurate, and single touch in its execution as possible, and should address these key challenges: • The asset identification retrieval system would have to be simple to use. • The cataloguing of existing data should be as painless and automated as possible. • Tools and information should be widely available and secure. • Searching and acquiring data should be as easy and intuitive. • Information should be viewable on various devices to give true point of need access. • The acquisition and cataloguing of ongoing data should be automated. This is where SmartPlant Fusion can help, as it does not focus on the creation of information, but on the automated capturing, extraction and aggregation of existing information from a variety of assets and available collateral. This information may be stored as P&ID and 2D drawings, datasheets, 3D models, laser scans, operation manuals, etc and can be in a variety of document, drawing, and data formats, but can be linked and accessed via a common tool. The above capabilities enable existing datasets, which share common tag names, to be quickly and automatically associated with one another. But what makes sure that future information does not sink into a black hole is that SmartPlant Fusion continually does this work on an ongoing basis. This means that personnel can quickly access, not only pre-existing information, but also information that is constantly being created as part of any facility’s ongoing process of development and reinvention. Let Us Get Physical One aspect of all of this that is seldom mentioned is the physical as-built documenting of an asset and the need for accurate information for Chemical Engineering World
Features CEW time sensitive site updates, maintenance, repairs and operations. Owners are increasingly electing to scan portions of their facilities, and intelligently tag scanned assets, such as pumps, valves, vessels etc. What is interesting is that, unlike in the past, these point clouds are not just a sea of either yellow, red, orange or green dots that seem formless. These captures now carry color and shade information about the asset being scanned, and a free tool, Leica TrueView, makes viewing this information easy to do. An advantage of documenting the physical site using scanned point cloud data is that after tagging assets in the model, these can also be linked into the dataset by SmartPlant Fusion for ongoing linking and information retrieval.
VOL. 49 NO. 3 March 2014 US $ 10
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` 150
EPCM Special ChemTECH World Expo 2015 28-31 January ry r 2015, Mumbai, India
28-31 January 2015, Mumbai, India
Ongoing Maintenance, Repair and Operations Point cloud models can also be leveraged by Intergraph CADWorx fieldPipe and CADWorx Plant Professional and by picking surface points on the scanned model owners are able to create intelligent models based on the latest as-built information for the production of fabrication or analysis deliverables. If only a few lines are needed to be as built, and scanning seems like overkill, teams no longer have to rely on the ‘accuracy’ of plumb bobs, tape measures and unnecessary scaffolding to carry out as-built studies or verification of an installation. Now teams can go on the site and still leverage the power and accuracy of lasers and use Intergraph CADWorx fieldPipe and Plant Professional, in conjunction with Leica Total Station, and just by picking a few points on a line, create intelligent as-built models, and fabrication deliverables directly in the field. Conclusion The maintenance of up-to-date, and therefore viable, site information has always been and challenge, with the elephant in the room being the acquisition of existing facilities’ data. Tools like Intergraph CADWorx and SmartPlant Fusion are now available that make this task, not only more palatable, but now realistic. In the 21st century we now the chance to give all stake holders to access the latest information at their points of need so that they can make informed accurate decisions based on the best possible data.
Author’s Details Vornel Walker Vice President - Product Marketing Intergraph CADWorx & Analysis Solutions W: www.linkedin.com/in/vornelwalker Chemical Engineering World
November 2015 • 55
CEW Features
CHEMTECH SOUTH SPECIAL Company Profile
Tubacex Grows to Become A Global Solutions Provider
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ounded in 1963, Tubacex brings the experience of a world leader combined with a strong research and development effort which is needed to fulfill the future needs of the industry. One of the main seamless stainless steel producers worldwide, the recent acquisitions of the Italian company IBF and the seamless division of Prakash in India allows Tubacex to increase manufacturing range in tubes and pipe, further products and premium solutions, a wider market presence in different areas an industries, and synergies at operations and R&D levels. With IBF, Tubacex offers the most complete dimensional range in seamless stainless tubes, with outside diameter up to 72”; and increases significantly its position in the fittings and special components market. Through its new Indian mill, Tubacex increases its presence in Asia, with new equipment and possibilities empowered by future investments. With these acquisitions Tubacex advances in the development of its strategic plan which enters in a phase of growth. The Tubacex group, with sales over USD 600 million, has a vertically integrated production presence (steel, seamless and mechanically bored pipes and tubes, and fittings and special connections) with manufacturing mills in Spain, Austria, Italy, the US, India and China and a worldwide commercial presence with sales representation in 30 countries and several service centres all over the world – Tubacex Service Solutions. Manufacturing range in tubular products goes form 3 mm OD to 72” with a wide range of steel grades, according to main manufacturing standards or special requests from our customers. Our metallurgical engineers are devoted to
56 • November 2015
Quality of the product remains a strongpoint of Tubacex Group Manufacturing Units.
the development of sophisticated steels capable of operating in the demanding environments of the future. Our customers are leading companies in the oil and gas, refining, petrochemical, fertiliser, power generation and metalmechanic industries, with high quality standards and innovation and the need of increasingly sophisticated tubular solutions for the most challenging environments, in applications and products as Oil Country Tubular Goods (OCTG), tubes for subsea application (umbilical, risers, manifolds, flowlines), tubes for furnaces, heaters and re-heaters for the petrochemical industry, tubes for boiler equipment for the power generation industry and heat exchanger, reactor and condenser tubes for the petrochemical and fertiliser industries. Quality and service to our customers are the main drivers of our activity, with a wide list of approvals by
end users and international organisms of both products and management systems. Tubacex Group is highly engaged with the environment and all production units are ISO 14001 certified. Additionally occupational health and safety is also a key element of our culture. The group’s manufacturing sites are ISO 9001, ISO 14001 and OSHAS 18001 certified.
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TUBACEX INDIA 402-A, Platina G-Block Bandra Kurla Complex, Bandra( E) Mumbai 400051, IndiaINDIA T:+91 22 40015 300 E:sales@tubacexindia.com W: www.tubacex.com Chemical Engineering World
Features CEW
CHEMTECH SOUTH SPECIAL Company Profile
Stainless Innovations for Heavy Engineering Industry
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uplex grades have proven superior to austenitic grades in many applications. Owing to their low nickel content, these grades afford better price stability than austenitic grades. The strength of Duplex grades – close to 90 per cent higher than that of austenitic grades – allows for the use of considerably thinner materials, resulting in major weight and cost savings. Stainless steel is available in a whole range of duplex grades from the lean alloyed LDX 2101 up to the super duplex grades SAF 2507 and 1.4501. These duplex grades have been used in a wide range of applications mentioned below. • Heat exchangers • Water heaters • Pressure vessels • Large storage tanks • Rotors, impellers & shafts • Components for structural design • Firewalls and blast walls on offshore
platforms • Desalination plants • Digesters and other equipment in the pulp and paper industry • Flue-gas cleaning • Seawater systems • Cargo tanks and pipe systems in chemical tankers Illustrated below are some fine examples where Duplex Stainless Steel has achieved recognition and created a revolution in Duplex applications. Pressure Vessels Duplex stainless steel grade LDX 2101 revolutionises the pulp industry with a breakthrough for pulp bleaching: the new hydrogen peroxide reactor at Smurfit Kappa Kraftliner Piteå in Sweden is the world’s first industrialscale pressure vessel built entirely out of LDX 2101 plate. LDX 2101 replaces traditional hydrogen peroxide reactor materials – the highperformance, high-alloyed austenitic stainless steel grade 904L (EN 1.4539) or the more commonly used Duplex 2205 (EN 1.4462). LDX 2101, which has a very low nickel content, is well adequate to handle the hydrogen peroxide reactor process, an environment with a low corrosion rate under alkaline conditions but high pressures up to 10 bars and temperatures around 110 degrees Celsius. The main reason for the selection of LDX 2101 was its high strength, which allowed the designers to use thinner gauges compared to traditional grades. That and the low nickel content of LDX 2101 brought considerable cost savings. Additional benefits to the tank fabricators came from the good machinability. The
Chemical Engineering World
contractor at the site expressed surprise at the easiness of the fabrication process. Edible Oils Loders Croklaan used LDX 2101 duplex stainless steel for their palm Oil tanks. The material choice gave the tank owner the guarantee of high corrosion resistance of all duplex stainless steel grades. This helps to safeguard the tank content by reducing the risk of cross-contamination. Moreover, as LDX 2101 has 90 per cent higher strength than standard austenitic stainless steels, the material enabled Siemerink to achieve a 30 percent weight saving compared to a conventional stainless steel tank. Another benefit to Loders Croklaan came from extra-wide material: duplex stainless steel in 2-meter-wide coils and tailormade plates up to 3.2 meters wide. The large widths translate into cost savings due to fewer rings and less welding. LDX 2101, a low-alloyed duplex grade, is ideal for moderate corrosion conditions such as storing palm oil and other edible oils. Thanks to its low nickel content, LDX 2101 can well compete in price with carbon steel tanks when the life cycle cost is taken into account. What palm oil is said to be to the world, LDX 2101 is to storing it. November 2015 • 57
CEW Features project contractor concluded that the right grade was Duplex 2304 (EN 1.4362). Duplex 2304 offer the water utility company multiple benefits in addition to vast savings in the initial price compared to 1.4404. Thanks to its high surface hardness, 2304 will withstand better the abrasion caused by solid suspended particles. Thinner material gauges and consequently lighter structures allowed by the grade translate into less edge preparation, less need for welding consumables, fewer welding hours, lower-capacity cranes, and overall easier handling of structures. It promises longer usable lives and lower life cycle costs. Biofuel Tank fabricator Oostwouder Tank- & Silobouw BV of the Netherlands chooses Outokumpu’s Duplex LDX 2101 for the company’s largest tank project to date: a farm of 66 tanks to be built for Noba Vetveredeling BV in a large-scale biofuel project in the Port of Amsterdam.
