Chemical Engineering World December 2018

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

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NEWS Industry News

06

FEATURE Evaluation of Batch Vs Continuous Ammoniacal Nitrogen Stripping 24 Arvind Madalgi, AGM Process Engineering, Coromandel International Ltd, and Samarpita Chakraborty, Asst Manager Process Engineering, Coromandel International Ltd, Sarigam Is Sustainable Energy Transition in India on Track?

Dr D C Patra, Fellow Energy Institute, London, Chief General Manager, In-Charge, Planning, Bharat Petroleum Corporation Limited

32

Vacuum technology in the chemical industry Pfeiffer Vacuum GmbH, Headquarters · Germany

44

Integrated Engineering, Operations and Asset Management are Vital for Chemical Industries Valentijn de Leeuw, Vice President, ARC Advisory Group, Europe Are M&As Shaping the New Road Map for Chemical Industry?

Viejay Bhatia, Director, AVA Chemicals Pvt Ltd

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The economic value of steam flow measurement

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Choosing the Right Vacuum Pump - A Range from Toshniwal House

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Disclaimer: The Editorial/Content team at Jasubhai Media Pvt Ltd has not contributed to writing or editing “Marketing Initiative.” Readers would do well to treat it as an advertisement.

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Chemical Engineering World

CEW Industry News Asia and the Middle East lead global ammonia capacity additions by 2026

Nigeria has highest capex on crude and natural gas projects in sub-Saharan Africa over next seven years Nigeria accounts for more than 34 per cent of the proposed capital expenditure (capex) on planned and announced crude and natural gas projects in the sub-Saharan Africa over the period 2018–2025, according to GlobalData, a leading data and analytics company. The company’s report: ‘H2 2018 Production and Capital Expenditure Outlook for Key Planned Upstream Projects in Sub-Saharan Africa – Royal Dutch Shell Dominates Production and Capex Outlook’ reveals that Nigeria leads in the sub-Saharan Africa with a capex of USD59bn on 28 planned and announced projects during the 2018–2025 forecast period. Of the total count, 8 are planned and 20 are announced projects.

Global ammonia capacity is expected to experience considerable growth between 2017 and 2026, increasing from 230 million tons per annum (mtpa) in 2017 to more than 280 mtpa by 2026, led by Asia and the Middle East, according to GlobalData, a leading data and analytics company.

The company’s report ‘Q4 2018 Global Ammonia Capacity and Capital Expenditure Outlook – Dangote Industries Ltd and Nagarjuna Fertilizers Lead Global Capacity Additions’ reveals that around 100 planned and announced plants are scheduled to come online, predominantly in Asia and the Middle East, over the next nine years. Within Asia, India plans to add a total capacity of approximately 8.6 mtpa by 2026 with the help of 18 planned and announced ammonia plants. Major capacity additions will be from Nagarjuna Fertilizers and Chemicals Ltd and Rashtriya Chemicals and Fertilizers Ltd. The domestic producers in India are set to have large capacity additions, primarily targeting the country’s increasing fertilizer demand and import substitution.

GlobalData has identified the Middle East as the second highest in terms of ammonia capacity additions. Within the region, Iran has 21 planned and announced ammonia plants, with a total capacity of 8.4 mtpa by 2026. In Africa, Nigeria plans to spend USD7.21bn and add capacity of roughly 6.6 mtpa, expected to come onstream by 2026. Dangote Industries Ltd is setting up large ammonia plants in Nigeria, primarily targeting domestic fertilizer demand and other export markets in the region. The US has nine planned and announced ammonia plants, with a capacity of around 3.1 mtpa over the next nine years, and plans to spend USD3.23bn. Major capacity additions will be from Cronus Corporation and Ohio Valley Resources LLC. In the Former Soviet Union (FSU), most ammonia capacity additions are in Russia, with capacity of approximately 2.9 mtpa by 2026.

Capex for these plants totals USD 1.95bn by 2026. MCC EuroChem is the top company accounting for the major capacity additions in Russia.

In South America, the major ammonia capacity additions are in Peru, with planned and announced capacity additions of around 0.9 mtpa by 2026.

Capex for these plants totals USD 0.76bn. In Europe, Hungary plans to spend USD24.0m and add capacity of 0.1 mtpa, expected to come onstream by 2026. The report states that Dangote Industries Ltd and Nagarjuna Fertilizers and Chemicals Ltd leads among the key companies in terms of global capacity additions, with an estimated capacity addition of 2.9 mtpa (3 plants) and 2.0 mtpa (4 plants) respectively 6 • December 2018

Nigeria is investing heavily in new oil and gas projects to further boost its oil and gas production. Majority of production from these projects is for exports, generating significant revenues for the country. In total, 67 crude and natural gas projects are expected to start operations in the sub-Saharan Africa during the forecast period. Among these, 16 are planned projects with identified development plans, and 51 are earlystage announced projects that are undergoing conceptual studies and that are expected to get approved for development. According to the report, Angola as the second highest country in the sub-Saharan Africa with five upcoming projects, which are expected to come online by 2025. Among operators, Shell Petroleum Development Company of Nigeria Ltd leads with the highest operatorship of four upcoming projects in the sub-Saharan Africa during the forecast period – three announced and one planned – all being conventional gas projects.

Sonangol P&P occupies second place with operatorship of three upcoming oil projects.

Key projects in the sub-Saharan Africa are expected to contribute about 1.1 million barrels of oil equivalent per day and around 9.4 billion cubic feet per day of global gas production in 2025. The region is expected to spend proposed capex of USD20.3bn to bring the planned projects online and USD154.6bn on key announced projects during the forecast period. Royal Dutch Shell Plc, Exxon Mobil, Nigerian National Petroleum Corporation, Eni SpA, and Sonangol EP are the key players in terms of highest capex spending on the major planned and announced projects in sub-Saharan Africa. These companies are expected to collectively spend about USD64bn on planned and announced projects during the outlook period.

Rubber chemicals market to reach USD 5.3 billion by 2024 The worldwide market for rubber processing chemicals is poised to grow 4.9 percent annually, from USD 3.63 billion last year to more than USD 5.31 billion by 2025, according to new research from Global Market Insights. The CAGR figure is in line with other markets reports on the rubber processing chemicals sector. Some studies, however, project the market value to approach USD 7 billion with volumes of around 45 million metric tons by 2026. In its latest market study, GMI said it expects the rubber-curing accelerators segment to deliver the highest levels of growth, building on 2017 revenues estimated at over USD 1.5 billion. The pace of demand, it noted, reflects the contribution of accelerators to reducing production times and facilitating fast and economical production of rubber parts to required quality standards.

Demand for anti-degradant rubber chemicals also is set for to grow significantly to 2024, the report also indicated.

Chemical Engineering World

CEW Industry News Galaxy Surfactants Ltd bags ICIS Innovation Awards for Best Process Innovation

ExxonMobil diverts over 90 percent of waste produced in global plant network from local landfills ExxonMobil’s global network of lubricants blending and packaging plants, which manufacture all Mobil-branded products, has received the Zero Waste to Landfill Silver validation from UL, making it the first petroleum products company to secure this validation. The company’s lubricant operations is successfully diverting over 90 percent of the waste produced in its global plant network from local landfills. More than 50,000 tons of waste produced per year are being redeployed into new, productive uses that will bring greater value to the environment and the economy.

This achievement demonstrates the company’s commitment to reducing environmental impacts and enables commercial and retail consumers more sustainable choices through Mobil-branded lubricants.

Galaxy Surfactants one of the fastest growing speciality chemical companies has won the Green Process Innovation in recognition for the manufacture of amino acid surfactants used in personal care FMCG products. The winning innovation enables a more environment-friendly production of surfactants. Dr Nirmal Koshti, Director of Innovation at Galaxy Surfactants Limited believes that if a product is not good for the environment, then it loses its charm. It is important that both the product and the process of making it are eco-friendly. This attitude was the main driver behind search and subsequent invention of a “smart catalyst”. The Best Process Innovation category saw a number of strong entries, but the judges elected to give the award to Galaxy Surfactants for its novel, environmentally friendly process to produce N-acyl amino acid surfactants.

These mild anionic surfactants find uses in personal care products such as skin and hair care, providing cleansing as well as sensory benefits.

The process of amino acid surfactant manufacture employing ‘the smart catalyst’ meets all the norms of Green Chemistry. Since the catalysis is effected by the surfactant which is non-toxic & biodegradable, one doesn’t have to isolate from the intermediate or end product unlike the traditional process. It therefore addresses all the woes of conventional manufacture of amino acid surfactants. Acknowledging the Global Award for Process innovation, Mr. U. Shekhar, Managing Director, Galaxy Surfactants Limited said, "Sustainability is an important part of Galaxy’s strategy to give attention to the environment and provide sustainable technological development. This matches with our belief in a collective commitment to Do Good, Do Well." This innovation is applicable to an entire family of amino-acid based surfactants and can be extended to other acid chlorides in general that are intermediaries for a variety of chemical industries.

Dr. Koshti feels that Galaxy’s strong desire to create new value through innovation has led to this breakthrough. The process of manufacturing is based on smart chemistry, wherein the surfactant is used to catalyze the synthesis of the precursor of the same surfactant. This is a case of ‘surfactant catalyzes synthesis of surfactants’, making it a closedloop manufacturing process. On a concluding note, Mr. U Shekhar added, “We are committed to developing an ecosystem that supports disruptive thoughts to create new products or processes and add value through Innovation.”

8 • December 2018

“Reducing environmental impact is an important focus for ExxonMobil and a core part of our commitment to operating responsibly everywhere we do business,” said Terry Neal, global lubricant operations manager at ExxonMobil. “Achieving UL’s Zero Waste to Landfill at the silver level is an accomplishment towards our goal to ‘Protect Tomorrow. Today.’ and further demonstrates our commitment to bring all consumers high quality solutions to meet their business objectives.” To achieve the validation, ExxonMobil implemented a range of waste diversion techniques and strategies across its lubricant production network.

Specifically, the company identified 14 types of waste produced at these facilities that could either be avoided entirely, reused or recycled.

“Customers and consumers can feel confident they are making Mobil lubricant purchasing decisions that help fulfill their personal and business goals, including choosing partners that share in a commitment to reducing environmental impacts,” said Bennett Hansen, global lubricants marketing director at ExxonMobil. ExxonMobil began developing this waste management program in 2012 and by 2015, had implemented it across the globe. Examples of these programs include implementing a device to safely drain aerosol cans in an environmentally conscious manner, allowing the metal and liquid to be recycled in Port Allen, Louisiana and, in Serviburnu, Turkey, implementing a simple distillation process to recover laboratory solvent.

To achieve these results, ExxonMobil engaged UL in a rigorous, multiyear process, which included readiness assessments, pilot programs, and extensive examination of documentation and on-site practices for final validation. From operations, research and engineering to marketing and sales, each team played an integral role in helping to achieve the validation.

Sabic, Signs MoU to Upgrade Tacoil Sabic has recently signed a memorandum of understanding (MOU) with UK-based Plastic Energy, a pioneer in chemical plastics recycling, for the supply of feedstock to support Sabic’s petrochemical operations in Europe. Sabic and Plastic Energy intend to build a commercial plant in the Netherlands to refine and upgrade a valuable feedstock, known as Tacoil, a patented Plastic Energy product, which will be produced from the recycling of low quality, mixed plastic waste otherwise destined for incineration, or landfill. The plant, anticipated to enter commercial production in 2021, is a significant milestone for Sabic towards the company’s commitment to establishing a circular economy and, more broadly, its sustainability goals. Plastic Energy has successfully commercialised a patented thermochemical conversion technology to convert a wide range of end-of-life, dirty and contaminated plastics, hardly recyclable for conventional processes, into useable feedstock.

Chemical Engineering World

CEW Industry News Government to promote use of Domestically Manufactured Drugs and Medicines National Pharmaceuticals Pricing Policy, 2012 (NPPP-2012) was notified with the objective to put in place a regulatory framework for pricing of drugs so as to ensure availability of required medicines – “essential medicines” at reasonable prices even while providing sufficient opportunity for innovation and competition to support the growth of pharma industry thereby meeting the goals of employment and shared economic well-being for all. In order to promote and to make available quality generic medicines at affordable prices to all through specific outlets, a scheme in the name of ‘Pradhan Mantri Bhartiya Janaushadhi Pariyojana’ (PMBJP) is functioning across the country.

In order to promote domestically manufactured drugs, the Government is providing financial support for research and development through Drugs & Pharmaceuticals Research Programme (DPRP) run by the Department of Science & Technology. The companies undertaking Research & Development activities are provided income tax benefits.

The Drugs (Prices Control) Order, 2013, Para-32(iii) provides exemptions from price control to a manufacturer producing a new drug involving a new delivery system developed through indigenous Research and Development for a period of five years from the date of its market approval in India.

The government vide its notification dated 28th January, 2016 has withdrawn exemption of customs duty on certain categories on Bulk Drugs/APIs to provide level playing field to the domestic manufacturers.

In order to make generic medicines more accessible, the Department of Pharmaceuticals has requested all the States/Union Territories to explore and enforce the proposal of keeping a separate shelf/rack for generic medicines in every pharmacy in the country.

Global Paper Chemicals Market to Reach USD 40.2 Billion by 2023 According to Research & Markets paper Chemicals Market is estimated to be USD 36.4 Billion in 2018 and is projected to Reach USD 40.2 Billion by 2023, at a CAGR of 2.0 per cent between 2018 and 2023. Paper chemicals are a group of chemicals that are used in pulp and paper mills to convert wood pulp into paper products. Various types of chemicals are used depending on the pulp and paper manufacturing process. The pulp and paper chemicals are classified into three types - pulp chemicals, process chemicals, and functional chemicals. Pulp chemicals mainly include bleaching chemicals and pulping chemicals. Caustic soda and sodium sulphide are the widely used pulping chemicals. Wood pulp is bleached to remove colour from the trace amounts of lignin, which is not extracted during the chemical pulping process.

Chlorine, sodium chlorate, chlorine dioxide, hydrogen peroxide, and oxygen are the widely used bleaching agents. Process chemicals mainly include biocides, coagulants and flocculants, defoamers, deposit control materials, and retention and drainage aids. Functional chemicals mainly include dyes, pigments, and colorants, fillers, surface coatings, sizing agents, and softeners and binding agents. APAC was the largest paper chemicals market in 2017. It is projected to reach USD 14,014.2 million by 2023 at a CAGR of 3.3 per cent between 2018 and 2023. APAC accounted for a share of 32.4 per cent of the overall paper chemicals market in 2017. The growth of the packaging 10 • December 2018

industry in the region contributes to the growth of the paper chemicals market. The packaging industry generates a considerable demand for paper and paperboard in the region.

The paper chemicals market is mainly driven by the persistent growth in the production of packaging paper. The demand for several paperbased packaging products for the packaging of food and beverages is boosting the development of specialty paper chemicals. The global trend of digitization has decreased the demand for printing and graphic paper, which has resulted in the closure of many pulp and paper mills in Europe and North America. This has restrained the paper chemicals market. The market growth is challenged by the downturn in paper production in China due to the implementation of stringent regulations in the country regarding effluent disposal and old pulp and paper processing equipment. On the other hand, pulp mill biorefineries are creating new growth opportunities for pulp and paper chemical companies to convert pulp into valuable bioproducts such as bio-based phenols, binders, and polyesters.

Global Textile Chemicals Market Will Reach USD 3160 Million By 2024 According to the report by Zion Market Research, the global textile chemical market was valued at around USD 2500 million in 2017 and is expected to reach approximately USD 3160 million by 2024, growing at a CAGR of slightly above 4.5 per cent between 2018 and 2024. The textile industry can also be termed as a chemical dependent industry, as it utilizes a variety of chemicals during the manufacturing process.

Textile chemicals include a huge range of products, such as surfactants, starch, sulfonated oils, and grease, among various other products. These chemicals are largely used for applications in pre-treatment processes, like coatings, sizing, etc.

Alfa Laval GCU Preferred Choice for LNG New Builds The Alfa Laval Gas Combustion Unit (GCU) has been chosen for boiloff gas management on more than half of the LNG carriers built during 2018. This brings the total number of GCUs sold to well over 100 units, with new developments promising still greater market potential. Since buying the fledgling technology from Snecma in 2013, Alfa Laval has proven the GCU concept and built up a strong position for the product in the LNG market. This simple and reliable incineration unit for boil-off gas, with few components and a minimal number of interfaces and moving parts, now has a long track record among the largest LNG ship owners.

In 2018, the GCU has been the choice for the majority of LNG newbuilds.