Waste Water Treatment Stainless steel is still a relatively new material in wastewater treatment, but it is becoming the standard in plant hardware owing to the needs to fight corrosion and abrasion while lowering maintenance needs and life cycle cost. Planning for a minimum plant life of 25 years, Confederación Hidrográfica del Norte specified the austenitic grade EN 1.4404 (ASTM 316L) for gates, suction precipitator bridges, sand removers and lamellas. Between the time of initial planning and when Cadagua took over the project engineering in 2006, the price of 1.4404 had skyrocketed due to high nickel prices. To find an alternative, Cadagua decided on duplex stainless steel as the engineering company was well familiar with the unique capabilities in Duplex grades. Based on corrosion tests, EDAR de Bens, Cadagua and the 58 • November 2015
Already experienced in the use of Outokumpu’s low-nickel Duplex grade LDX 2101, Oostwouder chose that grade for the main part of the tanks, a total of approximately 1,500 tons of the material. The decision in favor of LDX 2101 was both for the high mechanical strength of the Duplex grade – close to twice that of the alternative austenitic grade EN 1.4301 (ASTM 304) – and for the low nickel content of LDX 2101. Because of recent surges in the price of nickel, LDX 2101 has emerged as the more economical choice compared to higher-nickel grades. In addition to the price advantage, Oostwouder achieved a 25 per cent material weight saving by using LDX 2101 compared to austenitic grades. Oostwouder’s MD Jan Piet Oostwouder explains that tank engineering requires a certain minimum material thickness. This does not allow fabricators to take full advantage of the strength of Duplex grades, as compared to some other applications where the weight saving
can be even greater. For the bottom part of the tanks, where a higher level of corrosion resistance is needed, Oostwouder uses Outokumpu’s Duplex 2304.Outokumpu has been a long-term supplier for Oostwouder. Storage Tanks Emypro built a large tank farm that represents a revolution in tank storage: making all tanks out of Duplex LDX 2101, the tank builder achieves major cost savings. The weight saving was approx 200 tons in Relisa’s first 13 tanks, built with 1,350 tons of LDX 2101 plate; the saving in the 9 new tanks, built with 730 tons of LDX 2101, was approximately 150 tons. At a time of fluctuating nickel prices, LDX 2101 offers highly welcome price stability and a lower price than austenitic stainless grades.
Outokumpu India Pvt Ltd 609-612, Hemkunt Tower Nehru Place, New Delhi - 110019 T: +91 11 46518440 W: www.outokumpu.com E: yatinder.suri@outokumpu.com Chemical Engineering World
Features CEW
CHEMTECH SOUTH SPECIAL Company Profile
Samson Controls Pvt Ltd (SCPL)
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amson Controls Pvt. Ltd. (SCPL) is 100 per cent owned subsidiary of Samson AG, Frankfurt, established during 1964 as manufacturing unit for the following products :1) Globe Type Control Valve 2) Self-Actuated Pressure Regulating Valve 3) Self-Actuated Temperature Regulating Valve 4) Differential Flow Meter 5) Pneumatic / Electrical Analog Type Positioner SCPL imports following products from Associate companies of Samson AG. 1) Butterfly valves, Ball valves and Segmented Ball valves from LEUSCH GmbH 2) PTFE/PFA lined valves, butterfly and ball valves, Pigging systems from PFEIFFER GmbH. 3) Rotary Plug valves and Actuators from VETEC GmbH 4) Piston Actuators from AIR TORQUE SpA. 5) Ball valves for Petro chemical Applications from STAR LINE SpA. 6) Ceramic Ball and Gate Valves from CERA GmbH. 7) Engineering, low-power solenoid valves and limit switch units from Samsomatic GmbH 8) Diaphragm Valve for Aseptic application from SED Flow Control GmbH 9) On/Off, Critical/Non Critical, Manual BALL VALVE,ON/OFF, Manual - Gate Valve, On/Off, Manual - Plug Valve, Manual and High Pressure Critical Globe Control Valve from Ringo Valves. Samson AG, located in Frankfurt Main, established in 1907 to produce high quality control valves for worldwide distribution. Samson AG has its presence in 50 countries with over 36 subsidies and 104 engineering and sales offices all over the world. Samson Chemical Engineering World
India (SCPL) has a manufacturing facility at Ranjangaon, Pune, Maharashtra. SCPL has 150 personnel including 9 field sales offices all over India. The project department supports worldwide projects of Samson and offer various services to EPC’s, PMC’s and other engineering companies. MANUFACTURING FACILITIES: SCPL has state-of-the-art in house manufacturing capabilities. Our machine shop has several CNC, VMC, HMC, Drilling machines. We have Phosphating, Degreasing, Statfield Powder Coating, Stelliting and other facilities. QUALITY CONTROL: SCPL an ISO 9001:2008 certified company is equipped for internal inspection, job inspection, final inspection with following test facilities:- Hydrostatic pressure test, Dyepenetration test, Seat leakage test as per ANSI-B16, 104, for leakage upto class VI, Actuator cycle test, CMM, Magnetic particle test, Helium leak test facility by Pressure Test or by Vacuum Method, Dynamic CV test etc. PRODUCT APPROVAL: All the products SCPL produces for local market consumption are well received by Indian market. We produce products in line with Samson worldwide philosophy to have common design and construction. Once the product is produced in India it is sent to our Principals for various tests and approval before we officially launch the product in Indian market. We follow drawings and manufacturing practices of Samson AG and thus, do not have separate design department. All products of SCPL are CE marked. SCPL products have been well received for several years by prestigious organisations like :-
Department of Atomic Energy and its affiliated units, Bharat Petroleum Corporation Ltd, and its affiliated units, Hindustan Petroleum Corp Ltd, India Oil Corporation Ltd, National Fertilizers Ltd, Rashtriya Fertilizers and Chemicals Ltd, Indian Space Research Organization & SHAR and Liquid Propulsion Space Centre, Tata Steel, Essar Steel, Jindal Steel, Bhushan Steel, Thermax, Praj, BHEL, Bharat Heavy Plates and Vessels Ltd, Akzonobel, Biocon, Teva, Ballarpur paper, Grasim, Bombay Dyeing Bayer, BASF and many more SCPL acquired approval from most of the Indian consulting and contractor’s organisations. To name a few:Engineers India Ltd, Uhde India Ltd, Kvaerner Powergas, Humphreys and Glasgow Consultants Ltd, Development Consultants Ltd, MECON, Ranchi, Technimont ICB Pvt Ltd, Project Development of India Ltd, Baroda and Noida etc. SCPL has achieved double digit growth for the past few years and is proud of its quality, delivery and services.
SAMSON CONTROLS PVT. LTD. D-281, MIDC Ranjangaon Village Karegaon, Taluka Shirur District Pune - 412220, Maharashtra November 2015 • 59
CEW Market Insights
Chemicals Market in India to Grow to $214 Billion by FY19
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Report by TSMG has revealed that the chemical market in India will reach about USD 214 billion by 2019. The report provides an analysis of key segments of chemical industry such as petrochemicals, base chemicals, specialty chemicals, agrochemicals and fertilisers. It highlights that at USD 139 billion the current domestic chemical market constitutes about 3.3 per cent of the global chemical market. Further the report also provides insights on key market, technology and regulatory trends and concludes by identifying the levers for delivering growth through capitalising on opportunities and addressing key challenges. The report also highlights critical issues the chemical industry is facing today like, availability of key feedstock, infrastructure status, scale of operations, access to technology, energy security and ease of doing business. These issues have hampered industry growth and it needs government interventions to achieve its true potential. Adoptions of alternate feedstock, increasing investment in R&D and achieving scale through collaboration are some of the key levers industry can act upon to overcome some of these challenges.
Figure 1: Indian Chemical Industry Major Clusters
60 • November 2015
The special feature on Gujarat illustrates the advantages it offers. The chemical industry is today the largest and fastest growing component of Gujarat’s manufacturing sector. Gujarat as a state contributes a major share of the country’s chemicals output; 62 per cent of petrochemicals, 51 per cent of chemicals and 35 per cent of pharmaceuticals. The report by Tata Strategic Management Group also highlights the advantages that Gujarat as a state offers with its business friendly policies and robust infrastructure which is helping the chemical industry to contribute to the Gujarat growth story. However, there is a need for the state to compare itself with international examples for an integrated development which will be a key to make Gujarat as a chemical hub. The report, which is titled ‘Chemicals – A way of life’ has provided insight into several sectors including Bulk Chemicals, Petrochemicals, Speciality Chemicals, Fertilisers and Agrochemicals. According to the report, Gujarat, Maharashtra and Tamilnadu are leading the charge being the major chemical manufacturers in the country. The key driver being the significant coastlines
Figure 2: Projected Market Growth till FY25
the states are endowed with (Figure 1). The country’s chemical industry has the potential to reach USD 214 billion by FY19 growing at a CAGR of approximately 9 per cent. The growth is expected to be driven by rising demand in end-use segments and expanding exports fuelled by increasing export competitiveness. The success, however, will depend on how well its key challenges are addressed such as high dependence on imports, small installed capacities, low focus on technology upgradation and the availability of vocationally trained manpower. The report further provides overview of Chemical Industry in India. It compares the demand and supply and import and export for major chemicals and petrochemicals in the country. The report highlights that with the upcoming government proposals, diversified manufacturing base, technology upgradation, exploring alternate feedstock etc, will give momentum to the manufacturing sector of the industry and help to meet the growth in demand that is expected in the coming five years. The demand growth will be primarily driven by domestic consumption because per capita consumption of most of the chemicals is much lower than global averages. Moreover, with a very strong outlook for the key end user industries the demand of chemical products is expected to surge in the coming years. Chemical Engineering World
Market Insights CEW MMBTU and is expected to increase further in the coming years. Natural gas, which is an essential feed stock for many Fertilisers and Petrochemicals is allocated to priority sectors like Power, Fertilizer, CGD, Refinery, Petrochemicals in that order. Therefore, petrochemical industry has to depend on imported gas which is expensive.
Figure 3: Gujarat’s Contribution to Indian Industry
Figure 4: Contribution of Gujarat’s Industry to India
The report also carries an article on Gujarat and highlights that the chemical and petrochemical industry in state is the fastest growing sector in the state’s economy. Apart from having sound infrastructure facilities, skilled manpower, excellent domestic and international connectivity and availability of raw materials, a key differentiating factor for Gujarat is its focus on industrial development in the state. It has evolved as an urbanised economy ensuring easy off-take of industrial output. Gujarat is the ‘Petro Capital’ of India, and contributes significantly to the country’s petrochemicals production (62%), chemicals production (53%) and pharmaceuticals production (45%). Gujarat contributes 15 per cent of the country’s chemical exports. Bulk of this goes to US, Europe and other developed nations - a clear sign of global competitiveness.
Natural Gas is a major feedstock for the production of ammonia and majority of the ammonia produced is used in the manufacturing of fertilisers. It is also the feed stock for gas cracker which produces ethylene. Ethylene is in turn used in the manufacture of Polyethylene, Mono Ethylene Glycol (MEG), PVC, Styrene etc. The report mentions the possibility of setting up downstream plants and cracker in the countries rich in these resources or invests in these plants and secures an off-take agreement. “All the three countries (Mozambique, Iran and Myanmar) are rich in natural gas and a source of cheap natural gas. Iran is also rich in crude. Select Indian companies have seen these opportunities and have either already invested or exploring the possibility of investing in these countries. The chemical and petrochemical industry is still at the nascent stage in all these three countries. Indian companies can share know-how, provide capital or build their own plants to reap economic benefits,” it reads further. The document suggests setting up a gas cracker to produce ethylene and its derivatives, which can be sent to India for the manufacture of further downstream value added products.
Reverse SEZ The report has also highlighted the significance of Reverse SEZ and mentioned that it can be noteworthy opportunity for Indian chemicals and petrochemicals industry. Natural gas demand in India is expected to grow from 242 million cu m/day in fiscal 2012-13 to 378 in 2016-17 and 516 million cubic meters/day in fiscal 2021-22. India is projected to import ~38 per cent by 2016-17. Approximately, 19 per cent of the natural gas demand was met through imports in 2012-13. LNG imports were projected to rise sharply from 44.6 million cu m/day in 2012-13 to 143 million cu m/day (~38% of total imports) in fiscal 2016-17. The domestic price of natural gas in USD 4.2/ Chemical Engineering World
Source: TSMG Report - “Chemicals – A way of life” November 2015 • 61
Marketing Initiative
More than 100 Manufacturers A parts data wizard has made the integration of product data into the Eplan Data Portal much easier. This benefits both the manufacturer and the user. For the first time, more than 100 manufacturers will be represented in the portal when SPS IPC Drives in November starts. With comprehensive device data, the more than 90,000 portal users worldwide will be able to simplify and accelerate their engineering processes. The necessary macros, component data and 3D data for the construction of a virtual control cabinet can be easily and directly integrated into the CAE design
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ith start of the SPS IPC drives, the Eplan Data Por tal breaks a remarkable record. Over 100 manufacturers – many of them from the European, Asian and US-American markets – will have integrated their manufacturer data into the portal. In mid October, there were already 99 manufacturers with over half a million qualified device and product data entries listed in the portal – at the fair end of November there should be around 110 manufacturers. The number of new members is also interesting: In 2015 alone, Eplan was able to gain 30 new manufacturers. One factor contributing to this extraordinary success is the new parts data wizard for manufacturers, among other things. Based on Excel technology, manufacturer data can now be made available more easily in the portal and at the push of a button. Manufacturers don't need any special knowhow – the technology can also distinguish between the commercial and graphics data within the listed allocations and collate it all together intuitively. Over ten manufacturers of clamps, cables, connectors and sensors have already experienced the simplicity of this new integration. A Further 1.2m Device Data Entries per Configurator But it doesn't end with the more than half a million integrated manufacturer data files: Those who use measuring instruments benefit from additional 1.2m variations in device data which can be configured in any specification. In addition to this, the measuring instrument manufacturer Endress+Hauser has already integrated existing web configurators into the Eplan Data Portal interface via web front-end. Based on the Eplan Engineering Configuration (EEC), which is online in the background, and 62 • November 2015
in combination with the Data Portal, a plethora of potential variations can be configured online. Global Expansion New manufacturers within the field of measurement technology include Janitza with its digital panel meters, Ziehl with its measurement and monitoring systems and Flowserve, a US-American manufacturer of measuring instruments. Other new members from the USA are Mencom, Priority Wire & Cable and Comtran Cable – all successful cable manufacturers, Molex from the cable and connector field and Hubbell, also a USAmerican manufacturer of connectors. The Eplan Data Portal is therefore becoming the international hub of product data. The most significant new member from China is Chint – one of Asia's largest manufacturers of automation technology. Noark, a subsidiary of Chint, has also made contactors and circuit breakers available in the portal. Liaoning Create Cable from China produces cables and Ningbo GOOSVN Electronic is a manufacturer of connectors and addresses the Asia-Pacific market. It goes without saying that European manufacturers have also joined – for example, ILME, an Italian manufacturer of electrical connectors, KEBA, an Austrian manufacturer of automation technology and Roxtec, a Swedish manufacturer of housing accessories and cable penetration. Kabelschlepp has employed energy chains and conveying systems, Hirschmann is involved with its ethernet switches and other manufacturers such as Citel, HBM, Klemsan, Lumberg, Promet and Sensopart complete the portal with their data. Conclusion: Users benefit from high-quality product and device data, whose wide range offers
Figure 1: Data Portal1 + 2..jpg: Device data – like those of Janitza or Noark depicted here – can be inserted into the Eplan project with ease.
Figure 2: Configurator_selection_in EDP: 1.2m device data entries can be configured with the Endress+Hauser configurator integrated into the Eplan Data Portal.
international manufacturers an ideal, flexible platform for true "global engineering". The data can be incorporated into the project 1:1 and guarantee users quick, efficient design while taking into account the current manufacturer data. The huge diversity of devices allows maximum freedom within engineering.
Rittal India Pvt. Ltd EPLAN Division NCC Urban Windsor, 3rd Floor, Opposite to Jakkur Aerodrome, New Airport Road, Bangalore - 560 064 T: +91 80 33240700 W: www.eplan.in E: krishnappa.s@eplan.in Chemical Engineering World
Marketing Initiative
Issue’s On Valve Selection Ends Here
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ynamic Controls and Services make sure that the requirements of the clients are understood in a proper manner and the instruments suggested to them are at par as per the process inputs, which satisfies the customer requirement and shall be the best possible solution for the application. Our teams are truly our valuable assets. The organization is made up of functional team and all team members are capable of contributing to customer needs product development, on time delivery and after sales support. We have been able to strike a balance in our relationship with our clients which have enabled us to cater to their needs to the utmost. To establish cordial relationship with our clients we pursue good business ethics in our dealings with each and every client. Our aim is to understand the requirements of our clients and deliver as per the specifications provided by them.