Today the GCU is central to the Alfa Laval portfolio of systems for LNG, which also includes the renowned Alfa Laval Smit LNG inert gas generators. Alfa Laval has continued to develop the GCU technology, both in partnership with customers and at the Alfa Laval Test & Training Centre in Aalborg, Denmark. Since the expansion of the Test & Training Centre for gas applications in 2017, a full-size GCU has been the focal point of the 1350 sq.m. testing space. Yet another GCU development will appear in 2019, when a smaller version is expected for commercial release. Whereas the current GCU is most suited to large vessels, the new unit will be optimized for 100–1000 kg/h of boil-off gas. “The smaller GCU will be an excellent fit for small LNG carriers, floating storage and regasification units, LNG bunker vessels and vessels using LNG as fuel, which also need an option for burning boil-off gas,” says Borg.

Chemical Engineering World

CEW Industry News A USD 68.86 Billion Opportunity in Plastic Additives According to Research & Markets, the Global Plastic Additives market accounted for USD 39.25 billion in 2017 and is expected to reach USD 68.86 billion by 2026 growing at a CAGR of 6.4 per cent from 2017 to 2026. The market is majorly driven by factors such as growing consumption of plastics driven by the rising applications and increasing disposable earnings of the people from emerging economies. The affluent packaging application in emerging countries and increasing usage of additives in medical and agricultural applications are some of the factors fueling the market growth. However, factors such as unpredictable prices of raw materials and stringent governmental regulations are hindering the market growth. Amongst Type, the Plasticizers segment accounted for significant market share during the forecast period. The plastic additive market as it is extensively used to process polymers and is less expensive than other additives. They are usually combined with PVC or other polymers to impart unique physical and technological properties for use in various applications such as cable jacketing, floor and wall coverings, and coating fabrics. Asia-Pacific is the largest market for plastic additives. The growing packaging industry coupled with the increased demand from the retail industry drives the market of plastic additives in the region. Polymer industries are witnessing high growth in developing nations such as India and Brazil due to their growing economies.

Perstorp announces production capacity increase for Di-Penta, securing future growth Perstorp has increased capacity of di-pentaerythritol i.e. Di-Penta with 40 per cent at site Perstorp. This is a result of improved efficiency and debottlenecking at all Di-Penta producing sites. Di-Penta is used in a vast number of applications such as UV cured coatings, synthetic lubricants, high solids alkyd coatings, fire resistant Charmor™ coatings and lead-free PVC stabilizers. Di-Penta brings properties such as a thermo-stability, UV-stability, weather-, chemical- and scratch resistance. It’s also a very important raw material in many environmentally friendly applications.

As the largest global producer of Di-Penta, leading specialty chemicals company Perstorp, is working on all fronts to meet the increased customer demand of Di-Penta and the performance it offers. Since years back the entire industry has suffered from shortages in the Di-Penta market. To secure product availability Perstorp has worked to maximize Di-Penta production capacity which now has resulted in a capacity increase and a fully available product. Kent Hamacek, Product Manager, Advanced Polyols & Formates says “We strongly believe in Di-Penta and will work hard to continue to grow with our customers and customer’s customer, bringing new and innovative solutions to market”. The complete strategy to meet customer demand for Perstorp Di-Penta now and in the future also includes a number of innovation projects focused on application development for complementary solutions.

Eastman Chemical Company Completes Acid Manufacturing Facility Eastman Chemical Company has finished a new isobutyric acid manufacturing facility at its Kingsport, TN site. Production is expected to commence shortly. The new facility along with the isobutyric acid manufacturing facility in Texas doubles Eastman Chemical’s production capacity, making it the premier isobutyric acid supplier in the global market.

Isobutyric acid has wide range of usages in various markets, including food flavours and fragrance, protective coatings and agriculture intermediates.

12 • December 2018

Lotte Invests USD 3.5 Billion for Indonesia's Largest Petrochemical Plant Lotte Group is expected to invest at least USD 3.5 billion in what is claimed to be Indonesia's largest petrochemical plant.Scheduled to be completed in 2023, the petrochemical plant will aim to meet the company’s demand for ethylene in the country. In addition to this, it will also cater to the rising domestic demand which is expected to outpace the global order. If everything goes as planned, Indonesia could witness a boost in its downstream industries. This will enable the country to curb imports and decrease the current-account deficit.

Lotte Chemical Indonesia recently held a groundbreaking ceremony for an ethylene cracker along with the petrochemical complex in Cilegon, Banten Province. With a production capacity of 1 mtpa, the new cracker plant will only be the second such plant in the country. On completion of the new complex, the company will be able to meet its ethylene demand within Indonesia and also has plans to make it available for the domestic market. The firm will also be producing polypropylene which is used in the automotive, textile and other industries.

Haldor Topsoe Cements Presence in Indonesia Topsoe has opened the office in Indonesia by officially opening an office in Jakarta to support Indonesian refining customers with state-of-theart technology and catalysts to meet new fuel specifications. While customers in the petrochemical industry have known and benefited from Topsoe catalysts, technological solutions, and highly specialized services for many years now, the new office will strengthen the relationship further.

The fertilizer industry will benefit from Topsoe solutions that optimize energy consumption.

“We have been supporting Indonesian customers for more than four decades. We will now be able to provide them with even faster services tailored to their specific needs,” says Jack H. Carstensen, Managing Director of Topsoe’s office in Kuala Lumpur, Malaysia.

Indonesia is an important and fast-growing market with numerous needs and opportunities that the new office will help to fulfill. “It is a crucial milestone in our further expansion in the region, a natural step with regards to the promising development of the Indonesian economy,” says Morten Schaldemose, Executive Vice President, Refinery Business Unit, who was also present at the inauguration.

There is an expected growth in ammonia to accommodate the need in the fertilizer industry, in methanol production as feedstock for the downstream petrochemical industry, and in DME as the alternative to LPG for household use. Indonesian customers will benefit from Topsoe´s vast experience and capabilities within all these areas.

With the upcoming transition of Indonesian fuel legislation into Euro V, refining customers can look forward to utilizing Topsoe technology and catalysts in both existing and new refineries to meet current and future fuel specifications with an optimal cost-benefit ratio. At the same time, the fertilizer industry will profit from Topsoe solutions to enhance plant efficiency and optimize energy consumption.

“We are well prepared to complement the current and future strive of Indonesian companies to enhance their production – and to grow locally and regionally,” says Michael Gruss, Chief Representative of the new office in Jakarta. Next to the office in Kuala Lumpur, Malaysia, Jakarta is Topsoe’s second representation in Southeast Asia.

Chemical Engineering World

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CEW Industry News Cabinet Approves MoC between India and Japan in the field of Environmental Cooperation The Union Cabinet chaired by Prime Minister Mr Narendra Modi has given ex-post facto approval to the Memorandum of Cooperation (MoC) between India and Japan. The MoC was signed on 29th October 2018 during the visit of Hon’ble Prime Minister of India to Japan. The MoC will enable establishment and promotion of closer and long-term cooperation between India and Japan in the field of environment protection and management of natural resources on the basis of equity, reciprocity and mutual benefits, taking into account the applicable laws and legal provisions in each country. Further, the MoC entails exchange of information and technology between the two countries. Environmental degradation falls on the socially and economically disadvantaged, more heavily than better-off sections of the society. Any effort at thwarting environmental degradation would lead to environmental equity in the sense of availability of sound environmental resources to all sections of the society. The MoC is expected to bring in the latest technologies and best practices suited for bringing about better environment protection, better conservation, better management of climate change and bio-diversity conservation.

Unique Fire-Resistant Shelters Simplify Chemical Plant’s Control System Upgrade Novel outdoor equipment shelters from Intertec Instrumentation have been chosen to help a leading European chemical manufacturer to upgrade its distributed plant control system. Constructed using unique composite GRP (glass fibre reinforced polyester) materials, four Intertec shelters will provide advanced fire resistance properties. This attribute will simplify the housing and protection of electronic control and instrumentation equipment at optimised satellite locations within the processing plant.

Additionally, the GRP-based fabrication materials significantly reduces the weight of the shelters compared with traditional metal- or concretebased constructions. In this application, this weight reduction will allow the plant operator to further optimise the positioning of the control system by mounting three of the shelters at height on steelwork frames. The shelters offer F60-rated passive fire resistance, providing a barrier to fire spread for 60 minutes. This is achieved by means of a unique composite material that combines GRP sheets with embedded layers of mineral wool. The shelters provide large interior floor areas up to 55 m2 (5 x 11 m). To help speed this plant upgrade project, Intertec is providing the plant buildings fitted with lighting, a raised floor to accommodate cabling, and ducting for the cooling air with a sophisticated downflow cooling system to protect the electronics equipment.

Air Liquide to Build First World Scale Liquid Hydrogen Production Plant Air Liquide expects to invest over 150 million US dollars to build a liquid hydrogen plant in the western United States, with construction to begin in early 2019. The plant will have a capacity of nearly 30 tons of hydrogen per day — an amount that can fuel 35,000 Fuel Cell Electric Vehicles (FCEVs). Through this investment, Air Liquide will enable the large-scale deployment of hydrogen mobility on the west coast, providing a reliable supply solution to fuel the 40,000 FCEVs expected to be deployed in 16 • December 2018

the state of California by 2022. The plant will also support other fuel cell vehicle and transportation markets in the region, such as material handling and forklifts and heavy duty trucks. The new plant is the first large scale investment into the supply chain infrastructure needed to support hydrogen energy solutions for the energy transition, starting with transport and mobility. The pace of FCEV deployment has now reached a level requiring a growing scale of investment and is paving the way for the growth of zero emission mobility in other geographies.

In addition to the long-term supply agreement, Air Liquide and FEF have entered into an agreement outlining Air Liquide’s intent to make an equity investment in FEF, following previous assistance to the company by Toyota and Honda. With these agreements, Air Liquide also builds upon its existing collaborations with Toyota and Honda to further enable a robust hydrogen fueling infrastructure and, along with others, bolster the deployment of fuel cell electric vehicles and the retail fueling infrastructure in California.

New Nitrate Monitor Lowers Costs Responding to global demand for improved monitoring of nitrate in freshwater, OTT HydroMet has launched a new optical nitrate sensor, the OTT ecoN. “This is fantastic news for scientists, catchment managers, water companies, regulators and environmental consultants,” says Ronan O'Maitiu, Global Product Manager for the OTT ecoN. “In the past, customers have been caught between low-cost/limited-performance sensors and highend technologies, for which purchase costs prevent large scale deployment. The OTT ecoN neatly fills that gap; as a continuous nitrate monitor, with minimal maintenance requirements, it can be left to monitor in remote locations, and an optional wiper makes it suitable for extended deployments.” In addition to a low purchase cost, the ecoN also lowers the cost of ownership because it is factory calibrated for life. As an optical sensor, the ecoN provides high accuracy and low resolution without the drift and interferences of ion-selective electrodes, or the ongoing reagent and maintenance costs of wet-chemistry analyzers.

PCPIRs in India register good progress in attracting Investments Minister of State for Chemicals & Fertilizers, Road Transport & Highways, Shipping, Mr. Mansukh L. Mandaviya informed the Department of Chemicals & Petrochemicals, under Ministry of Chemicals & Fertilizers has registered good progress by facilitating increased investments in Petroleum, Chemicals and Petrochemical Investment Regions (PCPIRs) for boosting industrial development and employment generation. Under the cluster-based development model, the department has identified four PCPIRs - in Gujarat, Andhra Pradesh, Odisha and Tamil Nadu – that are in advanced stages of implementation. Upon completion, these PCPIRs will have an estimated investment of approximately ` 8 lakh crores and are expected to generate employment for approximately 40 lakh people.

So far, around ` 1,83,000 crores have been invested in these PCPIRs and more than 3 lakh people have been employed.

ONGC Petro Additions Ltd (OPaL) has been established as the anchor unit at Dahej. 170 industrial units are already functional, while over 830 units are in different stages of implementation at PCPIR Dahej and so far ` 86,000 crores have been invested and employment has been generated for a total of 1,32,000 persons, the Minister informed.

Chemical Engineering World

CEW Industry News Dr. Alka Mittal takes charge as Director (HR), ONGC Dr Alka Mittal has joined as Director (HR) of Oil and Natural Gas Corporation Limited . A post graduate in Economics, MBA (HRM) and Doctorate in Commerce and Business Studies, she joined ONGC as a Graduate Trainee in 1985 and brings with her an extremely rich experience spanning over three decades.

She is the first woman to hold the charge of a full-time Director in ONGC’s history. She is also on the board of ONGC Mangalore Petrochemicals Limited (OMPL) as ONGC nominee Director since August 2015.

Prior to joining as Director (HR), Dr Mittal held the post of Chief Skill Development (CSD) of the Company. In her capacity as CSD she streamlined the activities and brought in uniformity in the working of the Skill Development Centres of ONGC. During this period, she has also implemented the National Apprenticeship Promotion Scheme (NAPS) in ONGC engaging more than 5000 apprentices across all work centres.

Previously she worked as Head CSR at Corporate Office and took up major CSR projects across India. Earlier, she has led the HR-ER functions in various capacities across regions including Vadodara, Mumbai, Delhi and Jorhat, and was also the Head of Corporate Communications of ONGC during 2009. She has a special penchant for training and mentoring, and has trained more than 11000 GTs of ONGC since 2001 on “Corporate Governance” as part of their induction program. As a senior HR specialist, Dr Alka Mittal has made rich contributions in various professional forums and bodies. She is an Executive Committee member of NIPM (National Institute of Personnel Management), and was President of Forum for Women in Public Sector (WIPs) Northern Region till recently and heads the Women Development Forum of ONGC.

Work on CGD projects commences in five Geographical Areas in Haryana Hon’ble Prime Minister Mr. Narendra Modi today launched the commencement of work for City Gas Distribution projects in 63 Geographical Areas across India, including five in Haryana, heralding the availability of convenient and environment-friendly natural gas for millions of residents.

Natural gas can be used in CGD sector four distinct segments of Compressed Natural Gas (CNG) predominantly used as auto-fuel, Piped Natural Gas (PNG) used in domestic households, Commercial and Industrial segments. At present, CGD authorization has been given for 92 GAs covering 129 districts (99 complete and 30 part) spread over 23 States and UTs. These cover about 20 percent of India’s population (as per 2011 census) and 11 percent of its geographical area. In addition, CGD operations are being carried out in 5 districts.

& Palwal Districts (to Adani Gas Limited), Hisar District (to Consortium of Haryana City Gas Kapil Chopra Enterprise & Rati Chopra), Sonipat District (except areas already authorized) & Jind District (to Hindustan Petroleum Corporation Limited). With the completion of 9 th CGD Bidding Round, natural gas would be available in 178 GAs comprising 290 districts (278 complete and 12 part) spread over 26 States and UTs covering more than 46 percent of India’s population and about 35 percent of its geographical area.

As per the commitment made by the various entities in the GAs, authorized for development of City or Local City Gas Distribution Network under 9th CGD Bidding Round in Haryana, 7,13,213 domestic PNG connections and 249 CNG stations would be installed largely during a period of eight years up to September, 2026, in addition to 4,987 inch-km of steel pipeline. Further, the entities would be authorized to supply natural gas to industrial and commercial units in their respective GAs as per the limits provided in the CGD Authorization Regulations. This month, PNGRB launched the 10th CGD Bidding Round for 50 GAs spread across 14 states. This would increase coverage of city gas distribution to 70% of the country’s population and 53% of its area. The GAs in Haryana included in the 10th CGD Bidding Round are Kaithal district, Sirsa, Fatehabad & Mansa districts (this GA includes areas in Punjab also).

hte equips IFPEN with high throughput technology for naphtha reforming applications IFP Energies Nouvelles (IFPEN) has selected hte’s proprietary technology for catalytic naphtha reforming testing applications to speed up catalyst and process development. hte will supply a high throughput reactor system which is highly optimized for constant RON operation under both industrial semi-regenerative and continuous catalyst regeneration (CCR) reforming conditions. hte will supply a flexible high throughput reactor system for catalytic naphtha reforming testing applications to IFPEN. The test unit is ideally suited for catalyst and process development purposes. It will be installed at IFPEN’s research center in Solaize, France at the beginning of 2019.

The fully integrated catalyst testing solution is fitted with unique features such as automated parallel adjustment of temperature profiles, operation at a constant research octane number (RON) under both industrial semiregenerative and continuous catalyst regeneration (CCR) reforming conditions, and enhanced online analytics. Furthermore, it includes the latest software solution, myhteTM, for integrating, storing, retrieving, analyzing, and visualizing data.

PNGRB had launched the 9th CGD Bidding Round in April 2018 for the 86 GAs which includes 174 districts (156 complete and 18 part), spread over 22 States and Union Territories (UTs). After the evaluation of bids, Letters of authorization for development of City Gas Distribution (CGD) projects in these GAs have been issued to 23 entities.