We have expanded our business in the past couple of years and have also paid special attention in attaining high-end expertise in manufacturing, supplying and exporting world class Instruments. All our products have been designed to cater to various complex requirements in an efficient manner which is widely appreciated by our clients. Our strengths: • Experienced professionals involved. • Business policies favorable for our clients. • Feasible and affordable prices. • On time delivery Support. • After Sales support – in time. We Stock long delivery Instruments such as Pneumatic Operated Globe Control Valve, Pneumatic Operated Ball Control Valve, Pneumatic Operated Butterfly Control Valve, Electrical Operated Butterfly / Ball Valves, Rotary Actuators, Smart Positioners, Electro
Pneumatic Positioners, Rotary Limit Switch Box, I/P Converters, Solenoid Valves, Air Filter Regulators and Differential Pressure Transmitters. Our Product Range includes Pressure Reducing Valves, Online Desuperheater, Power Cylinder, Knife Gate Valves, Pressure Switches, Flow Switches, Level Switches, Differential Pressure Switches, and Differential Pressure Gauges. Also we do Retrofit of Valve Positioners for all Indian / Imported make Control Valves. Dynamic Controls & Services Plot No: 1, Door No: 3/7, Krishnaveni Ammal St, Thirumalai Nagar, Ramapuram, Chennai – 600 089, T: 044 2486 3811 / 9840898063 E: sales@dynamiccontrols.in W: www.dynamiccontrols.in
ADVERTISE TO EXPAND your reach through
For Details Contact
Jasubhai Media Pvt. Ltd. Taj Building, 3rd Floor, 210 Dr D N Road, Fort, Mumbai - 400 001 Tel: 022-4037 3636, Fax: 022-4037 3635 Email: industrialmags@jasubhai.com Chemical Engineering World
November 2015 • 63
Marketing Initiative
Improved Diagnostic Information Resulted In Significant Cost Savings
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n a recent project SHP Automation Ltd used data provided by the PR 4511 communication enabler to develop software modules in the DCS that provide full diagnostics. SHP's client company has been able to use the data for preventive maintenance ... With the 4511 mounted on PR 4000/9000 devices, it is possible get digital access t o p r o c e s s va l u e s a n d b e n e f i t f r o m extensive diagnostics capabilities. Regular monitoring of data throughout the manufacturing process can help plan for preventative maintenance, identify problems in advance and save cost. Diagnostics data for preventive maintenance The 4511 offers several ways to access process data. One option is Master-Slave connection via Modbus RTU.
Figure 1:
The HMI interface then allows for easy monitoring of process values and d i a g n o s t i c s - W l i c h c a n b e u s e d fo r preventative maintenance. The data available depends on the type of installed PR devices. The PR 4114 universal transmitter, for example, offers a w d e r a n g e o f p r o c e s s a n d d ev i c e diagnostics related to device output, input, sensor, etc. Reduced maintenance cover SHP Automation Ltd located in the North West of England, specializes in all aspects of instrumentation and electrical control systems. On a recent project, the company used data provided by the 4511 to develop software modules in the DCS that provide full diagnostics and status information on the operator's control screen. Stephen Pucill, Director at SHP Automation, explains: "On the outside, the 4511 may look like a simple communication enabler, but the goodness of it is inside... On one of our projects we have used it to generate real-time process data -which is shown on the operator's control screen. The data is now used for preventive maintenance. Using the diagnostic information we have been able to visualize on the screen, our client company has been able to significantly reduce maintenance cost. The 4511 diagnostics and our software h ave ac c ounted for 80% of the fault finding process". The solution has also simplified the customer's daily operation.
Figure 1:
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The software interface we have developed for this customer shows the operator ex a c t l y v. t l i c h s i g n a l s a r e d ow n . H e immediately knows v.tlat is wrong and can
Figure 1:
act accordingly'', Stephen Pucill says and continues: "There is nothing better than having something tell you Wlat's wong, before you have to get the manual out it makes taking care of daily operation a lot easier''. Example of screen showing diagnostics data. Courtesy of SHP Automation Ltd. (Click to enlarge). In this example the faceplate on the right has lost its signal and displays '0' as one could expect with an open loop. In the lower part of the face plate the operator gets the 'LO_LO' alarm and a 'LOOP_BRK' alarm to indicate a loop fault. When the operator presses the 'detail' button (bottom left with the magnifying glass) it opens the detail window shown on the left. The 4511 diagnostic alarms at the lower left show an open loop being detected and the under range signal. The operator feeds this information to the maintenance team who now only has to find the broken cable.
Toshniwal Hyvac Pvt Ltd. 267,Kilpauk Garden Road Chennai - 600010 Contact: +91 44 26445626/8983 E : sales@toshniwal.net W:www.toshniwal.net Chemical Engineering World
Products CEW Rolling Shutters Gandhi Automations Pvt Ltd is the only manufacturer of rolling shutters certified to ISO 9001-2008 quality management system. Gandhi has developed technical expertise in manufacturing various kinds of automated rolling shutters. Gandhi’s rolling shutters are ideal for situations where side room is at a premium and security is required. They combine strength with elegance along with durability and are designed for both external and internal applications. Gandhi’s rolling shutters are fabricated of interlocking galvanized insulated and non-insulated, SS, patented aluminum or polycarbonate profiles and patented MS rolling grills. Each of their rolling shutters are designed as per the clients specifications conforming to IS 6248 and solidly constructed to promote trouble-free operation and long life. Gandhi rolling shutters fit openings to a maximum width of 30,000 mm and height of 40,000 mm with an endless array of options to satisfy both aesthetic considerations as well as working requirement. For details contact: Gandhi Automations Pvt Ltd Chawda Commercial Centre, 2nd Floor Link Road, Malad (W), Mumbai 400 064 Tel: 022-66720200, 66720300 | Fax: 91-022-66720201 E-mail: sales@geapl.co.in or Circle Readers’ Service Card 1
Waterproof Portable Meters Cole-Parmer offers new range of waterproof portable meters. It’s optical RDO technology is a cost-effective option for dissolved oxygen meter users. The new Oakton GLP compliant Waterproof DO 450 and pH/DO 450 Meters are optical meters with the convenience of no membrane replacement, no electrolyte replacement, no incoming flow requirement and no hydrogen sulphide interference. The meters also offer a short response time, minimal drift and minimal maintenance. Users gain more accurate readings on these DO meters with automatic and manual temperature compensation, which adjusts for fluctuating temperatures. They can see more data at a glance by viewing measurements with temperature and calibration data on a large, backlit display. Up to 500 data sets can be stored and easily downloaded with USB or RS-232 cable. The Oakton DO 450 meter features manual barometric pressure and salinity corrections. It also includes an annual sensor cap replacement. The Oakton pH/DO 450 meter offers six-point calibration—either USA, NIST, DIN or custom buffers. Convenient auto buffer recognition automatically identifies the correct pH meter buffer for rapid calibration. For details contact: Cole-Parmer India 403 Delphi-A, Hiranandani Business Park, Powai Mumbai 400 076 Tel: 022-61394410, 61394444 Fax: 91-022-61394422 E-mail: response@coleparmer.in or Circle Readers’ Service Card 2
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CEW Products U Tubes
Cartridge Filter Systems
Latest type of U bending machine is used for precision cold bending of tubes. Specially prepared jigs and fixtures are used to ensure 3-dimensional accuracy for U bend tubes. Bending is done for all kinds of heat exchanger, condenser, economizer, boiler tube in seamless as well as welded. Subsequent U bending tubes are hydro-tested and stressrelived if asked for. Also mock-up pieces are prepared for determining thickness reduction on the bend portion. Dye penetrant testing on bend portion is done to detect cracks, flaws or any type of defects. Special packing is provided to prevent any damage during transit. For details contact: MBM Tubes Pvt Ltd Maruti Mandir Marg 5 th Numbharwada Lane, Mumbai 400 004 Tel: 022-66381354, 66381355 Fax: 91-022-66595047 E-mail: mbmtubes@gmail.com or Circle Readers’ Service Card 3
Cartridge filter system offers wide range of flow capacities and contaminant holding capacities. Cartridge filter housing diameters can accommodate around 1 to 500 cartridges. Cartridge filters are normally used as polishing filter in almost all process industries. Cartridge filter is constructed of filter housing, filter cartridges, tube sheet, positive sealing arrangement for cartridge depending upon type of cartridge and choice of end connections. Positive sealing arrangement for cartridge filter assures no particle migration or fiber migration, even after high differential pressures. For details contact: Filter Concept Pvt Ltd 302 Aalin, Opp: Gujarat Vidhyapith Ashram Road Ahmedabad, Gujarat 380 014 Tel: 079-27541602, 27540069 Fax: 91-079-27540801 E-mail: engg2@filter-concept.com or Circle Readers’ Service Card 4