“After a thorough market evaluation, we selected hte’s technology because of its proven expertise in test units for catalyst and process development. This technology and fully integrated software solution will contribute significantly to reducing the time and costs associated with the development of new processes and new catalysts,” says Denis Guillaume, Director of the Process Experimentation Division at IPFEN. “This unit will supply data for catalyst screening and for process development, providing representative data for industrial scale,” says Cécile Thomazeau, Reforming Project Leader at IFPEN.

The GAs awarded in Haryana are Panchkula District (except areas already authorized), Sirmaur Districts, Shimla & Solan District (to IndianOil-Adani Gas Private Limited) (this GA includes areas in Himachal Pradesh also), Bhiwani, Charkhi Dadri & Mahendragarh Districts, Nuh

Wolfram Stichert, CEO at hte, comments: “We are proud to work with such a renowned research institute. We have invested significantly in the development of this technology over the past years and are happy to see the market acceptance it has received.”

20 • December 2018

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CEW Industry News IndianOil promotes CBG

In order to sensitise the stakeholders to participate in the SATAT (Sustainable Alternative Towards Affordable Transportation) initiative, the Public Sector Oil Marketing Companies (OMCs), viz. Indian Oil Corporation Ltd., Bharat Petroleum Corporation Ltd. and Hindustan Petroleum Corporation Limited, organized a Road Show on 16th December 2018 at Bhubaneswar. Chief Guest of the event, Hon’ble Union Minister of Petroleum and Natural Gas and Skill Development & Entrepreneurship, Shri Dharmendra Pradhan inaugurated the road show.

The SATAT initiative aims to boost availability of more affordable transport fuels, better use of agricultural residue, cattle dung and municipal solid waste besides providing an additional source of revenue to farmers. As part of SATAT, the OMCs invited Expression of Interest (EOI) to procure Compressed Bio Gas (CBG) from potential entrepreneurs and make available CBG in the market for use as automotive fuel. Under the initiative, it is envisioned that 5000 CBG plants would be established across the country with an estimated annual CBG production of 15 million tonnes by the year 2023. CBG introduction in transport sector has multiple benefits such as waste management, reduction in carbon emissions, additional revenue source for farmers, boost to entrepreneurship and rural economy by generating employment opportunities. It is estimated that if the total potential of CBG is exploited in the country, India can produce approx. 62 million tonnes equivalent of CBG annually which is sufficient to replace the entire gas demand of the nation.

Mr Sanjiv Singh, Chairman, Indian Oil Corporation Limited, in his welcome address said that under the leadership of MoPNG ‘SATAT’ a transformational initiative in the green energy space was launched on 1st October, 2018 at New Delhi with an aim to revolutionize transport sector by introducing Compressed Bio Gas (CBG) in this segment. It will further help India achieve self-reliance in the energy sector by enabling the country in drastic reduction of its crude imports which currently constitute over 80% of its total energy consumption. On this occasion, Hon’ble Minister Mr Pradhan said that CBG can be produced from various types of feedstocks such as agriculture residues, press mud and spent wash of distilleries, sewage water, Municipal Solid Waste (MSW), cattle dung, biodegradable fractions of industrial waste etc. CBG is replacement of Natural Gas and can be used in the transportation sector in place of Compressed Natural Gas (CNG). Presently, consumption of Natural Gas in India is around 140 MMSCMD out of which domestic production is only 70 MMSCMD and remaining 70 MMSCMD is imported which is around 50% of total consumption. Government intends to move towards Gas based economy by increasing the share of Natural Gas in India’s energy basket from present 6-7% to 15% by the year 2022. With the rising demand for Natural Gas in transport and industrial sector, CBG has been identified as a potential route. Under this initiative, IOC, BPCL, HPCL and GAIL have invited Expression of Interest (EoI) to procure CBG from potential entrepreneurs and create necessary infrastructure for marketing the same as automotive fuel. While IOCL, HPCL, BPCL have already done so, GAIL will float EOI on behalf of GAIL and its CGD JVs. 22 • December 2018

Ashland completes expansion of HEC production in China Ashland recently completed a successful expansion for Natrosol™ hydroxyethylcellulose (HEC) in Nanjing, China, increasing the company’s manufacturing output at the site by nearly 30 percent.

Ashland is the global leader in HEC sales and production and has manufacturing sites located in China, the Netherlands, and the United States. Key markets for HEC include coatings, personal care, oil and gas, construction, and pharmaceuticals. “This capacity expansion enables us to support our customers’ growing demand for Natrosol™ HEC,” said Chris Brown, vice president and general manager, Ashland Coatings. “Continuing to maximize our current network provides Ashland with a better return on capital versus building a new plant while also strengthening our cost position.

GAIL Gas Signs MoU with EESL for Fast-Tracking Co-Generation & Tri-Generation Projects

GAIL Gas Limited, a subsidiary of GAIL (India) Limited, has signed a Memorandum of Understanding (MoU) with Energy Efficiency Services Limited (EESL) for fast-tracking the implementation of co-generation and tri-generation projects and use of natural gas in industrial and commercial segments.

The MoU was signed by Mr. A K Jana, Chief Executive Officer, GAIL Gas and Mr. Saurabh Kumar, Managing Director, EESL in the presence of Mr. Gajendra Singh, Director (Marketing), GAIL (India) Limited & Director, GAIL Gas and Mr. Rajeev Mathur, Director GAIL Gas at INSPIRE 2018 conference. The MoU is set to benefit commercial installations like hotels, hospitals, airports, commercial malls, commercial/ government building, integrated residential complexes, educational institutions, data center, among others, with the advantages of combined heat & power technology.

It will help increase the consumption of natural gas through City Gas Distribution networks in co-generation and tri-generation projects, being a natural choice for operating the gas engines. Under the MoU, EESL will manage equipments at the customer’s location and GAIL Gas will supply natural gas to the feasible projects within the authorised geographical areas. This MoU will help in achieving target set by Government of India to increase the share of natural gas in the energy mix of the country from the present level to 6.5% to 15% by 2020. Co-generation project will facilitate substantial financial savings on utility costs, large carbon reduction and increased security of supply.

It can be used on any scale – from a micro to a medium-sized power station servicing a whole industrial complex as well as commercial complexes. It is fuel-efficient means of generating electricity and useful heat in the same process.

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CEW Features Case Study

Evaluation of Batch Vs Continuous Ammoniacal Nitrogen Stripping In this work, the case of a real industrial problem is selected to evaluate the efficiency, operability and economic performance of NH3-N Stripping by Batch Vs Continuous methodology. The removal of ammoniacal nitrogen (NH3-N) is investigated by both the methods. The alternative method of continuous stripping by packed bed column was first modelled in the professional software environment of ASPEN Plus. Real time data was collected from plant trials for both the methods for comparison. The same is considered for design of Continuous packed bed stripping column. It is proved that Continuous steam stripping by packed bed shows better operability and economic performance than batch wise steam stripping operation. Moreover the Ammoniacal Nitrogen can be recovered in the distillate making it a more environmental friendly method thus improving the sustainability.

The work presented in this paper was performed at Coromandel International Ltd, Sarigam. This study presents pilot-scale testing and commercial scale design of continuous stripping column performed at the facility.

Why Stripping?

Ammonia stripping is a simple desorption process used to lower the ammonia content of a wastewater stream. Some wastewaters contain large amounts of ammonia or nitrogen containing compounds that may reading form ammonia. It is often easier and less expensive to remove nitrogen from wastewater in the form of ammonia than to convert it to nitratenitrogen before removing it.[1] Ammonia (a weak base) reacts with water (a weak acid) to form ammonium hydroxide. In ammonia stripping, lime or caustic is added to the wastewater until the pH reaches 10.8 to 12 which converts ammonium hydroxide ions to ammonia gas according to the following reaction: NH4+ + OH- H2O + NH3 [NH3] =

[NH3 + NH4 + ] 1+ [H + ]/ Ka

pKa = 4 × 10−8T3 + 9 × 10−5T2 + 0.0356T + 10.072 where [NH3] is the molecular ammonia concentration, [NH3 + NH+4] is the total ammonia concentration, [H+] is the hydrogen ion concentration, and Ka is the acid ionization constant. Besides that, pKa can be expressed in terms of temperature. [2] General Stripping Process Ammoniacal Nitrogen Stripping can be performed as either a batch or a continuous process. Recent development in ammonia 24 • December 2018

removal by ammonia stripping fall into the following categories: ammonia stripping reactor modifications like packed bed stripping column (air or steam), semi-batch jet-loop reactor, water-sparged aero cyclone reactor, rotating packed-bed reactors as well as membrane contactor, membrane distillation, ion exchange-stripping loop, and microwave assisted ammonia stripping. [3] Ammonia stripping with air works well with wastewater that has ammonia contents between 10 to 100 mg/l for higher ammonia content (more than 100 mg/l) it maybe more economical to use alternate ammonia removal techniques such as steam stripping or biological methods.[1] In the stripping process, the wastewater is brought into contact with high amount of hot gas, vapour or steam to bring the volatile organic and/or inorganic contaminants into the gas/vapour phase from the aqueous phase. In the case of air-stripping, water is usually also transferred into the gas phase, which lowers the temperature of the hot air, and therefore lowers volatility of the impurities. Impurities are removed from the gas phase used for stripping and the gas/air can be used again.[4] Packed or tray columns can be properly used to remove the polluting compounds.

The process wastewater is fed at the top, and the air or steam is fed at the bottom.

The pollutants can be typically found in the

top product that can be also called distillate.

The treated wastewater is removed at the bottom. It is advisable to use the heat content of the removed warm, treated wastewater to preheat the cold fed wastewater.[5] The same technology of packed bed stripping column with random packing has been incorporated at the facility.

Operational Parameters Affecting Stripping Process 1) Temperature: Temperature has been proven to have a significant impact on the performance of ammonia stripper. This is because the solubility of ammonia in water is governed by Henry’s law. In Henry’s law, the constant of gas relies on solute, solvent, and temperature. Generally, higher efficiency ammonia removal can be obtained at higher temperature 2) pH: An optimum pH is required to strike a balance between process efficiency and economic cost. It was found that when the pH exceeded 10.5, the removal efficiency was insignificant because pH no longer the affected the ionization balance between molecular ammonia and ionic ammonium but the cost incurred rose significantly due to the additional caustic consumption required to increase the pH levels.

3) Steam to Water Ratio: Steam to water ratio is an important parameter that has an impact on the removal rates of ammonia Chemical Engineering World

Horizontal Chemical Peeler A batch type semi / automatic filtering centrifuge for chemical and intermediates.

CEW Features m-1). It was observed during the pilot trials that the pilot model satisfied the design intent and could be replicated in commercial scale.

Scale up, Erection and Commission of equipments for large scale was done for treatment by NH3-N removal by Packed bed NH3-N stripping column. The commercial scale ammonia stripping column was 7 meters in height with internal diameter of 600 NB and packed with Lessing ring (Surface area of 600 m2/m3 and dry packing factor of 6500 m-1). The schematic of the setup is as shown in Fig.3. Commissioning of the stripper column was conducted at different flowrates and the design intent was achieved. Based on the monitoring of continuous packed bed stripping column, the following results were obtained as shown in Fig.2.

Figure1: Pilot trial observations with Packed bed Steam Stripping column

in water. Mass transfer of ammonia into the steam is affected by the variance between ammonia concentration level in liquid form and vapour phase.

The case study described below aims at focussing on the aspects of batch vs continuous ammonia stripping and how packed bed columns are more efficient for controlling the temperature, pH and steam to water ratio and the best selection of these optimized operating parameters to achieve higher efficiency.

Conventional treatment method – Batch treatment by direct steam purging in agitated vessels The batch treatment of ammoniacal nitrogen stripping consisted of Agitated vessels for receiving the wastewater to be treated.

Direct steam purging was done using low pressure steam at 3-3.5 kg/cm2 and the NH3-N concentration was decreased. The temperature and steam flow rate exhibited a significant impacts on the ammonia removal rate. But this method appeared to be less effective than packed bed columns.

From the analysis of the batchwise data it was found that the average reduction in NH3-N concentration was only 81%.

Moreover, it was found that the temperature of the discharged water was quite high and a huge scope existed for optimization of energy for the same. The average steam norms for condensate treated in batchwise 28 • December 2018

stripping was 0.27 kg steam/kg condensate which was much high and had huge scope for optimization.

Continuous treatment of NH3-N – Treatment by using packed bed stripping column by counter current contact of steam On basis of the model simulated using ASPEN Plus, pilot set-up by inhouse system was designed and scheme was finalized.

The pilot column fabricated was 1.7 meters in height with internal diameter of 200 NB and packed with Lessing ring (Surface area of 600 m2/m3 and dry packing factor of 6500

Results From the observations as shown in Fig.2, the steam norms for the condensate treated in continuous packed bed stripping column decreased to 0.124 kg steam/kg condensate i.e a reduction of 0.15 kg steam/kg condensate as compared to batch process.

The space requirement has decreased as the stripping column has been retrofitted in the existing facility. A total savings of 1.03 crores/annum has been achieved considering the steam savings.

Conclusions Ammonia stripping performance is highly dependent on the column temperature and steam to wastewater ratio. Efficiency decreases significantly as column temperature decreases. The maximum ammonia transfer efficiency of about 96%

Figure 2: Continuous observation and monitoring of Packed Bed Stripper Column

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CEW Features was achieved at pH 12 in continuous packed column which was much higher compared to 81% efficiency achieved in batchwise stripping of ammonia. The success of an ammonia stripping process is greatly dependent on temperature, pH, and steam to water ratio which was easier to control in continuous packed-bed reactor. As such, the selection of optimized operating parameter is vital for the ammonia stripper to achieve higher efficiency. Thus. concluding continuous steam stripping column for NH3-N removal is highly efficient, easy to operate and leading to cost effective remediation.

Figure3: Scheme for NH3-N removal by Packed bed Steam Stripping column

Internals of Packed bed Stripping Column

References 1. Stripping, Ammonia. “Technology Fact Sheet.” (2000).

2. Wastewaters, Ammonia Removal from Highstrength. “G. B. Wickramanayake, Ph. D., PE Senior Engineer ENVIRON Corporation Princeton, New Jersey.”

3. Kinidi, Lennevey, Ivy Ai Wei Tan, Abdul Wahab, Noraziah Binti, Khairul Fikri Bin Tamrin, Cirilo Nolasco Hipolito, and Shanti Faridah Salleh. “Recent Development in Ammonia Stripping Process for Industrial Wastewater Treatment.” International Journal of Chemical Engineering 2018 (2018).

4. Toth, A. J., and P. Mizsey. “Comparison of Air And Steam Stripping: Removal Of Organic Halogen Compounds From Process Wastewaters.” International Journal Of Environmental Science And Technology 12.4 (2015): 1321-1330.

5. Hassan, Sardar Q., and Dennis L. Timberlake. “Steam Stripping And Batch Distillation For The Removal And/Or Recovery Of Volatile Organic Compounds From Industrial Wastes.” Journal of the Air & Waste Management Association 42.7 (1992): 936-943.

Author Details

Arvind Madalgi AGM Process Engineering, Coromandel International Ltd, Sarigam. madalgia@coromandel.murugappa.com

Samarpita Chakraborty Asst. Manager Process Engineering, Coromandel International Ltd, Sarigam Chakrabortys1@coromandel.murugappa.com 30 • December 2018

Chemical Engineering World

CEW Features

Is Sustainable Energy Transition in India on Track?

This paper assesses the transition underway in terms of intensity & actualization under the headings of: Energy transition measured, Physical energy transition, Energy transition: target vs accomplishment, Green energy programs and Future green energy initiatives. Dr D C Patra presented this paper in the Energy Systems Conference jointly organized by Elsevier and Energy Institute, London organises in Queen Elizabeth II, in Westminster, London in June 2017.

I

ndia’s energy transition trajectory is complex, encompassing myriads of factors. Energy systems and structure, both from the demand and supply side, are undergoing transformations, under the compulsions of three d’s, namely democracy (thriving and evolving), demography (young) and development (vibrant). While energy consumption has exhibited a secular trend, the energy basket is set to undergo a different composition.

Energy Transition Measured • India’s Energy Consumption India is world’s third largest consumer of energy (724 MTOE in 2016), after China (3053 MTOE) and USA (2272 MTOE). Keeping pace with its fast GDP growth and urbanization, the country’s energy consumption grew at 5.75 CAGR during last decade.