Diaphragm Pumps SRS Pumps offers domestic and industrial diaphragm type dosing pumps for hazardous, toxic and poisonous liquids, where leakage is not at all permitted. In hydraulic pump the process liquid is isolated from plunger by hydraulic oil and a diaphragm. The reciprocating plunger transmit displacement through hydraulic oil to the diaphragm, the oscillation of diaphragm produces pumping action on process fluid with help of non-return valve at both ends. Normally, Teflon is used as a diaphragm material. Shaped diaphragm or mechanically operated diaphragm pumps provide absolute solution for batching operations. It is developed for handling corrosive liquid and those containing suspension of abrasive solids. Here the shaped diaphragm is directly connected to the reciprocating mechanical parts from the connecting rod mechanism. Viton, Neoprene or Teflon faced rubber are working as a diaphragm material.Sandwich pumps have two identical diaphragms mounted together and operating as one piece. Since either diaphragm is capable of full pump performance, each is the backup of the other. Should one fail, operation continues without interruption on the other. There is no leakage or air sucked into the process and no mixing of the process fluid with the hydraulic oil. A pressure gauge reading between the diaphragms monitors the diaphragm conditions; no pressure indicates the diaphragms are okay while pressure indicates that the pump is operated on one diaphragm. For details contact: SRS Pumps Chawl No: B, Pitch No: 3, Pimpal Galli N R Hindustan Naka Charkop, Kandivli (W) Mumbai 400 067 Tel: 022-28688422 Email: info@srspumps.net / srspumps@gmail.com or Circle Readers’ Service Card 5
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Products CEW Closed-loop Controller ARO offers a closed-loop controller that offers remote operating capabilities, requiring less operator oversight and a dispensing repeatability within 1%. ARO offers the world’s first closed-loop controller for airoperated diaphragm pumps. ARO is responding to customer needs for a closed-loop system that allows them to customize production lines and remotely monitor fluid transfer to ensure greater efficiency and less production downtime.ARO’s smart touch-and-walk-away system can help optimize costs while controlling multiple pumps - ideal for tank filling, repackaging, blending, dewatering, pipe flushing, dispensing, fluid transferring, cleaning, batching, etc. From mixing chemicals to cleaning water to combining fluids and beyond, smart, efficient air control systems touch a variety of industries throughout the world, including chemical processing, paint/ink/coatings, waste water treatment, electronics, dry cleaning, nuclear power, pharma, pulp and paper, steel, water treatment, etc. For details contact: Ingersoll Rand India Plot No: 35, KIADB Indl Area Bidadi, Bengaluru, Karnataka 562 109 E-mail: Contact-India@irco.com or Circle Readers’ Service Card 6
Inverters NORD Drivesystems will equip all motor-mounted and cabinet-installed frequency inverters with new, more versatile microcontrollers and a new firmware. This enables the inverters originally designed for asynchronous motors to also control synchronous motors, which is becoming increasingly important particularly with the advent of IE4 efficiency motors. Highly dynamic drive tasks can now be executed even without encoder feedback. There are substantial benefits: for instance, customers who have been using IE3 motors with an encoder can save energy and costs by switching to IE4 motors without an encoder. Moreover, new generation NORD inverters are capable of performing drive-related PLC functions, which can significantly relieve external controllers. The inverters support the manufacturer-independent PLCopen function blocks for motion control. They can be freely programmed according to IEC 61131-3 in Structured Text or Instruction List. This makes application development less complex and reduces the associated costs. Customerspecific drive-related functions can be implemented by means of the inverter PLC without an application-specific firmware and free from cost-intensive verification and validation. For details contact: NORD Drivesystems Pvt Ltd 282/2, 283/2, Village: Mann Tal: Mulshi, Adj Hinjewadi MIDC II Pune, Maharashtra 411 057 E-mail: jyoti.mishra@nord.com or Circle Readers’ Service Card 7
Chemical Engineering World
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CEW Products Viton Rubber Sheet
Ribbon Blender
Fluoro elastomer rubber or Viton has high resistance to heat with a temperature range of - 40 to 250 oC. It also possesses a good flame resistance and is usually self-extinguishing. Viton or FKM have excellent resistance to oxygen, ozone and natural weathering and also have outstanding resistance to compression, especially at elevated temperature. Its resistance to most solvents and chemicals give long service life as it has excellent resistance against hydrocarbons, aliphatic, aromatic and chlorinated chemicals and resistance to acids and alkali including oxidants. For details contact: Kiran Rubber Industries 135 Shiv-Krupa Indl Estate, LBS Road Opp: Raj Legacy, Vikhroli (W) Mumbai 400 083 Tel: 022-42637400 Fax: 91-022-42637499 E-mail: info@kiranrubber.com or Circle Readers’ Service Card 8
Ravi Engg Works offers ribbon blender to a wide range of applications, viz, powder, blending, coating particles with a minor ingredient, mixing solids of different shapes and sizes, preparing solid liquid suspensions, slurry and paste mixing, etc. Ribbon blenders consist of a U-shaped horizontal trough and an agitator made up of inner and outer helical ribbons that are pitched to move material axially, in opposing directions, and also radially. This combination promotes fast and thorough blending. The MoC of blender may be carbon steel, SS or any other material as per the customer’s specifications. The classic ribbon blender serves multi-purpose uses in the manufacture of food, beverage, pharma, chemical, plastic and other poducts.. For details contact: Ravi Engg Works Nagarwada, Vadodara, Gujarat 390 001 E-mail: info@raviengg.com or Circle Readers’ Service Card 9
Big Display Counters Event counter/production counter is available in 4-digit and 6-digit with 1-inch and 4-inch display height. Sensor can be directly connected to this counter. It is hanging type and can be seen from long distance. RPM indicator/speed switch displays RPM of any rotating shaft object. It is available in 4-digit and 6-digit with 3/4 th inch and 4 inch display height. Preset counter/preset length counter available in 4-digit and 6-digit with 1-inch and 4-inch display height. It is hanging type. Setting provided through hanging pendent with cable. Relay output is available when set value is reached. Temperature indicator is available in 3-digit and 4 inch display height. Input is through PT 100 or J/K thermocouple. Process indicator/universal indicator is available with seven segment LED display. Models available with 4-inch display height. Units operates on 220 V AC supply and accepts universal input from 0-10 V DC or 4-20 mA. These are used in displaying various parameters such as temperature, pressure, flow, viscosity, pH, displacement, speed, etc, proportional to the input signal. For details contact: Electronic Switches (India) Pvt Ltd Plot No: K-11 MIDC Area Ambad, Nashik, Maharashtra 422 010 Tel: 0253-6697701, 6603954 Fax: 91-0253-2380918 E-mail: electronic.switches@gmail.com or Circle Readers’ Service Card 10
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Products CEW Seal-less Internal Gear Pumps Maag Industrial Pumps EnviroGear seal-less internal gear pumps have taken the safe, efficient and reliable handling of high-value, dangerous or hazardous chemicals to the next level of full containment. Traditional magnetically coupled internal gear pumps utilize two fluid chambers that are separated by an adapter plate, which can result in product entrapment and poor reliability when transferring high-viscosity fluids. However, EnviroGear pumps feature a revolutionary between-the-bearings design that places magnets directly on the rotor, eliminating the need for an adapter plate and allowing for a single fluid chamber. The result is a pump that features a simpler flow path, which allows the pump to handle both water-like liquids and those with viscosities to 50,000 cSt, while providing leak-free product containment. EnviroGear pumps have been constructed with only seven primary parts. Additional features include a SS, ductile-iron or carbon-steel construction; a rotor and idler supported at three locations that eliminates cantilever load; large, long radial bushings to support the entire length of the rotating element; and consistent flow when handling either water-like or highly viscous liquids. For details contact: Dover India Pvt Ltd – PSG 40 Poonamallee By-pass, Senneerkuppam Chennai 600 056 Tel: 044-26271020, 25271023 E-mail: sales.psgindia@psgdover.com or Circle Readers’ Service Card 11
Water Chiller Mellcon Engineers offers a state-of-the-art package water chiller ranging from 1.5 to 150 TR nominal cooling capacity. The system is compact in design and is provided with a digital temperature controller where the chilled water temperature can be set as per the requirement. The chillers are complete with pump and SS tank with coil/PHE/shell and tube chiller and are fully insulated. Standard chillers are available in air cooled/water cooled version with sealed reciprocating/ sealed scroll/semi-sealed (reciprocating/screw)/open (reciprocating/screw) compressors. The system operates in closed loop giving an outlet water pressure of 2 to 3 bars. Standard chillers are available in outlet water temperature ranging from 12 to 25oC. However, custom-built systems can be offered for outlet temperature as low as (-)40oC and water pressure as high as 15 bar. Oil chillers are also available in similar capacities. Complete system enclosed in powder-coated sheet metal enclosure with easy access to all controls. For details contact: Mellcon Engineers Pvt Ltd B-297 Okhla Indl Area, Phase 1 New Delhi 110 020 Tel. 011-26811727, 26816103 Fax. 91-011-26816573 E-mail: mellcon@mellcon.com or Circle Readers’ Service Card 12
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CEW Products Basket Filters & Strainers
Bag Filter Housing
Basket filters and strainers will permit the straining and filtering of a wide variety of fluids to retain solids of almost any size. All baskets are easily removable and cleanable.
Bag filter system is designed for optimum filtration performance. Its range provides filtration solution for a broad variety of fluid applications in the process industry.
Basket strainer elements can be offered in single cylinder, double cylinder, multicylinder and pleated design depending upon requirement of application. They are constructed of filter housing, filter element supported with perforated cage, positive sealing arrangement to avoid any bypass and choice of end connections.
They are particularly useful for filtering large volumes of high-viscosity liquids. Bag filter is constructed of filter housing, filter bags, internal cage to support bags, positive sealing arrangement and choice of end connections.
For details contact: Filter Concept Pvt Ltd 302 Aalin, Opp: Gujarat Vidhyapith Ashram Road Ahmedabad Gujarat 380 014 Tel: 079-27541602, 27540069 Fax: 91-079-27540801 E-mail: engg2@filter-concept.com
The internal support ensures bags will not burst as high differential pressures build up during operation. For details contact: Filter Concept Pvt Ltd 302 Aalin, Opp: Gujarat Vidhyapith Ashram Road Ahmedabad, Gujarat 380 014 Tel: 079-27541602, 27540069 Fax: 91-079-27540801 E-mail: engg2@filter-concept.com
or Circle Readers’ Service Card 13
or Circle Readers’ Service Card 14
ABR Automated Breakthrough Analyzer Hiden Isochema offers ABR automated breakthrough analyzer, which complements their existing larger scale breakthrough reactor systems. The ABR is designed to meet the needs of researchers wishing to characterize the gas separation performance of novel materials, such as metal-organic frameworks (MOFs), zeolitic imidazolate frameworks (ZIFs) and covalent organic frameworks (COFs), without the time or expense of synthesizing larger quantities of material. Breakthrough curve measurement allows high-throughput screening and testing of adsorbents, for a wide range of separation processes including CO 2 capture and storage, the purification and recovery of noble gases, natural gas and biogas upgrading, toxic gas removal and air separation. The ABR is a dedicated breakthrough analyzer, fully automated and supplied with an integrated close-coupled quadrupole mass spectrometer. Different configurations are available to suit research-scale samples, with bed volumes from 2 to 20 cc. Up to 6 gas inlets are available as well as a dedicated purge stream. Flow rates are selected to suit the specific applications, and the ABR includes an ultra-low dead volume switching valve. Options include an upgrade for operation at pressures up to 50 bar and an integrated vapour generator module for gas-vapour operation. The breakthrough data obtained are complementary to the adsorptiondesorption isotherms measured using their IGA, XEMIS and IMI sorption analyzers. For details contact: Hiden Isochema Ltd 422 Europa Boulevard Warrington WA5 7TS, U.K. Tel: +44 (0)1925 244678 Fax: +44 (0)1925 244664 E-mail: cwardropper@hidenisochema.com / info@hidenisochema.com or Circle Readers’ Service Card 15
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ChemTECH Chennai 2015 Dates: 10-12 December, 2015 Venue: TNTPO, Exhibition Ground, Chennai Details: World meet of chemicals, petrochemicals, pharma and process industry in India encompassing exhibition and conferences. Contact: +91 22 40373636 Email: sales@jasubhai.com Website: www.chemtech-online.com
ChemTECH Gujarat 2016 Dates: 10-12 February, 2016 Venue: Ahmedabad, India Details: World meet of chemicals, petrochemicals, pharma and process industry in India encompassing exhibition and conferences. Contact: +91 22 40373636 Email: sales@jasubhai.com Website: www.chemtech-online.com
20th Annual ARC Industry Forum Dates: 8 - 11 February, 2016 Venue: Orlando, USA Details: Discover what companies are doing to prepare for the new age of industrial innovation and how they expect to improve their business performance by doing so. Organiser: ARC Advisory Group Contact: +1 781-471-1175 Email:pking@arcweb.com Website: www.arcweb.com
Best Practices for Chemicals Dates: 14-16 March 2016 Venue: Texas, USA Details: The premier industry conference for organizations using SAP. Organisers: SAP, The Eventful Group and ASUG Contact: +1 877 411 4675 Email: sarah.carr@theeventfulgroup.com Website: www.sapforindustries.com
It is time to Migrate to an advanced Structural Analysis Software
Easy User Interface Chemspec 2016
ORPEC 2017
Dates: 7-8 April, 2016 Venue: Bombay Exhibition Centre, Mumbai Details: Meeting and networking with existing and potential partners and business facilitators Organiser: Quartz Businesss Media Ltd, Contact: +91 22 240 44472 Email: rohit@chemicalweekly.com Website: www.chemspecevents.com
Dates: 13-15 May 2017 Venue: Muscat, Oman Details: Designed to deliver key buyers to Oman’s growing refining and petrochemical industries creating a forum aligned with the government’s growth plans Organiser: OMANEXPO LLC Contact: Mr Ebrahim Taher Email: info@omanexpo.com Website: www.omanexpo.com
Conformancee to nuclear industry QA/QC - NRC Integration with smartPlant 3D / Tekla / STAAD.Pro Validation & veri�cation for more than 5000+test problems Base plate modeling & analysis Linear and Non linear Static-Dynamic analysis Steel Frame & reinforced concreate design CIS/2 analysis data interface Comprehensive & detailed user documentation Offshore structure analysis & deisgn
Automation 2016
The 2016 Automation Summit
Dates: 22 - 25 August 2016 Venue: Bombay Exhibition Center, Mumbai Details: Automation 2016, a four day automation event is set to introduce new and upcoming technology this year Organiser: IED Communications Ltd Contact: 91 22 22079567 Email: jyothi@iedcommunications.com Website: www.iedcommunications.com
Dates: 27-30 June, 2016 Venue: Las Vegas, USA Details: Siemens Automation Summit – A User Conference. All areas of industrial automation will be covered including factory, process, motion, and drives. Organiser: Siemens Industry, Inc Contact: +1 800 241 4453 Email: rich.chmielewski@siemens.com Website: usa.siemens.com/summit
Chemical Engineering World
Email: sales@iges.in
www.iges.in TOLL FREE : 1800 102 4437
November 2015 • 71
CEW Project Update
New Contracts/Expansions/Revamps The following list is a brief insight into the latest new projects by various companies in India. • CHEMICALS Globex Laboratories (R&D) proposes a pigments manufacturing unit at village: Dabhasa, district: Vadodara, Gujarat. According to MoEF sources, the project will come up in the existing land on 9,312 sq m. Kadam Environmental Consultants, Vadodara is the environmental consultant. The project will entail manufacture of 40-TPM red pigments, 40-TPM yellow pigment and 450-TPM dilute phosphoric acid. Environment clearance has been obtained for the products – red pigments and yellow pigments. Construction work has begun, as EC and NOC have been received. Effluents generated will be treated in effluent treatment plant having MEE. The company has applied for Amendment in Environmental Clearance dated 26 th September 2012 for change in fuel from LDO to agro waste briquettes and addition of one raw material, ie, phosphoric acid and generation of dilute phosphoric acid (25 per cent basis) as by-product. Bohra Industries is implementing an expansion of its chemical and fertilizer manufacturing unit at Umarda, district: Udaipur, Rajasthan on 14,500 sq m of existing land. The project will entail expansion of single super phosphate capacity from 400-TPD to 600-TPD, granulated super phosphate from 200-TPD to 300TPD and addition of new products namely 150-TPD triple super phosphate, 550 - TPD synthetic gypsum, 30 - TPD di-calcium phosphate, 160-TPD phosphoric acid, 0.3-TPD potassium fluoride, 150-TPD H 2SO 4 and 0.3-TPD Sodium Tri Polyphosphate (STPP). Machinery has been ordered from China. Civil work is in progress. The project is scheduled for completion in 2018. Ami Lifesciences proposes expansion of its synthetic organic chemicals manufacturing unit (viz, pharmaceutical bulk drugs and drug intermediates) from 65.70-TPM to 131.60-TPM in Padra, district: Vadodara, Gujarat. The estimated cost of the project is ` 87.046-million. Environmental Consultant to this project is Envisafe Environment Consultants. According to MoEF sources, total plot area is 23,760-sq m (existing 10,270-sq m and 13,490-sq m for expansion). The unit currently manufactures 2-TPM 1-Acetyl Naphthalene, 1-TPM 2-Acetyl Naphthalene, 6-TPM itopide HCl, 1.20-TPM loxapine succinate, 0.30-TPM amoxapine, 6-TPM venlafaxine, 6-TPM progunil HCl, 6-TPM CB2-L-Valine, 0.60-TPM nateglinide, 0.60-TPM quetiapine, 24-TPM carbomazepin and 12-TPM oxacarbomazepin. The expansion will involve addition of new products. Water requirement from ground water source will be increased from 34.53-cu m/day to 181-cu m/day after expansion. Effluent generation will be increased from 9.35-cu m/day to 79.5-cu m/day after expansion. Highly concentrated effluent will be sent to captive incinerator for incineration. Remaining effluent (70-m3/day) will be treated 72 • November 2015