Significant to observe that per capita energy consumption in the country

Year

Energy Consumption in peta joules

Midyear population (in Million)

GDP ( ` crore)

Per Capita Energy Consumption (in Mega Joules)

Energy Intensity (Mega Joules per Rupee)

2005-06

14286

1118

3253073

12778

0.4392

2006-07

16571

1134

3564364

14613

0.4649

2007-08

17878

1148

3896636

15573

0.4588

2008-09

18936

1161

4158676

16310

0.4553

2009-10

21408

1175

4516071

18220

0.4740

2010-11

22458

1182

4918533

19000

0.4566

2011-12

23872

1219

8736329

19579

0.2732

2012-13

25128

1237

9213017

20307

0.2727

2013-14

25755

1256

9801370

20513

0.2628

2014-15

27589

1274

10527674

21660

0.2621

2015-16

28337

1292

11386145

21935

0.2489

2016-17

29279

1310

12196006

22351

0.2401

Table 1: Per-capita Energy Consumption and Energy Intensity

1965

1980

1990

2000

2014

• Transition in energy basket Transition in energy consumption is to be seen from the points of view of: a) significant increase in energy demand and b) shift towards low carbon energy mix.

India is poised to occupy the centre stage of world energy consumption, as its share goes on increasing from 6.5 per cent of world consumption in 2016 to 10.8 per cent in 2040, which is CAGR growth of 2.67 per cent.

• Move towards sustainability Sustainability in energy consumption has been captured by two indices: (1) Energy Trilemma Index, formulated and estimated every year by World Energy Council, and (2). Energy Architecture Performance Index, formulated and estimated by World Economic Forum every year.

Source: Energy Statistics, MOSPI, GOI, 2018 and previous issues.

1970

is growing and the energy intensity per unit of output on average is on a declining path. This is primarily explained by increasing share of national income from service sector and deployment of energy saving equipment and programs.

2015

Energy Trilemma Index Energy Trilemma Index of World Energy Council (WEC), computed since 2010, 2016

2025

Actual – Historical

2030

2040

Projection

World

3731

4912

6642

8142

10035

13684

13633

13760

13921

13836

14084

India

53

65

102

195

441

824

851

897

1118

1236

1479

% of India to World

1.4

1.3

1.5

2.4

4.4

6.0

6.2

6.5

8.1

9.2

10.8

Table 2 : Total Primary Energy Consumption: Actual up to 2016 and Projection thereafter- India vs. World 32 • December 2018

Fig - MTOE

Source: Figure till 1990 – BP Statistical Review of World Energy, 2017, by BP Figure from 2000 onwards – World Energy Outlook, 2017, by IEA

Chemical Engineering World

CEW Features 2012

2013

2014

2015

2016

2017

Energy Security

86

76

76

60

51

66

Energy Equity

110

110

105

93

93

96

Environmental Sustainability

123

121

123

96

97

92

Contextual Performance

-

76

90

105

100

86

Overall Rank

117

115

122

92

91

92

Balance Score CDD Table 3: Energy Trilemma Indicators for India Figures indicate Rank, except the Balance Score, which is a Composite Score

CDD

BDD

BCC

CCC

Source: World Energy Trilemma Index 2017 & 2014, World Energy Council

Energy Transition Index World Economic Forum in 2018 has formulated concept of Energy Transition Index (ETI) and computed value (in terms of percentage) for 114 countries.

In addition to measuring country’s energy system performance, ETI evaluates the extent to which countries have created the conditions for being future ready for becoming sustainable energy economy.

3 Broad Index

What the Sub-indices indicate

Economic Growth and Development

This sub-index measures the extent to which a country’s energy architecture adds or detracts from economic growth

Environmental Sustainability

This sub-index measures the environmental impact of energy supply and consumption

Energy Access and Security

This sub-index measures the extent to which an energy supply is secure, accessible and diversified

2017 2016 2015

Rank out of 127 Countries 87 90 95

Composite Score

Economic Growth & Development

Environmental Sustainability

0.55 0.53 0.51

0.54 0.51 0.50

0.49 0.49 0.42

Table 4: Energy Architecture Performance Index for India (score on the scale of 0 – 1)

Energy Transition Index System Performance Index Transition Readiness Index Table 5: Energy Transition Index for India

Source: Global Energy Architecture Performance Index, World Economic Forum

India Score 49 52 47

Highest Score – Country 76 - Sweden 84 – Norway 73 - Finland

Figures in Percentage

considers 3 dimensions of a country’s energy system: a) Energy Security, b) Energy Equity and c) Environmental Sustainability.

India has moved up in overall rank from 122 in 2014 to 92 in 2017. The improvement has come from all the three indicators and is more pronounced with respect to environmental sustainability.

Energy Architecture Performance Index World Economic Forum, since 2013, devised a composite index, ‘Energy Architecture Performance Index’ (EAPI), as a measure of 3 key indicators of a 34 • December 2018

Energy Access & Security 0.62 0.61 0.61

Source: WEF, 2018

country’s energy system, which are again split into 18 sub-indicators. EAPI index ranks 127 countries in descending order and gives score to the 3 key indicators on a scale of 0 – 1.

Table 4 brings out the fact that India has improved score on all fronts, during last 4 years, particularly with respect to energy access and security and environmental sustainability. There is marginal

improvement

in

composite

score over the years, though the rank scrolled down in 2015 and went up in 2016 and further up in 2017.

Physical Energy Transition • India’s Resolve Transition

for

Energy

India ratified its Nationally Determined Contribution (NDC) commitment made in Paris Agreement in COP 21 of United Nations Framework Convention on Climate Change (UNFCCC) on 2 nd October 2016.

The significant measurable commitments are: • To reduce the emissions intensity of its GDP by 33 to 35 per cent by 2030 from 2005 level.

• To achieve about 40 per cent cumulative electricity installed capacity from non-fossil fuel based energy resources by 2030 with the help of transfer of technology and low cost international finance including from Green Climate Fund (GCF).

• To create additional carbon sink of 2.5 to 3 billion tonnes of CO 2 equivalent through additional forest and tree cover by 2030.

Government of India announced in 2014 its intention to have cumulative renewable Chemical Engineering World

CEW Features 2040

Distribution Companies (DISCOMs) which are being addressed.

456

408

293

331

348

Table 9 shows capacity addition during last 4 years has been compared with the 2022 target.

47

102

135

203

10

10

28

59

116

11

12

11

19

26

38

188

194

196

200

168

142

167

0

4

4

5

6

45

87

199

441

775

824

851

897

1118

1236

1479

1990

2000

2013

2014

Actual

Coal

92

147

341

378

379

401

463

Oil

63

112

176

185

206

222

Gas

11

23

45

43

43

Nuclear

2

4

9

9

Hydro

6

6

12

Bio Energy

133

149

Other Renewables

0

Total

307

2016

2025

2030

Projection

Table 6: Energy Type Mix (Actual till 2016 and projection till 2040)

Figures in MTOE

• Energy Basket for India

Target

Vs.

• Status of India’s Transition Trajectory In this section, we will critically evaluate the progress that India has achieved on the path of transition, in terms of volume and de-carbonization.

• How Much Renewable Energy Capacity Built in India?

India till 2017 has renewable energy capacity of 106 GW including 40 GW of large hydro projects, forming 4.88 per cent of world capacity. There has been substantial addition of

Source: World Energy Outlook, International Energy Agency

renewable capacity in India, growing at 9.76 CAGR during last decade. The capacity addition has been accelerated during last 3 years, when it grew at 14.55 CAGR. There has been 5-fold increase in solar capacity from 3.5 GW in 2014 to 19.3 GW in 2017. Wind energy capacity has increased by 14% in 2017.

power generation capacity of 175 GW by 2022 (excluding large hydropower). Out of this, solar will be 100 GW, wind 60 GW, biomass 10 GW and small hydro projects will be 5 GW.

Energy Transition: Accomplishment

2015

• Green (Renewable) Power Generation Capacity as per India’s Commitment in Paris Agreement

From the Table 8 & 9, looking at the actualization during last 4 years, the target for power generation from solar and wind appear to be daunting.

However, reviewing the progress of several initiatives underway, the targets are not outside the zone of realization.

Green Energy Programs • National Mission for Enhanced Energy Efficiency India put in place a ‘National Mission for Enhanced Energy Efficiency’ (NMEEE), as part of 8 point National Action Plan for Climate Change’ in 2008.

• Carbon Sink India committed in COP 21 at Paris creating additional carbon sink the equivalent of 2.5 to 3 billion tonnes carbon dioxide by 2030.

The carbon stock in India (as in January 2018) is roughly 7 billion tonnes, equivalent to 25.66 billion tonnes of carbon dioxide. The average annual increment of carbon stock is 35 million tonnes, which is equivalent to 128.33 million tonnes carbon dioxide.

Number of schemes are in place and regulatory environment has been created for taking the country’s generation and use of renewable energy on fast forward mode. Still there are micro issue centring on technology, investment and functioning of State Electricity

By 2030, the increment is expected to be equivalent of 1.92 billion of carbon

2007

2008

2009

2010

2011

2012

2013

2014

2015

2016

2017

Hydro

32432

33493

34393

35307

36734

37571

38097

39570

41471

42801

44596

Wind

7845

9655

10926

13065

16084

18421

20150

22465

25088

28700

32878

Solar

4

10

12

37

565

926

1336

3518

5396

9647

19275

Bio

1586

2016

2453

3023

3758

4019

4280

5148

5605

9024

9533

Total

41867

45174

47784

51432

57141

60937

63863

70701

77560

90172

106282

Table 7: Trend of Renewable Energy Capacity 36 • December 2018

Figures in MW

Source: IRENA, 2018

Chemical Engineering World

CEW Features Source of Power

Estimated Potential As on 31. 03.

2017. @1

Target Capacity as per INDC committed in Paris COP 21 in Oct. 2015, to be created by 2022

Actual Capacity as on 31. 03.

2018. @2

Capacity added in 3.5 years (Apr 2014Dec 2017)

Balance to reach the target in 4 years

Solar

649.3

100

21.6

12.87

78.4

Wind @ 100 mt. height

302.2

60

34

11.70

26

Biomass

18.6

0.79

0.6

0.7 10

Bagasse Cogeneration

7.3

Small Hydro

21.1

5

4.5

0.59

0.5

Waste to Energy

2.5

-

0.1

-

-

Total Renewable

1001

175

69.6

27.07

105.5

Table 8: Target vs Accomplishment of Renewable Electricity dioxide, which would mean shortfall of 0.6 to 1.1 billion tonnes.

• Emission Intensity of GDP India aims to reduce emission intensity of GDP by 33 to 35% by 2030 from 2005 level. India is attempting to achieve this by two ways: a) by tapping non-fossil energy source and, b) by creating additional carbon sink.

On the issue of reduction of GHG, India has two types of policy instruments: a) Domestic market mechanism, such as, renewable energy certificates market (REC) and energy efficiency certificates market (PAT) b) Carbon pricing policies, such as carbon tax in the form of coal cess.

In 2005, India’s emission intensity was 0.47 metric tonnes of carbon dioxide per $1000 of GDP. (Charles Frank, 2016). By 2010, the emission intensity has reportedly reduced by 12%.

• UDAY Scheme Ministry of Power, Government of India in November 2015 launched a scheme for the State Electricity Boards (Electricity Distribution Companies), named as Ujwal DISCOM Assurance Yojana (UDAY). Objective of the 40 • December 2018

8.7

Figures in GW

Sources: @1. – Energy Statistics, 2018, CSO, MOSPI, GOI @2. – mnre.gov.in, accessed on 15.05.2018 (Physical Progress-Achievement)

scheme were to provide support for: a) financial turnaround, b) operational improvement, c) reduction of cost of generation of power, d) development of renewable energy and e) energy efficiency and conservation. Under the scheme, State Governments were to takeover up to 75% of their respective DISCOM’s debt by issuing sovereign bonds to pay back the lenders. So far, 32 States and Union Territories have become partner of the UDAY scheme. ` 2.32 lakh crores worth bonds have been issued to 16 States and estimated ` 2.69 lakh crores will be issued.

• International Solar Alliance International Solar Alliance (ISA) is open to 121 countries located between the Tropic of Cancer and Tropic of Capricorn, of which 61 countries have joined the ISA framework agreement and 32 countries have ratified it.

due to cooling effect on the panels and requires lesser installation time than conventional land mounted ones.

• Hybrid Solar and Wind Plant The Ministry of New and Renewable Energy (MNRE) has issued the national wind solar hybrid policy on May 14, 2018. The key objective of this policy is to provide a framework for promotion of large grid connected wind-solar PV hybrid system for optimal and efficient utilization of transmission infrastructure and land, reducing the variability in renewable power generation and achieving better grid stability.

Future Green Energy Initiatives

• Corporate Renewable Energy Leadership Corporate sourcing of renewable energy has become a global phenomenon and the market is growing, currently at 645 TWh in 2017 in 75 countries. There are 35 companies in India who have got into this mode. (IRENA, 2018 a)

• Floating Solar Plant India has started building floating solar plant as alternative to conventional ground mounted photo voltaic systems which are land intensive. It has benefits like conserving water through reduction of evaporation, increased generation

Mumbai metro committed to buy 50 MW in April 2018 from the solar plant to be set up in Dhule district of Maharashtra.

Delhi metro committed to buy power from the 750 MW Rewa solar plant in Madhya Pradesh. Microsoft in Bengaluru has signed to purchase 3 MW solar powered Chemical Engineering World

CEW Features Source

As on end March

34.0

Solar

2.5

4.9

8.1

12.3

21.6

19.1

Biomass @1 Waste to Power Small Hydro Total

4.01

4.45

4.88

8.83

9.36

5.35

0.11

0.13

0.12

0.11

0.14

0.03

3.8 31.5

4.2 38.8

4.3 45.1

4.4 57.9

4.5 69.7

0.7 38.2

Table 9: Grid Connected Renewable Electricity – Target vs Addition in Capacity electricity, which is 80 per cen of its electricity need for its office building, from Atria Power. Three companies have so far committed to be hundred per cent renewable energy powered; Infosys, Tata Motors and Dalmia Cement.

• National Bio Fuel Policy India had a national bio fuel policy 2009. A new national bio fuel policy 2018 has been approved by the Government in May 2018.

The policy that calls for usage and production of ethanol from damaged food grains and farm products has paved way for optimal utilization of agricultural waste to produce bio-power (1st, 2nd and 3rd Generation bio-fuel, bio-CNG).

It has also made provisions to convert waste/ plastic and municipal solid waste to fuel.

• Green Energy Corridor India commenced work on the ground its first green energy corridor project with an ultra-high-voltage direct current link over 1800 km passing through five States. The link is a key element of integrating renewable energy with main grid. It will integrate thermal and wind energy for transmission of power from high consumption centre located thousands of kilometre away, supporting electricity demands in the south (Pugalur in Southern State of Tamil Nadu) and transmitting clean energy to the central India (Raigarh), when there is excess wind power. The project is worth over ` 4,350 crores, partly funded by Asian Development Bank and is part of IndoGerman Energy Program.

42 • December 2018

Figures in GW

Contribute to CEW

Target 2022 60 100

CHRONICLING PROCESS INDUSTRY INNOVATIONS SINCE 1966

VOL.52 | ISSUE 12 | DECEMBER 2017 | TOTAL PAGES 92 | US $ 10 | ` 150

10 5 175

Source: @1 – Biomass & Gasification and Bagasse Cogeneration Author’s own record for historical data

• Electric Mobility India has all the compelling reasons to leapfrog into the electric mobility bandwagon that is out to disrupt automobile industry world over. India has expressed policy intent and has taken drive to fast forward the transition to electric vehicle.

Under Faster Adoption and Manufacturing of Hybrid & Electric Vehicles (FAME) scheme, Government of India subsidizes 60 per cen of total cost of an electric bus (each bus costs ` 1.7 to 2.5 crores) and has already sanctioned 390 buses in 11 cities (as on April 6, 2018).

Conclusion What emerges is that India has indeed embarked on the path of sustainable energy transition, very much in synch with global trend. However, the complexities of India’s socio-economic status and resource endowment have not allowed India to make a radical shift. Last four years have witnessed a massive thrust in right direction and results are visible in the form of green shoots.

Author Details

Dr D C Patra Fellow Energy Institute, London Chief General Manager, In-Charge, Planning, Bharat Petroleum Corporation Limited E-mail: patradc@bharatpetroleum.in

` 150

32.3

2018

Mumbai

27.7

2017

VOL.52 ISSUE 12

25.1

2016

DECEMBER 2017

21.1

2015

CHEMICAL ENGINEERING WORLD

Wind

Addition during 4 years 12.9

2014

GUJARAT - 2018

MUMBAI - 2019

23-25, January 2018 20-23, February 2019 Venue: Ahmedabad, Gujarat, India Venue: Mumbai, India

Dear Readers, Chemical Engineering World (CEW), the Official Organ of ChemTECH Foundation, is India’s premier technology magazine for the chemical process industry professionals. This highly reputed monthly publication provides novel insights on the dynamics of Indian and global process industries. CEW, a niche publication with proven track record, has been disseminating authentic information on process industry innovations for more than five decades.