in the ETP comprising primary, secondary and tertiary treatment. Treated effluent will be sent to CETP for further treatment. ETP sludge, inorganic residue and incineration ash will be sent to TSDF. Spent carbon, organic residue will be sent to incinerator. Astrica Laboratories is implementing a 240-TPA synthetic organic chemicals manufacturing project at a cost of ` 78.8-million in village: Ananthsagar, district: Medak, Telangana. Team Labs & Consultants are the environmental consultants. The project will come up on 6.97-acre of land. According to MoEF sources, it is proposed to treat all HTDS effluent in stripper followed by MEE and ATFD. All LTDS effluent including domestic effluent shall be treated in biological treatment followed by RO system. RO rejects sent to MEE and permeate is used for cooling towers as make up. Solid wastes are generated from the process, solvent distillation, collection/neutralization tank, waste oil from DG sets, used batteries from DG sets. The ash from boiler is sold to brick manufacturers. The solid wastes; evaporation salts, wastes from the process in inorganic form, ie, process salts and filtration aids shall be disposed to the TSDF, while the hazardous wastes of organic nature, i.e, distillation residues shall be disposed to authorized cement units and other wastes like used oil and used batteries shall be sent to authorized recyclers. The sludge from treatment plant shall be sent to TSDF. The basic technology involved in the manufacturing of bulk drugs is the process kettles, heat exchangers, centrifuges and storage tanks. To suppor t the process, equipment boilers, chilling plants, cooling towers, etc, are required. All the above equipment can be sourced indigenously. 80 per cent of civil work has been completed and remaining 20 per cent is in progress. The project is scheduled for completion in December 2015. Adi Finechem is planning a 40-TPA specialty products manufacturing project on a 2-acre land at an estimated cost of ` 400-million in village: Chekhala, district: Ahmedabad, Gujarat. The project is waiting for environmental clearance. RSPL is planning a 1,500-TPD soda ash plant and 40-MW captive power project in village: Kuranga, district: Jamnagar, Gujarat. Land acquisition is in progress. 85 per cent of land has been acquired. The project is waiting for environmental clearance. The entire project is planned for completion in 5 years from zero date. Superhouse is planning an expansion of its chemical mix-manufacturing project from 200-kg/day to 500-kg/ day in UPSIDC Industrial Area, district: Unnao, Uttar Chemical Engineering World
Project Update CEW Pradesh. The product will be used in leather tanneries. The project will involve installation of containers. The project is in planning stage. Stellar Chemical Laboratories is planning an expansion of its organic chemical manufacturing project from 7.1-TPM to 84.1-TPM in village: Derol, district: Panchmahals, Gujarat. Machinery is yet to be ordered. Work on the project is expected to commence after receipt of environmental clearances and the completion date is yet to be finalized. • MINING Aryan Ispat & Power is planning an expansion of its coal washery in village: Bamoloi, district: Sambalpur, Odisha. The project will come up in the existing 204.65-acre integrated steel plant premises. The capacity of the project is to be augmented from 0.70-MTPA to 5.70MTPA. The cost of the project is ` 600.7 million. The project is awaiting environmental clearance and planned for completion in 1-year from zero date. According to MoEF sources, the expansion is based on heavy media cyclone (wet process) technology. The washery will produce washed coal of an average ash around 34% (GCV 4,350-Kcal/kg), middling (ash content about 58%) of GCV around 2,350-Kcal per kg useable as fuel in FBC boilers. The proposed expansion will be the state-of-the-art with close circuit water system, classifying cyclone, high frequency screens, thickener and multi-roll belt press filters. Power requirement of 5-MVA will be sourced from its own power plant connected with the Grid Corporation of Odisha. NTPC is planning the Kudanali-Luburi coal mining project in district: Angul, Odisha. The company has signed an agreement on June 15, 2015 with Jammu and Kashmir State Power Development Corporation (JKSPDCL) for promoting a joint venture company with 67:33 equity participation for undertaking exploration, development and operation of jointly allocated Kudanali-Luburi Coal Block at Odisha by the Ministry of Coal. DSP Associates is planning a 15,17,600-TPA sand (minor mineral) mining project in the mines of Tikola-1 Sand Unit at village: Tikola, district: Gurgaon, Haryana. Mining lease area is 42.50-hectare. The estimated cost of the project is ` 55-million. The project is waiting for environmental clearance. Mining work is expected to commence in December 2015. According to MoEF sources, out of the total area, 31.50-hectare area falls in the river bed and 11-hectare area falls in agricultural land (outside river bed). Method of mining will be opencast semi-mechanized without drilling and blasting. The mine will be excavated out in layers up to a depth of 3-m in riverbed and 9-m in agricultural field. Letter of Intent (LOI) for mining contract has been granted for a period of 9 years. Barmer Lignite Mining Company, a JV between Rajasthan State Mines & Minerals & Raj West Power, a subsidiary of JSW Energy is planning an expansion of the Kapurdi Open Cast Lignite Mining project from 3.75-MTPA to 7-MTPA in Kapurdi, district: Barmer, Rajasthan at an estimated cost of ` 18,000-million inclusive of a Chemical Engineering World
new lignite mining project at Jalipa mines. The project is waiting for environmental clearance. • NON-CONVENTIONAL ENERGY Hubli Electricity Supply Company is planning solar RTPV grid connected power plants in district: Belagavi, Karnataka. E-tenders have been floated to design, manufacture, supply, installation, testing and commissioning of solar RTPV grid connected power plants on the roof-tops of 31 of HESCOM office buildings in Belagavi Zone Jurisdiction for total load of 136-KWp including operation and maintenance for a period of five years. The approximate amount put to tender is ` 18.62-million. Karnataka Renewable Energy Development is planning a 10MW solar power project at an estimated cost of ` 600-million (approximately) in village: Tingloor, taluka: Madhugiri, district: Tumkur, Karnataka. Surana Telecom And Power has received Letter of Award (LoA) for development of the project. Maharashtra State Power Generation Company is planning a 50-MWp solar photo voltaic power project in Gangakhed, district: Parbhani, Maharashtra. The company is scouting for land. Other details are yet to be finalized. Azure Power India is implementing a 10-MW solar photovoltaic power project in taluka: Hiriyur, district: Chitradurga, Karnataka. PPA has been signed with Bangalore Electricity Supply Company (BESCOM). Civil work and panel installation work is in progress. Government of Odisha is planning a 20-MW solar power plant in Manmunda, district: Boudh, Odisha. Green Energy Development Corporation of Odisha is the nodal agency. According to reports, the nodal agency has identified about 120-acre of land at Manmunda for establishment of the project. The land has been allotted to the agency from the industrial park area earmarked by Odisha Industrial Infrastructure Development Corporation (IDCO).The EPC tender is for development of the power plant and maintenance for a period of 10 years. Apart from the Boudh project, the agency is in the lookout for additional land in Koraput, Kantamal and Bolangir areas for installing about 200-MW solar energy capacity.
ACME Solar Energy is planning a 30-MW solar photovoltaic independent power project at a cost of ` 2.4-billion in Chhattisgarh. The company is a JV between ACME Cleantech Solutions, EDF Energies Nouvelles (EDF EN) and EREN, Luxembourg. PPA is yet to be signed with Chhattisgarh State Power Distribution Company (CSPDCL). The project is in planning stage. The project is planned for completion in 1-year from zero date.
• NON-CONVENTIONAL POWER BMS Starch, a part of the BMS Group, is implementing a 6-MW biomassbased co-gen power plant in village: Kurandi, district: Bastar, Chhattisgarh. The project is coming up along with a starch manufacturing unit on 26-acre of acquired land at a total estimated cost of ` 1,350 million. Equipment supplier is yet to be appointed. Civil work is in progress. The project is expected to be completed by 2016. November 2015 • 73
CEW Ad Index Sr. No.
Client’s Name
Page No
Sr. No.
Client’s Name
Page No
Inside Cover I
15
Paharpur Cooling Tower
Avcon Controls Pvt Ltd
43
16
Poonawalla Group
3
Busch Vacuum India Pvt Ltd
19
17
Rasaii Flow Lines Pvt Ltd
21
4
Dalal Engineering Pvt Ltd
15
18
Rathi Transpower Pvt Ltd
47
5
Economy Refrigeration Pvt Ltd
9
19
Ross Process Equipment Pvt Ltd
11
6
Emjay Engineers
47
20
Rotex Manufacturers & Engineers Pvt Ltd
7
Goodie International Pvt Ltd
31
21
Samarth Engineers
45
8
Hanna Instruments Equipments (I) Pvt Ltd
45
22
Seal Excel (India) Pvt Ltd
41
9
Hi-tech Applicator
3
23
Suraj Ltd
49
10
ImageGrafix Engineering Services Pvt Ltd
65, 67, 69, 71
24
Toshinwal Hyvac Pvt Ltd
41
11
Integral Process Controls India (P) Ltd
23
25
Uni Klinger Ltd
29
12
International Combustion (India) Ltd
43
26
UNP Polyvalves (India) Pvt Ltd
17
13
Kirloskar Brothers Ltd
Inside Cover II
27
Venus Trading Company
49
14
Outokumpu India Pvt Ltd
27
28
Chemtech Events
1
Atomic Vacuum Company (Exports)
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Back Cover
Chemical Engineering World
Book Shelf CEW Industrial Automation: Hands On 1st Edition Author Price Pages Publisher
: Frank Lamb : USD 87.55 : 368 (Hardcover) : McGraw-Hill Education
About the Book: A practical guide to industrial automation concepts, terminology, and applications. Industrial Automation: Hands-On is a single source of essential information for those involved in the design and use of automated machinery. The book emphasises control systems and offers full coverage of other relevant topics, including machine building, mechanical engineering and devices, manufacturing business systems, and job functions in an industrial environment. Detailed charts and tables serve as handy design aids. This is an invaluable reference for novices and seasoned automation professionals alike.