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Vacuum technology in the chemical industry For many economic sectors, the chemical industry is an indispensable supplier of raw materials. The automotive industry, mechanical engineering, plastics, foodstuff, glass, or building materials industries, for example, are all reliant on substances that are produced by the chemical industry. Plastics or synthetic resins, which are used as the basis for coatings or foams, play by far the most important role. These are employed in a countless number of end products that we use daily. Vacuum technology is crucial for a large part of these applications in the chemical industry.

P

olycondensation is a chain reaction of small molecule compounds, or monomers. The functional groups of the monomers involved generally react by losing water and becoming long-chain molecules, or polymers. Accordingly, only monomers with at least two functional groups can create chains or networks. The product that is formed at the end of the polycondensation depends on the number and types of functional groups of the reacting monomer. During this process, vacuum technology is used in order to prevent unwanted byproducts of polycondensation. In polymer chemistry, polycondensation is one of the most important processes. It is used to produce plastics such as polyethylene terephthalate (PET), polyethylene or polycarbonate in large quantities. Adhesives are also produced with polycondensation as well as brake pads for automobiles.

Vacuum conditions in the medium vacuum range between 1 and 10 mbar are an essential part of the polycondensation process, especially in the production of highquality plastics. Together with temperature, vacuum technology steers the complete polycondensation process and significantly affects the resulting end product. Even the smallest fluctuations in pressure during the reaction can lead to damage of the end product or even render it unusable. The thermal load is reduced by vacuum during the process, especially with temperaturesensitive materials. Without vacuum, the production of certain plastics would not be possible; they would burn.

High-quality plastics such as PET, which the food industry uses to manufacture, among other things, millions of beverage bottles, must fulfil strict quality requirements. Those include a long life span and low diffusion in order to avoid leakage of carbon dioxide, for example. Vacuum technology guarantees high quality in the production of these plastics.

In order to generate the necessary vacuum 44 • December 2018

conditions, a multi-stage combination of Roots and liquid ring pumps is usually used. These must be exactly matched to fit the special requirements of the specific application. In the production of plastics, products that tend to stick and bake on to things are the order of the day. When configuring a vacuum system, it must thus be ensured that no process components leave deposits in the vacuum pumps. With its extensive product portfolio, Pfeiffer Vacuum offers diverse solutions that can be individually adjusted to suit the requirements of your specific application. The aforementioned combination of Roots pumps – in normal and gas-cooled versions – with liquid ring pumps has established itself as a reliable solution. Especially this combination of liquid ring vacuum pump and gas-cooled Roots pump contributes significantly to the stability of the process. Besides numerous advantages for the chemical industry, liquid ring vacuum pumps also carry a crucial disadvantage in their use. This is based on their dependence on a liquid, which can lead to the pump not being able to reach the specified pressure or pumping speed in case of contamination or temperature fluctuations.

These variations can be compensated by the gas-cooled Roots pump, as this pump principle is self-regulating. This is based largely on the formula:

p (pressure) x V (volume) = constant The ratio between inlet and outlet pressure determines how much cold gas from the heat exchanger is fed into the hot gas inside the pump. In this way, any differential pressure could theoretically be realized. Limiting factors are the size of the heat exchanger and the power of the engine. Both are specifically coordinated for each application Vacuum distillation Distillation serves to separate liquid mixtures of substances into their pure starting substances.

This can be achieved by simple heating at atmospheric pressure, as is done with alcohol distillation.

But not all substances can withstand high temperatures. With some mixtures, it can lead to chemical reactions or to disintegration of one or more individual substances. For all these applications, distillation under vacuum is vital. Unlike distillation at atmospheric pressure, vacuum distillation occurs under lowered pressure. This allows for evaporation already at lower temperatures. The basis for this is the vapour pressure curve of the respective substance. Water, which begins Chemical Engineering World

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inside the pump. In this way, any differential pressure could the theoretically be realized. Limiting factors are the size of the ffects heat exchanger and the power of the engine. Both are specifins in coordinated for each application e end CEWcally Features s redumperaDifferential pressure 1 : 2 Differential pressure 1 : 5 on of p = 500 mbar p = 200 mbar n.

V

V

V V V V

p = 1000 mbar

Polyisocyanates and vacuum Polyisocyanates are highly reactive organic compounds. They are divided into aliphatic and aromatic polyisocyanates. Aliphatic polyisocyanates act as cross-linkers between two-component polyurethane, which is used to make coatings and foams.

V

p = 1000 mbar

Figure 1: Functional principle of gas-cooled Roots pumps – illustration of the automatic regulation in relation to the differential pressure.

Figure 1: Functional principle of gas-cooled Roots pumps – -3 illustration the automatic regulation in relation the diffeto boil at 100OC of under atmospheric pressure, piston stages, a pressureto of 10 mbar can be reached without great effort.

The liquid can already boil at lower temperatures rential pressure.

O in a vacuum, for example at 90 C and approximately 800 mbar.

This makes it possible to carefully separate heat-sensitive materials from each other or those who would begin to break down at high temperatures. Vacuum distillation, for example, is used for separating oils, fatty acids, esters or monoglycerides. One of the most important areas of application is the processing of crude oil. During the refining process, the long-chain hydrocarbons of crude oil are separated with the aid of vacuum distillation. In this process, the mixture is heated in a container. A vacuum is generated at the condenser. With so-called short path distillation, medium vacuum conditions in the area of 1 mbar are created. In this way, the evaporation temperature is reduced significantly. If the pressure selected is even lower, the process is called molecular distillation. In this case, the mean free path length is greater than the distance between the vaporizer and condenser. This means that at a distance of approximately six centimeters between the vaporizer and the condenser, a pressure of 10-3 mbar is needed – and with an even larger distance, lower pressure is required, accordingly.

For short path and molecular distillation, Pfeiffer Vacuum offers a large selection of suitable vacuum equipment. In practice, Roots pumping stations with liquid ring pumps have established themselves as the ideal solution. Depending on the number of Roots

ring pump can also be operated by using the substance which is to be distilled. This way, none of the distillate can be contaminated with the pump’s operating fluid.

One example is the processing of rolling oil.

The oil contaminated by the rolling operation is reprocessed through distillation. For this, three-stage Roots pumping stations, consisting of two Roots pumps and one liquid ring vacuum pump, are used. As the operating fluid for the liquid ring pump, the rolling oil to be distilled is used. At a pressure of around 1 mbar, only the rolling oil evaporates and can be condensed out Pressure [hPa]

stry beveose void ology tics. In multisually requiof plaare the it must posits olio,

Polyurethane is used to produce a multitude of different end products. The targeted hardening of the substance at room temperature and the use of a special coating device allows for adjustment of the hardening period for the individual application. In this way, coatings in a production system, for example, can simply be mixed right when they are really needed. Polyurethane created with the use of polyisocyanates plays a large role in numerous production processes. As a foam, for example, it is used for furniture upholstery, as mattress foam, carpet backing material, cleaning sponges, or filter material.

Polyurethane as a foam is also used in vehicle construction, for example as a soft covering for handles, interior panelling, steering wheels or arm rests.

As a component in coatings and varnishes, polyurethane is characterized by good adhesive properties and high resistance against solvents, chemicals, and atmospheric influences. These are used in many

1200

also be oper led. This way the pump's o

1100 1013 1000 900 800 Liquid water

700 600 500 400

Water vapor

300 200 100 (6,1 hpa: 0.01 °C) 0

0

10

20

30

40

50

60

70

80

90

100

One example nated by the on. For this, two Roots p used. As the ling oil to be only the rolli again in the removed and the applicati liquid ring pu

Temperature [°C]

Polyisocyan Polyisocyana Chemical Engineering World are divided i phatic polyis ponent polyu Vacuum distillation foams.

Distillation serves to separate liquid mixtures of substances

2:and Separating and insulating low-molecular Figure Figure 2: Separating insulating low-molecular components through distillation. through distillation.

46 • December 2018

again in the liquid ring pump. In this way, contaminants are removed and the rolling oil can be used again. Depending on the application, dry backing pumps can be used instead of the liquid ring pump.

components

CEW Features Head restraints

Sun roof

Head-Impact Side-Impact

Roof liners, Hat rack Door panels

Seals, plain bearings, stabilizers

Foam filling of cavaties

Zusatzfedern, Achs- und Stützlager, Endanschlag (Clips)

Front and rear skirts, door sill scuff plates Arm rest

Stearing wheel, air filter

Acoustic form, carpet

Seats Gear shift knob Instrumet panel

Special cable sheating

Cable sheating

Bumpers Spoiler

Spring aids, Spring isolation Seat damping

Top mounts, roll restrictors, emergency wheel

Figure 3: Areas of application of polyurethane in the automotive sector,

Figure 3: Areas of application of polyurethane in the automotive sector,

applications,

including

floor

coatings,

The production of polyisocyanates takes

vacuum technology used.

PfeifferinVacuum textiles, leather, various materials shoe offers place complete in potentially explosive areas. For this ATEX-certified vacuum systems for the production polyisomanufacturing and in motor vehicle interiors. reason,of system operators often use vacuum cyanates. Most processes require a multi-stage construction Especially in the last area of application, products that are certified according to ATEX of the vacuum system. The experts at Pfeiffer Vacuum developolyurethane has become indispensable. directive 2014/34/EU. In order to cover all ped, for example, a six-stage system for a large German cheaspects of quality and safety in the process mical corporation consisting of five Roots piston stages and Vacuum technology is also operation, exact configuration according to one liquid ring stage.

Atextremely differentimportant stages of the process, diffefor thegas production polyisocyanates.

Following rent inflowsofare to be taken into consideration.

The requirements systhe specific of the respective the production of theaccording isocyanate,toa the multi-stage tem was created customer’s specifications application is necessary. distillation process ensures theparameters. highest possible and fulfilled all individual

of customer-specific solutions. Especially with regard to applications in the chemical industry which require a pressure of <30 hPa, the Roots pumping stations of Pfeiffer Vacuum’s OktaLine have established themselves as ideal solutions.

Depending on the required pumping speed and ultimate pressure, different pumping stages can be built in. They are available in gas-cooled or standard air-cooled versions as well as in different materials, for example, spheroidal graphite cast iron or stainless steel.

Specific coatings and coupling types are also available and can be combined for individual requirements. Liquid ring, rotary vane, screw, and gas-cooled Roots pumps can be used as backing pumps. Furthermore, ATEXcertified Roots pumps are also available for use in potentially explosive environments.

From conception to implementation, the experts at Pfeiffer Vacuum develop individual solutions together with customers from all different areas of the chemical industry.

These solutions are exactly designed for the requirements of the individual application.

concentration. Medium vacuum conditions of up

Gas volume flows are calculated based

Figure 4: Three-stage pumping station for destillation processes

Vacuum solutions for the chemical industry In order to create the necessary vacuum conditions for different Are applications, Pfeiffer you looking for a Vacuum offers a full, comprehensive range perfect vacuum solution?

Vacuum solutions forforthe to 0.05 mbar are required this.chemical industry on material data and flows in the process.

In order to create the necessary vacuum conditions for diffeThese serve as parameters for selection of rent applications, Pfeiffer Vacuum offers a full, comprehensive the appropriate vacuum pumps. Important range of customer-specific solutions. Especially with regard to include, besides safety, the applications in the chemical industry which requirements require a pressure durabilityVacuum’s and reliability of the vacuum of < 30 hPa, the Roots pumping stations of Pfeiffer technology used. Pfeiffer Vacuum offers OktaLine have established themselves as ideal solutions. complete ATEX-certified vacuum systems Depending on the required pumping speed and ultimate pressure, different pumping stages can be built in. are availa-of polyisocyanates. Most for They the production ble in gas-cooled or standard air-cooled versions as well as ina multi-stage construction processes require different materials, for example, spheroidal graphite cast system. iron of the vacuum The experts at Pfeiffer or stainless steel. Specific coatings and coupling types are Vacuum developed, for example, a sixalso available and can be combined for individual requirestage systemRoots for a large German chemical ments. Liquid ring, rotary vane, screw, and gas-cooled corporation consisting of five Roots piston pumps can be used as backing pumps. Furthermore, ATEXstages and one liquid ring stage. At different certified Roots pumps are also available for use in potentially of the process, different gas inflows are explosive environments. From conception tostages implementation, to be taken into consideration. the experts at Pfeiffer Vacuum develop individual solutions Figure 4:The system together with customers from all different areas the chemipumping station was of created accordingThree-stage to the customer’s cal industry. These solutions are exactly designed for the and fulfilled for destillation processes specifications all individual requirements of the individual application. parameters.

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48 • December 2018

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Chemical Engineering World

CEW Features

Integrated Engineering, Operations and Asset Management are Vital for Chemical Industries This article discusses improving return on chemicals assets using integrated engineering, operations, maintenance and compliance management.

C

hemical industries are diverse in terms of products and processes, and the nature and state of the assets. In the developed world, assets are on average older, intrinsically less reliable and efficient, but in these regions companies have the highest skilled personnel and most advanced methods in place to compensate for it. The regular economic cycles in petrochemicals and polymers have been replaced by irregular, more regional economic ups and downs, with high amplitude. The high growth in developing Asia is slowing down significantly. The oil and gas boom in North America has created growth in the chemical industry in the region in the recent years. The recent drop in oil price has created economic relief for chemical producers globally but demand may suffer because of the economic slowdown. The best strategy for the future is likely one of high flexibility and adaptability to react to global and regional market fluctuations, product innovations, feedstock costs and regulations.

Necessary Steps A first step is to reduce the cost of assets throughout their lifecycle. This includes effective engineering, leading to more flexibility and lower cost designs that can be operational more quickly.

Engineering and design costs can be reduced by make information transparent across disciplines, regions, offices and sites and easier to reuse. Sharing and transparency must be extended across the enterprise borders to engineering, procurement and construction firms (EPC’s), subcontractors, to achieve tighter collaboration.

Collaboration 52 • December 2018

during design and construction has significantly increased during the past years, and as contractors provide more and more services for plants in operation too, it is expected that the importance of efficient cross-enterprise collaboration will further increase.

Companies that have pioneered these new practices, report increased engineering productivity, improved handover, accelerated operational readiness, reduction of regulatory compliance cost, reduced maintenance costs and improved reliability

Compliance of processes and equipment can be efficiently handled when requirement engineering is electronically linked to qualification processes.

Information should also be reused across engineering, operations and maintenance within the corporation, and by their subcontractors. As all stakeholders work on the same asset, they should all work off the same asset information to coordinate and optimize their plans and actions.

This concept is referred to as integrated engineering or integrated operations.

Asset Management Challenges

In a second stage, these efficient processes can be applied to more productive and flexible process designs using intensification, modularization, and mobile processing units.

Accurate asset information requires a state-of the art application and data repository that must be complemented by processes for keeping asset information up-to-date. People must be trained and motivated to use them. When these key success factors are in place, operations and maintenance can be optimized, to sustain a compliant and reliable asset at the lowest cost and with the lowest inventory of spare parts. This includes modern asset management strategies, such as predictive maintenance and condition monitoring, and the simultaneous optimization of asset capabilities and production requirements.

The chemical industry and, depending on the various characteristics. distinguish the following

is very diverse region, features We can broadly categories:

• Aging, commodity producing assets.

These are most likely to be found in advanced economies, and need to be operated and maintained at the lowest operating cost possible. At the same time, they need to operate reliably, safely and be compliant with regulations. Asset information is at risk of being dispersed on paper and in various systems.

• Recent for commodity assets products using classical, mostly continuous process technologies.

These assets are mostly found in growing economies, for example in South-East Asia, but also in the USA. Asset information is more likely to be available in electronic format.

Reliability, safety and compliance are likely to be satisfactory, but need to be maintained.

• Assets for specialty chemicals, specialty polymers, agrochemicals, food and pharmaceutical ingredients, mostly using traditional batch processing. The products have a high innovative content, and plants are regularly adapted and reengineered, or have been recently constructed. In Chemical Engineering World

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these cases, it is likely that electronic asset information is available.

Regulatory compliance is an increasing cost factor.

responsible for the plant’s performance and regulatory compliance at startup, they require design reviews in electronic form as well as the tracking of construction and commissioning progress against electronic documents.

More and more qualification processes use electronic design and requirement documentation, with electronic sign-offs.

• In existing plants, when engineering or maintenance troubleshoot an operational issue or need to start a modified project, they first spend time – sometimes weeks or months - to find out the actual status and performance of equipment and piping, the available or missing spare parts, etc., before starting their actual work.

Further time is lost in ordering missing parts or equipment, increased time to repair, and multiplying travel times.