The Value of Automation: The Best Investment an Industrial Company Can Make
Industrial Process Automation Systems: Design and Implementation, 1st Edition
Author Price Pages Publisher
Author Price Pages Publisher
: B R Mehta, Y Jaganmohan Reddy : USD 119.44 : 668 (Hardcover) : Butterworth-Heinemann
About the Book: Industrial Process Automation Systems: Design and Implementation is a clear guide to the practicalities of modern industrial automation systems. Bridging the gap between theory and technician-level coverage, it offers a pragmatic approach to the subject based on industrial experience, taking in the latest technologies and professional practices. Its comprehensive coverage of concepts and applications provides engineers with the knowledge they need before referring to vendor documentation, while clear guidelines for implementing process control options and worked examples of deployments translate theory into practice with ease. This book is an ideal introduction to the subject for junior level professionals as well as being an essential reference for more experienced practitioners
Automation, Production Systems, and Computer-Integrated Manufacturing (4th Edition) Author Price Pages Publisher
: Mikell P Groover : USD 238 : 816 (Paperback) : Prentice Hall
About the Book: Automation, Production Systems, and Computer-Integrated Manufacturing is appropriate for advanced undergraduate/ graduate-level courses in Automation, Production Systems, and Computer-Integrated Manufacturing. The book should also be useful for practicing engineers and managers who wish to learn about automation and production systems technologies in modern manufacturing. This exploration of the technical and engineering aspects of automated production systems provides the most advanced, comprehensive, and balanced coverage of the subject of any text on the market. It covers all the major cutting-edge technologies of production automation and material handling, and how these technologies are used to construct modern manufacturing systems
Chemical Engineering World
: Peter G Martin : USD 99 : 219 (Paperback) :The Instrumentation, Systems, and Automation Society
About the Book:Industrial automation systems have the potential to be one of the most value-generating vehicles available to industrial companies. Unfortunately, not all managers of industrial companies perceive automation systems that way and few industrial automation systems actually provide the value they could and should. There are a number of reasons for this such as: The value provided by automation systems is not well-measured; The value provided by automation systems is not visible; The capital budgeting process of most industrial companies is flawed; and Project engineering teams are typically not measured on the incremental business value of their projects. The result is that many automation systems are undervalued and underutilised and many industrial companies are underperforming. It is in the best interest of all parties involved with industrial automation systems that this situation is rectified, the latent capability of automation systems is activated and the value potential is realised. Drawing from 35 years of experience, the author examines the shortcomings in the current industrial business practices that have resulted in the underutilisation and under appreciation of industrial automation systems and will provide prescriptions on how these shortcomings can be overcome. Adhering to the changes recommended in this book may make this the most valuable book you have ever read! November 2015 â&#x20AC;˘ 75
CEW Interview
Interview CEW
Shortcuts Are Not Solutions Eternis has rebranded itself recently and is in the processes of re-inventing the company’s image and business models. In the backdrop of this change, Mittravinda Ranjan & Girija Dalvi had a candid conversation with Rajen Mariwala, M a n a g i n g D i r e c t o r, Eternis Fine Chemicals Ltd where he spoke about the reason for rebranding, t h e c o m p a n y ’s f u t u r e plans and the changes that could set the Indian chemical industry on a growth trajectory.
72 • November 2015 World Chemical Engineering
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Interview CEW In March 2015, the company rebranded itself from its previous name Hindustan Polyamides and Fibres Ltd (HPFL) to Eternis Fine Chemicals Ltd. Please tell us more about this move and why was it undertaken. In 1980s, HPFL was an old company in which we had made investments but had not changed its name. We realised that fundamentally, it did not reflect the work we have been doing. Almost 90 per cent of our business is overseas. In the next phase of our growth journey, we thought it was crucial to analyse how the company looked to us, to our customers and the world at large. We wanted to create modern relationships and sustainability was another vital aspect on our agenda. After lot of deliberations, the genesis of Eternis happened from the Old French world ‘Eternal’. The ‘E’ in the logo we have adopted represents the Greek symbol of sigma which highlights our thought process. We are of course proud of being an Indian company but with the steps that we have taken overseas, I feel we need a wider canvas to paint! How was HPFL functioning earlier and how has that changed in Eternis? What are its future plans? Today, we have a topline of USD 80 million and we have only been on a growth journey all this while. I believe, what has brought us to his point will take us to the next level. In the local market, we are at ` 50-60 crores. The company is likely to see a CAGR of 20 per cent. The first step necessary to meet with our new aspirations is to bring in the right talent; we need to look at bringing in more talent internationally. At present Eternis has two people working overseas for the company. This is a small step for a company that has 250 people working majorly in the manufacturing side of the business. Another strategic change that we are looking forward to is improving our processes and systems so that it is able to handle the larger context of the business. We are only in the business of fragrance chemicals, so for us fine-tuning our strategy and accelerating growth is Chemical Engineering World
of utmost importance. Culturally, we are undergoing a lot of changes as well. Fragrance chemicals is a highly niche space. How much of the revenue does Eternis invest in R&D? From the CAPEX of the company about 2-3 per cent is spent on R&D. At present the research centre is located in Rabale in India but we are open to opportunities. If we have the right people in place, we would look at setting up R&D facilities overseas. How is the market shaping up for fragrance chemicals and what are the major growth drivers? Globally, the market is expected to grow at 2 to 3 per cent while the Asian market is expected to grow at 6 to 7 per cent between Indonesia, India and China. The European and US market will be more or less stagnant. A country such as ours will see acceleration in the growth numbers mainly because of a significant increase in rural consumption. Today, the aspirations of people are rising and this is the case even in rural India as the consumption there has become fairly resilient making it one of the key growth drivers for the market. Today, the rural population is well aware and more educated and the data available should be able to map how the occupational profile has changed. Globally, the specialty chemicals industry is much disciplined and companies are highly focused on managing cost and margins, which is the same for specialty chemical manufacturers in the space of fragrance. Another key trend the market will project is that of volume growth. While the companies are most likely to see high levels of volume growth they might see a marginal drop in value growth. The market would see an upward and downward movement but there will not be any real impact from the perspective
of margins. There could be a rise in the consumption of some items; especially if there is a decrease in the prices of discretionary ones. A decrease in prices of perfumes could encourage people to use more. But it would actually pinch the pocket if the total value drops. Although there has been a lot of up and down movement in the global chemical industry and the prices would move in tandem with the oil prices; the industry will be resilient as it has been in the last 4-5 years. China, which has maintained its image as the leader in commodity chemicals business has announced plans to enter the specialty chemicals space in a big way. What are your thoughts on the change in business model? Chinese economy became very competitive in the business of commodity chemicals because of scales of economy, huge domestic consumption and cheap labour costs. In my view, the Chinese industry is highly disciplined and they are also at a stage where the government wants them to be much more compliant, they are probably more pro-active than the Indian government in terms of environmental health and safety issues. Moreover, their labour is getting expensive and I think that will definitely compel them to take business decisions. They will not continue the same way people feel they were doing earlier. I personally feel they are fairly business minded. Both the industry as well as the government work proactively towards building new business strategies and regulations to stay ahead in the global competition. One of the points that I find worth mentioning is the strong stance of the Chinese Government where it has
A country such as ours will see acceleration in the growth numbers mainly because of a significant increase in rural consumption. Today, the aspirations of people are rising and this is the case even in rural India as the consumption there has become fairly resilient making it one of the key growth drivers for the market. November 2015 • 77
CEW Interview Rather than focusing on aspects like budget memorandums, etc, we must focus on pooling all our resources together and set up centralised boiler plants, common effluent treatment plants, co-gen plants, bulk storage yards which will radically bring down the capital investment and save quite a chunk of the CAPEX, especially for midsize companies continued to protect the domestic manufacturing industry by imposing stringent import barriers. While buying from China is never a problem, but selling the products into Chinese market can be quite daunting for the suppliers from other countries. What changes would you like to see that could boost the growth of the Indian chemical industry? I feel one change that will give a boost to the growth of the chemical industry is ‘the change in the mind-set of the Indian entrepreneurs’. Globalisation may go through its ups and downs; competition is here to stay. It is necessary to find viable solutions to the problems rather than complain about shortages. Indian industry should aim at reaching the global scale, especially the chemical industry. Today the fact is that a company would not launch a product unless it is sure of acquiring about 30-40 per cent of the global market share of the product. But, many Indian companies are only doing conversion, to put it crudely; raw materials are being brought in from overseas, converted here and sent out again. Eternis is just beginning to build scale but we have some way to go. There is no denying that innovation is happening in India but there is no disruptive, path-breaking innovation happening here. You are not going to get a brand new polymer coming in today or something radical in terms of technology. I think combinations between the areas of scale and technology will truly drive the growth; scale brings ability to leverage on technology. Secondly, we need to constantly re-invent the business models. A perfect example of this is the Jurong Island Global Energy and Chemical Hub that is not just surviving but thriving. We need to step out and look for greener avenues in terms of feedstock availability rather than complaining of it lacking in India. We need to move out of the comfort zone that we have created and look to Oman, Dubai and other Middle Eastern countries. Along with re-branding, Eternis is also in the process of re-inventing its business model.
We need to get over the JUGAAD mentality that Indians have. Shortcuts are not the solutions. Also, a practice that Eternis that adopted of ‘customer first’ can actually be a differentiating factor for your company. This has been widely been adopted globally. I believe India needs to catch up. I think if we take the right steps, it would not be difficult to create a healthy sense of competition in the Indian market as it is still a large captive market. The spending power and rising aspirations of people will put it on a growth trajectory.
Some Insights • Fragrances, flavours, essential oils, aroma chemicals and specialty aroma ingredients are a part of the Fragrance & Flavours (F&F) industry • The largest consumer of flavours or fragrances will be food, home and personal care industry. Its market drivers would be cosmetics, household and personal care products. • By 2016, the F&F demand is predicted to reach USD 26.5 billion. • The Indian F&F market is estimated to be USD 400 million where MNCs account for 70 per cent of the market. Source: Fragrances & Flavors Industry in India – Opportunities & Challenges; mergeralpha.com
Rather than focusing on aspects like budget memorandums, etc, we must focus on pooling all our resources together and set up centralised boiler plants, common effluent treatment plants, cogen plants, bulk storage yards which will radically bring down the capital investment and save quite a chunk of the CAPEX, especially for mid-size companies. These can come across as radical thoughts but can truly turn things for the better. This will definitely encourage more and more people to invest locally over and above the MNC investments that come in. 78 • November 2015
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