In other cases wrong or excess parts are available, which increase working capital without benefit. Incomplete, inaccessible, and inaccurate asset information therefore leads to a longer project duration, longer “mean time to repair” (MTTR), higher operational and capital expenditure than necessary.

Compliance costs increase, or compliance becomes impossible as accurate information cannot be

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• From an and asset 2: 5!2//5& !#%engineering =) 7> 2&# ) %!& ) !> 2'traditionally 5!* 5&& 57!$ 5, #/#) %/F!!! handed over on paper, and information management perspective, a number of challenges can be distinguished.

• In plants under construction by engineering procurement and construction firms (EPC’s), owneroperators (OO’s) require a tighter collaboration than before.

Being 54 • December 2018

is often incomplete or outdated at the moment of transfer. NIST estimates that the cost of information losses during handover to be 1.8 percent of capital expenditure. There is a huge opportunity to improve the process by making it electronic, and make sure the information is reused.

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CEW Features produced at any point in time. NIST estimates the cost of information losses in the operate-maintain phases of the asset to 2.4 per cent of the capital expenditure cost, higher than the cost of losses during handover.

Chemical plants are usually part of large industrial complexes, where plants, and utilities and storage facilities are distributed over the premises. It is a real challenge to keep track of the asset state, as operations, maintenance and contractors work independently on the same assets.

These challenges imply that it is not a trivial task to obtain a complete, accurate and up-to-date virtual image of distributed assets, easily and rapidly accessible to office and field workers throughout a vast geographical area.

The different types of assets have partly different regulatory obligations, but for all of them regulatory pressure is increasing and will continue to increase in the future. The spirit of these regulations tends to evolve from describing the means for protection into a responsibility of the owner-operator to be able to demonstrate performancebased quantitative risk management.

Whether asset information is built up during engineering and construction, or by operations and maintenance of an existing installation, in the end there is always an installation in operation that undergoes maintenance activities and engineering projects related for reasons of improvement, troubleshooting or debottlenecking.

As a result, two or more organizational entities work on the same assets, using – ideally - the same asset information: engineering to design changes and improvements; operations and maintenance for day-to-day activities and long term asset management. To streamline the collaboration between those entities, the concept of “integrated engineering” was created.

56 • December 2018

The “Integrated Engineering” Concept In 2005, Dr Thomas Tauchnitz published a vision for “integrated engineering” (Tauchnitz, 2005), based on three basic principles: “[…] every information is generated and maintained at only one location, existing knowledge is reused where possible, and the software tools stay interfaced while the production plant is in operation.” He sketched the workflow as starting with process design followed by the transfer of the resulting process information to an engineering software tool, common to all engineering disciplines involved in frontend and detail engineering. To increase engineering efficiency, he proposed to implement modular engineering – using standardized, generic engineering modules comprising all functions built and maintained within the common tool.

Many plants apply a wide variety of control systems. To further increase engineering efficiency, control engineering should be done at a generic level, enabling reuse of designs. The designs can be used to configure systems, and compile the generic designs within different DCS brands.

The next step is the transfer of the engineering information to operations and maintenance and keeping it up to date with the goal to transform “as- built” information into “as-maintained” information to ensure accuracy and save time.

Therefore, “integrated engineering” incorporates different disciplines during design and build stages, and also integrates engineering, operations, maintenance and automation during operate and maintain stages of the installation life cycle.

Finally, the vision includes the implementation of standardized processes across the extended enterprise, reducing the number of systems and interfaces, and organizing centralized maintenance and support and promoting company-wide knowledge management.

In the case of maintenance and improvement projects related to automation and instrumentation, seamless, bi-directional integration with automation systems simplifies the changes to the automation systems significantly, by enabling the configuration of the control system directly from the design in the engineering tool. Vice versa, when a control system configuration is changed in the field, the control system would automatically update the application with the actual control system configuration.

The NAMUR standard NE 150 enables doing this in a standardized manner.

Collaboration between internal or external engineering departments and maintenance (and/or operations) may occur during these projects or changes.

It is of utmost importance that the stakeholders work off the same, up-todate asset and engineering data. This has important benefits for engineering and modernization projects by simplifying the work, unloading personnel, while guaranteeing accurate and up-to-date asset information.

It creates even more benefits by saving engineering work when the same changes need to be applied to several sites. Many standards are available for this complex domain. ISO 15926 is the most wellknown, standardizing the equipment specification.

Author Details

Valentijn de Leeuw Vice President ARC Advisory Group, Europe Chemical Engineering World

CEW Features

Are M&As Shaping the New Road Map for Chemical Industry?

Merger and Acquisition activity has significantly shaped the chemical industry landscape in the recent past, and it will continue to do so. Chemicals companies are constantly in quest of growth in an industry that offers ever-fewer and ever-smaller attractive growth segments and where incumbents face greater competition from upstarts in developing markets. This article try to analyze how the mergers and acquisitions poised to reshape the industry.

T

he chemical industry in India is the third largest producer in Asia and sixth largest in the world. According to the Department of Chemicals and Petrochemicals, as of 2017, the domestic chemical industry’s size is pegged somewhere between USD 150-155 billion, accounting for 2.1% of the country’s gross domestic product (GDP) but only a little more than 3.4% of the global chemical market.

With more than 80,000 chemical products being developed for either directly or indirect consumption for almost all the other sectors, the chemical sector is highly diversified. Besides the obvious petrochemicals, agrochemicals, specialty chemicals and fertilizers, other sectors such as pharmaceuticals, textiles and paints offer a huge market opportunity too in India. Hence, the chemical sector is instrumental for the overall economic development of the country.

the market as even more players make plans to enter the Indian market.

Faced with many handicaps like lesser funding than their foreign counterparts and intense domestic competition, local chemical companies continue to survive though with slim margins. As the global economic order awkwardly shuffles along with low growth volumes, the hypercompetitive environment continues to throw many new challenges.

Sluggish sales volumes in the industry clocked low growth rates in 2016 riding on the wave of a severe shortfall in industrial production and a large-scale optimization of inventories by their customers.

Petroleum-based products were worse hit in particular recording a lower-than-normal industry average.

The government itself expects the chemical industry to double in size to over USD 300 billion by 2025, clocking an annual growth rate of nearly 8-10 percent. According to leading market players, plans to introduce a new policy to promote the domestic industry and curb imports are already in motion.

In a bid to maintain sustainable production levels and take home encouraging profit margins in the face of weakened industry fundamentals, chemical companies are proactively exploring inorganic growth avenues such as mergers and acquisitions.

The limitations of organic growth are in fact forcing firms to look at strategic mergers and acquisitions (M&As) as a viable way forward for sustaining high valuations.

Taking all these factors into account, the domestic chemical market shines bright as a lucrative space to invest. Bundle these with a significantly lower cost of labour, easy availability of key raw materials, a large consumer base and the potential to scale-up with the adoption of technology, it becomes too good an opportunity to give it a miss for both existing and aspiring players. A number of local and MNC firms are already vying to get a larger share of

Most firms take the plunge keeping scalability as the central motivating factor for their growth plans. A consolidation of product offerings not only enables the players to leverage organisational synergies, but even allows them to explore previously unexplored business areas, which are in line with their long term objectives. The restructuring of the merged DuPont and Dow entity is a perfect example of this.

58 • December 2018

A flurry of inbound and outbound deals have taken place. Larger corporations abroad have made big tickets purchases to enter the promising Indian market.

Huntsman Corporation, an American chemicals major acquired Gujarat-based chemicals producer Laffans Petrochemicals in 2010. This gave quick access to Huntsman to implement their technology and expertise in the Indian market. The company’s plant at Ankleshwar became an integral part of Huntsman Performance Products, giving the group its first dedicated production plant in the country.

The pull of the Indian chemical sector as a strategic investment for foreign investors was further strengthened with the Japanbased Nihon Nohyaku Co. Ltd acquiring a majority of 74% stake in Hyderabad Chemical Ltd. in 2014. This gave the firm an opportunity to utilize the agrochemical manufacturer’s own distribution network and research and development function.

Another notable example of a foreign firm making a quick entry into the Indian market is the acquisition of Monarch Catalyst by the German specialty chemicals maker Evonik Industries in June 2015. Abroad, Evonik has a presence in almost 100 countries, serving life sciences and fine chemicals, industrial and petrochemical market segments. The acquisition allowed Evonik Industries to hit the ground running.

Balance sheets of companies and investment decisions also play a vital role in influencing M&A deals. Caught between steep investor expectations and frequent lull periods in demand, companies are increasingly turning Chemical Engineering World

CEW Features to M&As to ensure uninterrupted business operations and sustainable profitability.

In 2016, The Chatterjee Group (TCG) picked up a majority stake in Mitsubishi Chemical Corporation’s (MCC) Indian unit in Haldia, West Bengal for an estimated $48 million which gave TCG management control of the ailing company. TCG bought a 90 per cent stake in the company with MCC retaining limited shares. The MCC PTA had been making losses for several years as revenue had declined due to cheaper imports from China. The Competition Commission of India cleared the acquisition, giving MCC a second lease of life.

The lure of increasing export revenues and acquiring technical expertise potent factors for Indian firms to scout for partnerships abroad.

The number of Joint Ventures too have picked up pace. For example, Pidilite Industries Ltd., a maker of adhesives, construction chemicals, consumer

adhesives, sealants and specialty chemicals, entered into a joint venture agreement in 2016 with the Italy based Industria Chimica Adriatica Spa (ICA), a leading wood finish manufacturer. Pidilite holds 50% of the shareholding in the JV and the balance is held by ICA and Pratik Mehta, an Indiabased distributor. Such joint ventures with foreign firms will help all sides to scale their business operations and tap new markets with specialized products. Though valuations have soared, many companies continue to pursue M&A as a strategy to achieve growth and spur innovation.

Reference 1. http://www.moneycontrol.com/news/ business/economy/government-saysindias-chemical-industry-to-hit-300billion-by-2025-2449457.html 2. https://m.businesstoday.in/lite/story/ indian-chemical-industry-will-mandabe-a-game-changer/1/252784.html

Author Details

AVA Chemicals has been formulating and providing premium-grade chemicals to national and international clients in over 20 countries. In time, has progressed to become an accredited supplier of organic and inorganic chemicals in bespoke compositions and is recognized as a leading producer of various grades of different Fine Chemicals besides chelating agents. With a solid value chain in place, AVA Chemicals is open to explore JV’s and new business opportunities.

Viejay Bhatia Director AVA Chemicals Pvt. Ltd Email: exports@avachemicals.com sales@avachemicals.com

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CEW News Features

Environmental Protection through Greenhouse Gases?

From exhaust gas to raw material: intelligent technologies reduce emissions of carbon dioxide and give benefit to the environment and plant operators. Using CO2 as a raw material is a great way for the plant operators to save the feedstock cost, increase efficiency and reduce greenhouse gas emissions. Due to low operating costs and low maintenance requirements it is possible to reach a return on investment (ROI) after a short time.

A

lthough one of the main objectives of the Paris climate agreement of 2015 is to reduce global greenhouse gas emissions, according to the International Energy Agency (IEA), emissions have increased since 2017. Industrial activities are one of the largest generators of carbon dioxide (CO2) discharged as exhaust gas hence also considered as one of the biggest pollution factors. In particular, carbon dioxide can be recovered from industrial processes and recycled to be reduced in the atmosphere. This is an important advantage for the environment.

But the industry also profits in various ways by recycling CO2 from exhaust gases.

In fact, the infamous climate killer could become a valuable raw material, as a feedstock for chemicals or for use in food and beverages.

All these processes, as different as they are, have one thing in common, they can only be sustainable, if carbon dioxide is recovered from industrial processes and recycled to be reduced in the atmosphere.

“The mere emission of CO2 in form of exhaust gas does not only pollute our atmosphere, it also loses cash,” says Corinne Ziege, Managing Director of Cryotec Anlagenbau GmbH, a subsidiary of EPC Group. The Wurzen-based company specialized in technical gases, has been planning and building plants for air separation and treatment of process exhaust gases since 1995. She notes, “The fact that Germany is about to miss its climate goals illustrates the potential of CO2-utilisation.

We have to find solutions which are both sustainable and economically viable.” While undertaking any project the company takes a pragmatic approach starting with the very basic steps of identification of task at hand, source of CO2 and the purity required. Following this, the engineering know how comes into play to connect the available building blocks.

CO2 Applications There are two particular applications for carbon dioxide. First of all, it can be inserted directly into greenhouses where it is utilized as a natural fertilizer thus leading to considerable increases in profitability.

Furthermore, this can be reused as a raw material, as it is often the case in methanol production plants. The carbon dioxide is filtered out from the exhaust gas, cleaned in several steps and compressed. Depending on requirements, this is either recycled directly as a gas or after subsequent liquefaction. This is a great way for plant operators to save raw material costs while increasing the efficiency of plants and reducing greenhouse gas emissions. Due to low operating costs and low maintenance requirements it is possible to reach a return on investment (ROI) after a short time.

A further popular method for recycling CO2 is the production of dry ice. For the production, carbon dioxide is separated from the exhaust gas and then purified and liquefied. The liquid

64 • December 2018

CO2 is then expanded to ambient pressure and partially evaporated. The energy required for evaporation is extracted from the liquid CO2, which leads to freezing and the final product: dry ice. The frozen CO2 is then pressed into block or pellet form and is ready for use.

Dry ice offers a wide range of applications within the food industry, e g refrigeration of fish, meat or beverages, for entertainment events whenever a fog effect is needed. Dry ice is also used for medical transportation of sensitive products such as organs or blood. In the industry it is used for cleaning of sensitive surfaces by dry ice blasting, for refrigeration of technical equipment and machinery and for metalworking.

Dry ice has a constant temperature of -78.5OC (-109.3OF). It doesn’t melt but evaporates residue-free. This is where the term “dry ice” comes from. Also, it is non-toxic, odor- and tasteless and prevents and even inhibits bacterial and fungal growth. Due to its extraordinary properties, dry ice offers a various range of applications. In comparison to the achievable profits from the sale of dry ice, the costs for the construction of a dry ice plant are moderate and can be amortized within three to five years. Dry ice is already an established coolant of the future and there is lot of interest in private investors in construction of dry ice plants.

CO2 Liquefaction plants in Australia Cryotec Anlagenbau GmbH is erecting two similar plants for production of dry ice with simultaneous CO2 recovery each with a capacity of 600 kg/h for customer in Australia.

By optimizing the manufacturing process, the CO2 is liquefied and thus fed back into the production cycle. The innovative technology solutions of will enable a considerable increase of the profitability and efficiency of dry ice production. For worldwide delivery, before the final installations, skid-mounted systems go through rigorous process of inspection. Cryotec provides fast commissioning at customer’s site by using the plug & play principle.

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The economic value of steam flow measurement

L

ast month we considered the economic value of steam flow measurements. Liquid flows are typically more common, so let’s take a look at an example of their economic impact here.

Assuming the average liquid flowrate is one kg/min valued at ` 20.00 per liter operating all year, the flowmeter would pass approximately `175,200 of liquid per year (1 liter/min * 60 min/hr * 8760 hrs/yr * ` 20.00/liter).

Think about this for a minute … a small flow of a reasonably priced liquid results

in over ` 200,000 of liquid passing through the flowmeter each year. In custody-transfer applications, purchasing a flowmeter that performs 1 per cent better can reduce the measurement error by ` 2000 per year. This value is much larger in many custody-transfer applications, so reducing the magnitude of flow measurement error can be used to justify better (and more costly) flow measurement devices.

While justification for improved (and more costly) flow measurement devices is relatively easy in custody-transfer applications, how many times have you

had to fight (tooth and nail) to purchase a more expensive flowmeter for process applications? Did you ever calculate the value of the material passing through the flowmeter? You might be surprised with the results.

For example, a flowmeter operating year round at 100 liters per minute will pass over $25 million of liquid per year if the liquid is valued at ` 40 per liter. This may not be economically important in many process applications, such as recycle, cooling, or spray flows where the flow need only be higher than a minimum value. However, it can be of extreme importance in other process applications, such as reactor feeds, where addition of the proper amounts of reactants can drastically affect chemical reactions, process yield, and the economics of the operation.

The majority of process flow measurements typically fall between these two extremes and can exhibit a detrimental effect on process economics. For example, the flowmeter detailed here might be the slave process variable in a cascade level control. There could be a discussion as to whether to buy a flowmeter for $2700 or a superior flowmeter for $3300. Put in another perspective — should one spend an additional $600 to better measure $25 million of liquid per year?

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Chemical Engineering World

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Choosing the Right Vacuum Pump - A Range from Toshniwal House

W

hat’s the best vacuum pump? is one of those questions that can only be answered with another question such as, What are you trying to do? That’s because the real answer is that there is no best pump, and there is no worst pump. The best pump is, and always will be, the pump that does the best job at what you need it to do. Although that answer might seem to be obvious, the question continues to arise. It seems to arise due to the common human need of finding the answer to a problem. A team of experienced technical Toshniwal engineers are ready to solve your problem.

This is especially true when considering vacuum processes and vacuum pumps. There is no single type of pump that will provide all the attributes necessary to meet any and all process requirements. Although the available varieties of pumps seem to present a puzzling collection of choices, the best choice becomes more and more apparent as you go down the list and remove the pumps that will not meet your process requirements. This requires a careful analysis of your process and its pumping needs before you begin the elimination sequence. There are a number of important considerations to keep in mind when boiling down to the final and best choice for your process. Obviously, you need to consider the pump’s ability to produce and maintain the ultimate pressure your process requires. The pumping speed vs pressure curves usually supplied in the various manufacturer’s literature need to be carefully considered and compared.

The pump must have enough pumping speed to easily achieve and maintain the ultimate pressure required, etc.

All of these points can be garnered by a careful reading of the manufacturer’s data sheets and consulting the experts of vacuum pumps system manufacturers.

As the field narrows, the time arises to begin to look at the economic aspects. Although the purchase price is important, you should think carefully about “cost of ownership.” These include operating costs, maintenance cycles and costs, consumables, etc.

Roughing pumps are required by any vacuum process when it is necessary to reduce the pressure within the chamber from atmospheric pressure. All roughing pumps tend to have their highest pumping speeds at or near atmospheric pressure. As the pressure is reduced by the pump, efficient pumps such as offered by Toshniwal do not decline in their pumping speed. Vacuum pumps that suck 20 per cent more volume than other single stage pumps, therefore allowing the use of pumps with lower capacity are available in the market and are some of the most efficient ones.

Pumps with water liquid ring are also often used to avoid condensate but in this case there are great user inconveniences: Electrical energy consumed by watering vacuum pumps are 40 per cent higher than multi-vane oil lubricated vacuum pumps; Maximum achievable vacuum is 92 per cent unlike Toshniwal’s that is 99.95 per cent.

The ultimate pressure is of course important.

This can be clearly understood by the pump down curves the manufacturers provide in their data sheet.

There are various types of roughing pumps: • Oil lubricated vacuum pumps • Oil-less vacuum pumps An example of the graph of pump down curve is given below comparing oil-sealed manufacture oil-less vacuum pump of a different manufacturer and a liquid ring vacuum pump.

The oil-lubricated vacuum pumps works on the principle of a very small amount of oil being injected in the stator which acts as a sealing medium and lubricant. There are generally 3 or more vanes rotating at high RPM creating a centrifugal action without any springs internally.

Even though as perceived by many that an oilsealed vacuum pump cannot tolerate vapour, these pumps as they operate from 80 to 120oC can work effectively even under water vapour load. The subject of water vapour, in terms of processes, breaks down into two major segments. In some cases, the process itself is to remove water vapour. Examples would be such processes as vacuum drying of materials. Processes that are designed to remove water from materials will, obviously, result in extremely high gas loads of water vapour that result in a pumping problem that is traceable to the gas laws in that it is necessary to compress the vapour in order to pump it away. Compressing a condensable gas causes it to liquefy whenever it is compressed beyond the critical point. In some cases, steam jet or water ring pumps that are able to easily deal with condensate are used, but they are limited in the ultimate vacuum levels they are able to produce and very high power consumption factor. If the drying process requires that lower ultimate vacuums be achieved at the end of the process, oillubricated vacuum pumps can be used.

The new generation oil-lubricated vacuum pumps can replace a liquid ring vacuum pump for better efficiency and better vacuum.

A better understanding of the practical worka-day performance of vacuum systems can provide a better choice of pumps, pumping speeds and pump installation techniques.

Once the possible choices are narrowed down through whatever sorting stages are

68 • December 2018

Chemical Engineering World

CEW

Marketing Initiatives and that choice should not require any compromises.

Questions to ask while choosing a pump: • What ultimate pressure is required?

• Do the pumping speed vs pressure curves match the process requirements?

• Can the pump be installed easily on the system?

• What maintenance requirements or problems are there?

• What will the cost of ownership be? required, the particular choice of the actual pump becomes more and more important.

Comparing vendors can be a complex task.

Always keep in mind that the field of vacuum technology contains more opinions than facts and it becomes essential to talk to a number of people who are actually using a particular pump to collect their opinions. Only then should you attempt to reach that final and crucial decision. After all, you will have to live with that choice. Going carefully through the decision-making process described here will get you closer to the best choice for your process, but remember that there is no best pump. There is only the best pump for your process, installation and expectations,

Vacuum technology frequently makes it possible to replace processes that harm the environment with others that protect the environment. This is true of vacuum pumps and other vacuum components such as measuring devices and leak detectors, which are involved in many industrial applications.

These include, among others, • Vacuum packaging of food • Evacuation and environment-friendly charging of refrigerators and air-conditioners • Production of ultrapure high-strength metals • Manufacture of flat-panel displays • Evacuation of lamps and picture tubes • Chemical drying process • Distillation

Over three decades of expertise in vacuum technology, we offer tailored solutions ranging from individual products to a complete system. Toshniwal's vacuum products play a vital role in a vast range of technologies.

Toshniwal are the manufacturer and supplier of vacuum pumps, vacuum systems and roots pumping system for specific segments in the industry. Toshniwal owe their recognition competence as service providers with their own manufacturing facilities and as partners of high-tech manufacturers all over the world to the innovative methods with which they satisfy the highest precision and quality demands.

Expert, efficient and effective engineering study work is fundamental to success of any project, especially at the conceptual stage.

The services provided by Toshniwal meet all these criteria to produce practicable, operable and cost-effective engineering solution.

Toshniwal designs combine cost saving and low maintenance schedules to maximize client’s benefits. Toshniwal understands the importance of establishing and agreeing to the objectives of the customer before they begin to operate or suggest a solution. That is why Toshniwal always work very closely with their customers.

Service & Support

Toshniwal provides support not only as solution provider but also support the customers for after sales service: • • • • • •

Cost-effective Reliable Genuine spare parts supplier Service center Field service All periodic services like changing of parts and oil top up when required.

• Annual maintenance contract.

For details contact: Toshniwal Instruments (Madras) Pvt Ltd

267 Kilpauk Garden Road, Chennai 600 010 Tel: 044-26445626, 26448983 E-mail: sales@toshniwal.net Website: www.toshniwal.net 70 • December 2018

Chemical Engineering World

CEW Products Mass Flow Controller

Solid State Relay

The mass flow meters and controllers consist of a metal body with a straight through flow path. Two sensors are encased with stainless steel and protrude inside this bore; one is designed as a heater and the other is designed as a temperature probe.

The working principle is based on King’s law of the ratio between the mass flow and the heater energy. That means the higher the flow, the more energy is required to maintain the chosen.

Features direct inline measurement principle; usable for virtually every kind of gas or gas-mix; mass flow measurement and control for a wide scope of applications; compact and robust design; IP65 for full product range; sensor made of stainless steel; no inlet pipe required; measurement without moving parts; customised adjustable multi-functional display: actual flow, totaliser with memory and reset, alarm, setup and much more.

For details contact: Toshniwal Hyvac Pvt Ltd 267 Kilpauk Garden Road Chennai 600 010 Tel: 044-26448558, 26448983 Fax: 91-044-26441820 E-mail: sales@toshniwal.net

Solid state relay (SSR) used in numerous application where electro-mechanical relays together with protective components used to be installed in power semi-conductor devices with corresponding protective electronics circuits so-called solid state relays are used. SSR does not incorporate any moving parts in the load switching circuit and is insensitive to shock and vibration. The applications include controlling of temperature in electric ovens, plastic processing system, injection moulding machine, packaging industry, electro systems, heating application, furnace, traffic lighting controls, etc. These are available in DC-AC (input DC and output AC) in single-phase as well as threephase versions up to 250 A, AC-AC version in single-phase as well as three-phase up to 175 A, linear voltage control version up to 150 A, linear current control 4-20 mA version up to 100 A, DIN-mounted SSR relay module up to 36 relays having current rating up to 5 A, and PCBmounted DC-AC as well as AC-AC relay up to 5 A. DIN-mounted heat sink suitable for all types of SSR for heat dissipation are also available.

For details contact: MRK Engineers 15/1A2, Plot No: III, Lakshminagar Ramamoorthy Street, Moondramkattalai, Chennai 600 128 E-mail: ramakrishnan252008@yahoo.com

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Double-sided Rotary Press The tablet presses in the Romaco Kilian K Series are specially tailored to the needs of the Asian market. The K 720 double-sided rotary press was configured by Romaco Kilian for the production of mono and bi-layer tablets and can be switched flexibly between the two operating modes. This high speed press has a max output of 1,000,000 tablets per hour. The technology is used both in the pharma industry and in the non-pharma sector, and is particularly suited for compressing effervescent tablets, nutraceuticals and drug store items. The systematic reduction of product loss was a top priority when Romaco Kilian developed the K Series. Amongst other features, this is achieved by means of product scrapers, which are in constant contact with the die table surface due to magnetic force.

Targeted measures to improve the Kilian K 720’s productivity, availability and quality have simultaneously increased its overall equipment effectiveness. External fill shoe gears enable a lower process temperature, which is an advantage with temperature sensitive products. Patented bellows result in higher product quality by preventing so-called black spots on the tablets. Punch brake magnets, likewise patented, ensure constant braking forces and a small standard deviation of the tablet weight. The hermetic separation of the tablet press process area from the changeover and service areas moreover restricts cleaning to a minimum and extends the production time of the Romaco Kilian K 720 rotary press.

For details contact: Romaco Group Am Heegwald 11, 76227 Karlsruhe, Germany Tel: +49 (0)721 4804 0, Fax: +49 (0)721 4804 225 E-mail: susanne.silva@romaco.com or Circle Readers’ Service Card 03

72 • December 2018

Chemical Engineering World

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CEW Products IR Sensor Safety Guard

Rollon Slide Rings/Wear Rings

Safety light curtains are developed based on micro-controller technology for safe protection of hands, fingers and body parts whilst working on the machine. These are available in parallelbeam and cross-beam types. Safety guards are used for preventing injuries whilst working at power press for metal, processing machine for wood, plastic, leather, rubber, glass, etc, filter presses, folding or bending machines, robots, processing line, welding press, inserting machine, peletizers, handling and storing system, SPM, rubber moulding machine, injection moulding machine, etc. These are available in 4, 6, 8, 10, 16, 24, 32 beams with protected height of 90 to 1,710 mm. The response time of cut on is 10 to 15 milliseconds and easily connected with 230 V operating systems as well as directly connected with PLC system.

Rollon slide rings are used as bearings for reciprocating, oscillating moved piston rods and pistons in hydraulic cylinders, pads in booms of cranes, etc. Rollon slide rings are bronze-filled PTFE material with special wear additives with excellent wear-resistance and form stability.

For details contact: MRK Engineers 15/1A2, Plot No: III, Lakshmi Nagar Ramamoorthy Street Moondramkattalai, Chennai 600 128 E-mail: ramakrishnan252008@yahoo.com or Circle Readers’ Service Card 04

The advantage of slide rings produced as strip, they can be installed in closed grooves and that they permit the pressure medium to pass unimpeded through the gap to the sealing cavity.

The open slide ring can as well compensate for expansion caused by temperature changes in the system.

For details contact: Rollon Bearings Pvt Ltd Shah Sultan Complex Cunningham Road Bengalurure, Karnataka 560 052 Tel: 080-22266928, 22250287 Fax: 91-080-22250319 or Circle Readers’ Service Card 05

Handles & Levers Industrial design not only makes products more appealing to the eye, it also enhances their value as a whole. Design optimizes ergonomics and functionality, which Elesa+Ganter shows with its GN 126 adjustable flat tension levers and its GN 328 cabinet “U” handles and GN 428 machine handles.

Thanks to their modern form, these standard elements are ideally suited to the appearance of modern machines and systems. In this way, details such as handles and levers can be implemented with the same high level of design as the machine itself, regardless of the batch size. The option of customizing size or colour in a simple yet cost-effective manner further enhances the possibilities for use. Internal recessed grips and exact edge rounding ensure noticeably improved ergonomics.

The GN 126 adjustable flat tension levers are characterized by their dynamic shape, produced by zinc die-casting and finished with a plastic coating, and are ideal wherever pivoting ranges are limited. The integrated serration allows for the position of the handle to be adjusted without having to loosen it. If required, the same GN 126.1 shape is available with a completely stainless steel interior.

The GN 328 and GN 428 cabinet “U” handles and machine handles are made of cast aluminum or a bent aluminum profile and are also available with different surface finishes. For applications in particularly corrosive environments, the GN 328.5 cabinet “U” handles are also available in stainless A4 precision cast stainless steel.

For details contact: Elesa and Ganter India Pvt Ltd A-54, Sector 83 Noida, Uttar Pradesh 201305 Tel: 0120-4726666 E-mail: info@elesaganter-india.com or Circle Readers’ Service Card 06

76 • December 2018

Chemical Engineering World

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CEW Products Submersible Pumps

Versatile O2 Analyser Range with Multiple Options

Slurry revival is an essential part of day to day operations in a wide range of industries, such as mining, ore dressing, sand contracting, ash handling and steel milling. The applications in these industries make heavy demands on slurry pumps, particularly in terms of the cost incurred when it comes to wear and tear, repairs and maintenance. In Ni-HARD Series of pumps the wet end, indeed all wear parts, are made of Ni-HARD which provides complete wear protection.

It features unique non-depleting technology for long term stability and ease of maintenance; unique measurement stability allowing SPAN calibration only once a year; and unique Stab-EI acid gas alarm option neutralises trace contaminants.

For details contact: MBH Pumps (Gujarat) Pvt Ltd Plot No: 14, GIDC Naroda Indl Estate Ahmedabad, Gujarat 382 330 Tel: 079-22823066, 22821018 E-mail: marketing@mbhpumps.com

For details contact: Spectris Technologies Pvt Ltd Plot No: A-168 MIDC Thane-Belapur Road, Khairane Navi Mumbai 400 710 Tel: 022-39342700 E-mail: MEI_Sales@servomex.com or Circle Readers’ Service Card 07

An industrial gas analyser range designed to deliver stable, accurate and reliable O2 measurement at per cent and trace levels, the DF-100 Series utilises unique, non-depleting E-sensor technology to deliver accurate results with no sensor drifting, no false low readings or no frequent calibration requirements.

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Industrial Sectional Overhead Doors Avians industrial door systems guarantee max security and reliability as they are made of steel panels. The double-skinned PUF core design is heat insulating and particularly suitable for heated halls.

Doors are specifically designed to suit the modern industrial architecture. Avians offer a complete range of overhead sectional doors; either insulated sandwich panel doors or glazed doors. They can also be supplied as fully covered or semi-glazed versions for optimal daylight exposure. They provide good air tightness and insulation.

In industrial sectional doors complete sealing on the door prevents dust, air and water. High precision hinges made of galvanized steel, roller guide with adjustable ball bearing rollers are provided for smooth movement of the door.

Easy-to-integrate side and wicket doors ensure that pedestrian movement can be diversified. Intelligent safety edge mechanism stops the door if it comes into contact with an obstacle.

All doors are incorporated with EN safety standards. Industrial doors are attractive, robust and durable with different types of textures.

For details contact: Avians Innovations Technology Pvt Ltd Gat No: 60/61 Dehu-Moshi Road Chikhali, Pune Maharashtra 412 114 Tel: 020-71400600 or or Circle Circle Readers’ Readers’Service Service Card Card 09 24

78 • December 2018

Chemical Engineering World

CEW Products Continuous/Online Air Particle Counter

Electrolytically Regenerated Suppressor

MET ONE 6000P Series remote airborne particle counter is the most reliable top performing; high sensitivity remote particle counter with a built-in pump, MetOne6000P Series is designed to meet the specific needs of cleanroom operations within the pharma, semiconductor, hard disk drive and flat panel display industries. With an array of industry leading features and simplified installation options, the MET ONE 6000P is easy to integrate with any facility monitoring system.

Suppression works two ways to achieve the absolute best sensitivity and corresponding lowest detection limits for inorganic analysis; it increases analyte signal while simultaneously decreasing background signal and noise.

The Thermo Scientific Dionex ERS 500 electrolytically regenerated suppressor supports virtually all analytical scale ion chromatography applications for both anions and cations.

For details contact: Shreedhar Instruments 16 Shreeji Krupa Scty Opp: MGVCL Circle Office Next to GMERS Medical College Gotri Road, Vadodara, Gujarat 390 023 Telefax: 91-0265-232041 or Circle Readers’ Service Card 10

For details contact: Thermo Fisher Scientific India Pvt Ltd 102, 104, Delphi C-Wing Hiranandani Business Park Powai, Mumbai 400 076 Tel: 022-67429494 Fax: 91-022-67429495 E-mail: sagar.chavan@thermofisher.com or Circle Readers’ Service Card 11

Drive Units The standardised geared motor variants are specially designed for intralogistics and airport technology and are particularly suitable for reducing the number of versions.

LogiDrive drive units comprise an IE4 synchronous motor with rated powers of up to 5.5 kW, a 2-stage helical bevel gear unit and a frequency inverter which is installed close to the motor. The inverter is equipped with a mains switch, a key switch to isolate the drive unit from the system controller and a direction selector switch for local installation mode. AS-i and all common field bus and industrial Ethernet interfaces can be integrated. With Class IE4 motor efficiency and system efficiency to Class IES2, the drive units achieve excellent overall efficiencies - especially in the partial load and speed range. With this, they pay for themselves within a short time and considerably reduce the total cost of ownership (TCO).

LogiDrive drive units from NORD are equipped with the safety functions STO and SS1 according to DIN EN 61800-5-2 and DIN EN 60204-1 and have a high overload capacity. As the system for conveyor technology has a modular structure, all drive technology components can be serviced individually, which reduces service and maintenance costs in intralogistics. LogiDrive drive technology is suitable for horizontal conveyors, inclined conveyors and vertical conveyors. Thanks to extensive certification, LogiDrive systems can be installed without problems throughout the world.

For details contact: Getriebebau NORD GmbH & Co KG Getriebebau-Nord-Straße 1 22941Bargteheide/Hamburg Germany Tel: +49 45 32 / 2 89 -0 Fax: +49 45 32 / 2 89 -22 53 E-mail: Joerg.Niermann@nord.com / pl.muthusekkar@nord.com or Circle Readers’ Service Card 12 24

80 • December 2018

Chemical Engineering World

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CEW Book Shelf Introduction to Process Plant Projects Authors: H Selcuk Agca and Giancarlo Cotone Price: $118.21 No of pages: 347 pages (Hardcover) Publisher: CRC Press (1st Edition) About the book: The book covers all stages of process plant projects from initiation to completion and handover by describing the roles and actions of all functions involved. It discusses engineering, procurement, construction, project management, contract administration, project control and HSE, with reference to international contracting and business practices.

The End of Project Overruns Authors: Robert M Patty and Michael A Denton Price: $140.93 No of pages: 498 pages (Paperback) Publisher: Universal Publishers About the book: Applying the principles in this book unleashes ingenuity that achieves, solidifies and perpetuates a new performance culture of mutual benefit. In this culture, project teams will prepare their work in task packages and enable workflow necessary to leave inefficiency of time and resource, literally, no place to hide. Project examples will help teams implement the principles that shorten cycle times, eliminate error, improve quality and reduce costs to succeed in meeting project commitments. Emerging Lean enterprise relationships between clients, EPC contractors and their entire supply chain will advance what constitutes the new, marketdifferentiating performance of individuals, project teams and companies - justifying high levels of trust and inter-organizational efforts to improve. Client executives will learn to recognize root causes of risk and sources of excellence to mitigate them.

Well-developed strategic improvement is often constrained because the traditional way - current means and methods - fit squarely in everyone’s comfort zone. By learning to ask the right questions, top-client leadership will soon render overruns from the best traditional systems as not-good enough and strive for a new level of excellence.

EPC executives will better engage creative voices from their best resources and stakeholders to resolve all concerns and define a unified vision for how to deliver on clients’ expectations without overruns during capital project delivery. Lean methods will effectively assure that vision; principles and best expectations are understood and implemented at the workface. Department, discipline and stakeholder leaders will align and no longer frustrate each other and their clients. They will plan and execute with increased efficiency and effectiveness. Cost reduction will accelerate, retaining only client-valued quality - enabling a nimble response to market opportunities and threats.

Project and program managers will confidently accept intense, market-induced cost and schedule-reduction efforts. They will apply new metrics, measure potential and extract, align and pilot improvements. They will make workface progress transparent to simplify resource balancing, full utilization and workface flow during all project phases.

The results will differentiate team members and their project’s performance on the world stage. Project professionals and the skilled labour force will gain confidence to make and keep increasingly difficult commitments and experience thereby increasing opportunity in an organization known for excellence. They will fully engage heart and mind for leaders who expect excellence and they trust to enable and reward best practice performance while they jointly eliminate root causes of problems before they happen. This book guides readers through each essential role for the transformation to Lean...not just at the lowest levels but of the entire business model and all the supporting processes. Resulting market recognition of sustained excellence of people, their systems and the way they work together will create a market-leading force.

82 • December 2018

Fundamentals of Petroleum and Petrochemical Engineering (Chemical Industries) Author: Uttam Ray Chaudhuri Price: $159.54 No of pages: 411 pages (Hardcover) Publisher: CRC Press (1st Edition) About the book: The supply of petroleum continues to dwindle at an alarming rate, yet it is the source of a range of products - from gasoline and diesel to plastic, rubber and synthetic fiber. Critical to the future of this commodity is that we learn to use it more judiciously and efficiently. Fundamentals of Petroleum and Petrochemical Engineering provides a holistic understanding of petroleum and petrochemical products manufacturing, presented in a step-by-step sequence of the entire supply chain.

Due to the advancement of technology, new petrochemicals are being invented and will continue to be relevant to the petroleum industry in the near future. Those entering the industry need a firm grasp of the basics as the field continues to open up new avenues of possibility, while at the same time being cognizant of the challenges that exist through the heightened focus on sustainable energy.

Pump User’s Handbook Authors: Heinz P Bloch and Allan R Budris Price: $129.16 No of pages: 556 pages (Hardcover) Publisher: Fairmont Press ( 4th Edition) About the book: This text explains just how and why the best-ofclass pump users are consistently achieving superior run lengths, low maintenance expenditures and unexcelled safety and reliability. Written by practicing engineers whose working career was marked by involvement in pump specification, installation, reliability assessment, component upgrading, maintenance cost reduction, operation, troubleshooting and all conceivable facets of pumping technology, this text describes in detail how to accomplish best-of-class performance and low life cycle cost

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CEW Project Update

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

CHEMICALS Shalimar Paints lays down the foundation of its Nashik manufacturing plant with a planned monthly capacity of 2,180 kilolitres. Set to commence operations by April 2019 with a planned production capacity of 2,180 kilolitres per month, Shalimar's state-of-the-art Nashik facility will increase the brand's overall production capacity by 65 per cent. It is also expected to stimulate the local economy by creating around 200+ employment opportunities for prospective jobseekers in the region. The newest Shalimar plant hints at the brand's aggressive push to capitalise on the growing market demand for its high-quality, high-performance paint and coating products, as well as to further consolidate its position as one of the fastest growing paints companies in the country. Shalimar has also pledged further investment into its Nashik plant and aims to establish it as a key component within its regional distribution network, as well as its pan-India supply chain. The paint industry has been growing at a rapid rate in India and measures between 1.5 to 2 times GDP growths. Rapid urbanization, better transparency and consumer evolvement has been leading the growth of the industry.

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

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

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

Coal India aims to raise output from its troubled Rajmahal mine in Jharkhand to 60,000 tonnes a day by March 2019, having resolved land-acquisition related problems which had crimped production to 20,000 tonnes per day. Coal from the Rajmahal mine helps NTPC run close to 4,200 MW of power generation plants in eastern India, which supply power to Bihar, Jharkhand and West Bengal, and also to northern India including Delhi and Uttar Pradesh. NTPC’s generation capacities were faced with depleting coal stocks and lower power generation as supplies from Rajmahal dwindled. Reserves at Rajmahal within the land 84 • December 2018

acquired by Coal India were almost exhausted and required expansion to keep production levels intact. However, land acquisition at two villages - Bansbiha and Taljhari - spanning 160 hectares, adjacent to the existing project turned out to be a lengthy process, as sorting out ownership issues resulted in inordinate delay. It led to drastic fall in supplies and stocks at the coalfield, as well as at two critical power plants in the region - at Farakka and Kahalgaon. At present, Coal India is using 15 goods trains to transport coal from the Rajmahal mine to power stations in the region.

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

OIL & GAS The National Institute of Technology - Tiruchi (NITT) and Bhabha Atomic Research Centre (BARC) have jointly established a biogas plant with a capacity to process one metric tonne of kitchen waste from the hostel. The biogas plant called NISARGRUNA will process vegetable and food wastes and waste water generated from the hostel mess. The project was executed by the DTDDF (Department of Atomic Energy Technologies Display and Dissemination Facility) Centre that BARC had established in the NIT-T premises following a MoU signed with the institution last year. The BARC experts who briefed the NIT-T authorities about the operation principle said NISARGRUNA Biogas Plant will produce biogas containing 70-80 per cent of methane and only 30-20 per cent of carbon dioxide. Processing of one metric tonne of biodegradable waste creates will lead to production of 25-30 kg Methane gas and 50-90 kg manure per day. In comparison, conventional Gobar gas plants have a single digester and produce biogas containing 55-65 per cent of methane and 45-35 per cent of carbon dioxide. The gas generated from the NISARGRUNA Biogas Plant will be used as fuel in the messes for cooking. The weed-free manure has high nitrogen contents and acts as an excellent soil conditioner. It offers ‘Zero garbage and Zero effluent’, and this technology will be more helpful for the kitchen and solid waste management at NIT-T. The NIT-T has identified five villages for pursuing UNNAT Bharat Mission. The DTDDF centre will implement the BARC technologies in the villages.

Vedanta Ltd plans to expand its alumina refinery at Lanjigarh in Odisha to 6 million TPA by 2021 using alternate bauxite resources as it looks beyond. The firm believes there are enough alternate resources of bauxite available to feed the expansion and has moved beyond the previously pursued high-quality bauxite beneath the pristine Niyamgiri hills. The Lanjigarh plant produced around 1.2 million tonnes of alumina last fiscal and has a current capacity of 2 million tonnes. Refusing to give cost estimates, while the plant currently imports 2.5-3 million tonnes of bauxite and sources almost an equal volume from domestic mines, the expansion project would need a total of 18 million tonnes of bauxite annually. Vedanta had intended to supply the refinery with bauxite extracted from the Niyamgiri hills by a mining company owned by the state government, which backed the project. But protests from local villagers led to the union government and the Supreme Court blocking the move in 2013.

Chemical Engineering World

NATIONAL

INTERNATIONAL ENGIEXPO

Specialty & Custom Chemicals America

Dates: 05-07 January 2019 Venue: AES University Ground, Ahmedabad, Gujarat Event: ENGIEXPO has emerged as prestigious brand in the field of exhibitions and trade-fair. The organizers believe in creating brand value, support product market and enhance sustainability even in worldwide worst economic scenario for exhibitors and participants by unlocking the unmatched potentials and opportunities for the industries.

Dates: 11-14 February 2019 Venue: Omni Fort Worth Hotel, Fort Worth, U.S.A. Event: This event focus is on specialty, custom, fine and industrial chemical markets, focus on suppliers with a North American base, renew the value proposition for attending trade shows, and renew fundamental business values.

For details contact: American Chemical Marketing 809 North Fairway Road Glenside, PA19038, U.S.A

For details contact: ENGIEXPO 10 Mehta Apartment, 2nd Floor Above Union Bank Beside Radha Vallabh Template Jaihind Cross Road, Maninagar, Ahmedabad Gujarat 380 008 E-mail: engiexpo@gmail.com ambalal@engiexpo.com

Chemtech World Expo 2019 Date : February 20th - 23rd, 2019 Venue : Bombay Convention & Exhibition Centre, Goregaon (East), Mumbai, India IMTEX

Dates: 24-30 January 2019 Venue: BIEC Bengaluru International Exhibition Centre, Bengaluru Event: Metal cutting machine tool exhibition with international participation. IMTEX 2019 is a 7 day metal cutting exhibition being held from 24th January to 30th January 2019 at the BIEC Bengaluru International Exhibition Centre in Bengaluru, India. An initiative of IMTMA, IMTEX is a flagship event for the Indian metal cutting industry. It is South East Asia’s apex exhibition showcasing the latest trends as well as technological refinements from India and other global players. The mega event attracts visitors from a wide spectrum of manufacturing and ancillary industries including key decision and policy makers as well as industry captains who are keen to source latest technologies and manufacturing solutions for their product lines.

For details contact: Indian Machine Tool Manufacturers’ Association 10th Mile, Tumkur Rd Madavara Post Bengaluru, Karnataka 562 123 Tel: 080-66246600, 66246661 E-mail: imtma@imtma.in

Event : CHEMTECH World Expo 2019 will create a common platform to bring the entire ecosystem of the chemicals manufacturing and the allied services providing sectors for 27th time in India. The event is for equipment, services or developing processes for the Chemical and Process industries. The evolution and the growth of Indian chemical and related industries has been both reflected and catalyzed by CHEMTECH. The interactive Exhibition and Trade Fair pioneered by Chemtech has become the event that the chemical industry comes together.

Concurrent events include EPC World Expo, Industry Automation & Control World Expo, Bio Pharma, Pumps Valves & Fittings World Expo; and international conferences on Refining & Petrochemicals and Specialty Chemicals.

For details contact: Vaishali Pednekar Senior Executive – Conference Tel: +91-22-4037 3619 Email: vaishali_pednekar@jasubhai.com

ENGIMACH Dates: 04-08 December 2019 Venue: The Exhibition Centre, Gandhinagar, Gujarat Event: ENGIMACH is a leading engineering and machine tools show and showcase engineering products and services, heavy and light machines, machinery equipment and accessories, tools and parts, technological devices and products, engineering tools and allied products and services.

It is the most trusted machines and tools show that exhibits latest products and services, latest innovations and technologies. It is an ideal event that witnesses the best buyer and seller partnership and is a dynamic platform.

For details contact: K And D Communications Ltd Kailash-A Sumangalam Society, 3rd Floor Above HDFC Bank, Opp: Drive-In Cinema, Bodakdev Ahmedabad, Gujarat Chemical Engineering World

European Coatings Show Dates: 19-21 March 2019 Venue: NurnbergMesse GmbH, Nuremberg, Germany Event: This event showcases products that include coating raw materials, binders, solvents, pigments, fillers, additives, printing ink raw materials, adhesive raw materials, polymer dispersions, intermediates for construction chemicals, raw materials, additives and admixtures, laboratory and production equipment, testing and measuring equipment, plant and machinery, spray systems, drying and curing plant, environmental protection and safety at work, etc, in the chemicals and dyes industry.

For details contact: NurnbergMesse GmbH Messezentrum 90471 Nurnberg Nuremberg, Germany December 2018 • 85

CEW Ad Index

Sr.

No.

Client’s Name

Page No

Client’s Name

Page No

21 Lubi Industries LLP

7

1

Atomic Vacuum Company (Exports)

2

Avcon Control

77

22 Mettler Toledo India Pvt Ltd

29

3

Beda Flow Systems Pvt Ltd

55

23 Mist Ressonance Engg Pvt Ltd

59

4

Chentan Kotak

79

24 Nanubhai Mavjibhai Patel

5

Cole-Parmer India

75

6

D Parikh Engineering Works

27

7

De Dietrich Process Systems India Pvt Ltd

23

8

Desmi India LLP

45

9

Ekato India

15

10 Evergreen India

39

11

21

Gemini Associates

12 Grundfos

Inside Cover I

Sr.

No.

Inside Cover II

13 Hi-Fab Engineers

77

14 Hi-tech Applicator

3

15 Horizon Polymer Engineering Pvt Ltd 16 HRS Process Systems Ltd

18,19 5

17 Ion Exchange (india) Ltd

33

18 Jay Water Management Pvt Ltd

57

19 Kishor Pumps Pvt Ltd

31

20 KSB Pumps Ltd

86 • December 2018

9

Back Cover

25 Paharpur Cooling Tower

47

26 Ravel Hiteks Pvt Ltd

81

27 ResistoTech Industries Pvt Ltd

35

28 Ross Process Equipment Pvt Ltd

11

29 Roto Pumps

71

30 Shah Brothers

81

31 Shanbhag & Associates

81

32 Sulzer India Pvt Ltd

41

33 Suraj Ltd

79

34 Tecnimont Pvt Ltd

53

35 ThyssenKrupp Industrial Solutions (India) Pvt Ltd

51

36 TMVT Industries Pvt Ltd

83

37 Tubacex

75

38 UNP Polyvlaves (India) Pvt Ltd

17

39 Vacuum Drying Technology India LLP

43

Chemical Engineering World

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R.N.I. No. 11403/1966 Date of Publication: 29th of every month. Postal Registration No: MCS/095/2018-20 No.:88 Posted at Patrika Channel Sorting Office, Mumbai 400001, on 30th of every month. Total Pages No.:72