CHRONICLING PROCESS INDUSTRY INNOVATIONS SINCE 1966
CHEMICAL ENGINEERING WORLD DECEMBER 2017 VOL.52 ISSUE 12 Mumbai ` 150 GUJARAT - 2018
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4 • December 2017
VOL. 52 | ISSUE NO. 12 | DECEMBER 2017 | MUMBAI | ` 150
NEWS Industry News News Feature
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FEATURE Industry 4.0 and IIOT, Its Impact on the Industrial Scenario - by Sugata Bandyopadhyay, Discipline Head (Instrumentation & Automation) & Consultant, Tata Consulting Engineers Limited Process Monitoring Solutions for Chlor-Alkali Industry -by Ritesh N. Vyas, Product Manager (Asst.)-Electrochemistry, Metrohm India Ltd Differential Approach in Execution of Mega Projects - by Parthasarathi Chatterjee, Vice President, L&T Hydrocarbon Engineering Limited Failure of Double Wall Jacketed Piping in Refineries: Causes and Prevention - by S Chidambaram, Officer Inspection and Metallurgy, Inspection Department, Numaligarh Refinery Limited Concept of Integrated Technologies in Wastewater Treatment - by Dr. Nivedita Sahu, Sr. Scientist; S. Sridhar, Principal Scientist and Project leader Membrane Separations Laboratory, Chemical Engineering Division CSIR-Indian Institute of Chemical Technology, Hyderabad Water Management Using Membranes: Forward Osmosis and Pressure Retarded Osmosis as Technologies of Future - by Arijit Chakraborty, Undergraduate; Ridhish Kumar, Undergraduate; Anirban Roy Assistant Professor, Department of Chemical Engineering, BITS Pilani Goa A Roadmap to Unlock Future Growth Opportunities of Plastic Processing Sector in North East India - by Subodh Kumar, Deputy Manager; Tamagna Ghosh, Deputy Manager Roseleen Ahmed, Deputy Manager, BCPL Growth and Opportunities in Plastic Industry of India - by Arvind Mehta, Chairman & Managing Director, Welset Plast Extrusions Pvt. Ltd Ecological Sustainability for Economic Upliftment - by Sudhir Shenoy, CEO, Dow India
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NEWS FEATURE GSFC University- Taking a step towards Progressive Future of Engineering
70
MARKETING INITIATIVE B&R integrates vision into machine automation
72
Batch-of-one flexibility meets mass-production efficiency
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PRODUCTS EVENTS PROJECT UPDATE BOOK SHELF AD INDEX
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Chemical Engineering World
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CEW Industry News Brenntag Signs Joint Venture Deal with Raj Petro Specialities
BASF Opens New Chemical Catalysts Production Plant in China
Brenntag, the global market leader in chemical distribution, has signed an agreement to enter into a 65/35 joint venture with Raj Petro Specialities Pvt Ltd, India. The company, headquartered in Mumbai and Chennai, distributes its own-blended brands of petroleum-related products to diverse customer industries in India and other countries in Asia Pacific as well as in Africa and the Middle East.
BASF has opened its first Asian manufacturing facility for chemical catalysts in Caojing, Shanghai, China.
Brenntag will gain a majority stake of 65% with a first tranche to be closed in April 2018 and the remaining 35% via the second tranche after a period of 5 years, in which the business will be operated as a joint venture, with possible extension of additional 1-2 years. Steven Holland, CEO Brenntag Group: “For Brenntag, the acquisition of Raj is a further step into the Indian chemical distribution market which is the 7th largest globally for chemicals and 3rd largest for lubricants. Raj’s existing product portfolio and market presence, capability of its infrastructure and strategic locations make it a compelling investment target to expand our footprint not only in India but also in other Asian Pacific countries, in Africa and the Middle East.”
Ion Exchange Introduces High Purity Water Generation Product Industry leaders in water treatment, liquid waste management and environment solutions, Ion Exchange (India) Limited today announces the launch of INDION SWIFT 5Gx – a high purity water generation product catering to the special needs of the pharmaceutical industry. The product has been designed in consultation with pharmaceutical engineers and end users for maximum performance. This launch marks the company’s expansion of its product line for the sector within its ‘INDION’ purified water systems range. INDION SWIFT 5Gx improves efficiency and purity by introducing a new and unique technology which uses ‘Uniform Particle Size’ resins instead of the conventional resins otherwise used in water treatment and purification. The new product uses a short-cycle regeneration method and takes up to 35 minutes only in order to regenerate as compared to other available conventional products which have an average time of 8 hours for a single regeneration cycle. The product is a first of its kind for the pharmaceutical sector and with validation package.
Located at the Shanghai Chemical Industry Park (SCIP), the new automated and energy-efficient plant will supply base metal catalysts and absorbents in China and around the Asia-Pacific region. The firm expects the move to help it boost relationships in the chemical industry and improve customer service with enhanced product availability and decreased lead times. BASF Process Catalysts senior vice-president Detlef Ruff said: "The start of our new, world-scale production plant for chemical catalysts in Shanghai represents a milestone for our process catalysts business.
Orion Engineered Carbons Opens New Specialty Carbon Black Production Line in Korea Orion Engineered Carbons, a worldwide supplier of specialty and highperformance Carbon Black, has completed construction of a new Carbon Black production line at its plant in Yeosu, South Korea, to produce specialty products. The line started production on November 23rd and has begun commercial sales. “This new line in Yeosu will produce premium grades of Specialty Carbon Black for demanding customer applications such as automotive coatings, engineered plastics, printing inks and adhesives & sealants,” said Jack Clem, Orion’s Chief Executive Officer. “It is another step in Orion Engineered Carbons’ ongoing transition to higher value added products for specialty and technically demanding rubber applications.” The Yeosu Plant has also just completed a major upgrade to a Technical Rubber Carbon Black production line. This line too is back in commercial production. These projects are major components of the consolidation of the Bupyeong [Incheon] Plant into the Yeosu facility. The transition is on track to be completed by July 2018.
Albemarle to Divest Part of Polyolefin Unit to WR Grace
Clariant, Xuzhou HaiDing Chemical Technology to Develop New PDH Unit in China Clariant has signed an agreement with Xuzhou HaiDing Chemical Technology to develop a new CATOFIN catalyst and propane dehydrogenation (PDH) unit in Pizhou, Jiangsu Province, China.
US-based specialty chemicals company Albemarle Corporation has agreed to divest its polyolefin catalysts and components business to WR Grace & Co in a deal worth $416m. The deal does not include organometallics and curatives portions of the Performance Catalysts Solutions business, which will remain with Albemarle.
Clariant will carry out the project in alliance with its technology partner CB&I. The agreement covers licence and engineering design of the custom-built plant.
Under the agreement, Grace will assume the lease and operations at the Product Development Center in Baton Rouge, Louisiana, and operations at the Yeosu, South Korea site.
The unit will be designed based on Clariant's CATOFIN catalytic dehydrogenation technology to produce 600kt of propylene per annum.
The disposal ofpolyolefin catalysts and components unit is the latest in a series of changes that have reduced Albemarle's presence in Baton Rouge.
Clariant's technology utilises CATOFIN dehydrogenation catalyst that is used for producing olefins from light paraffin feedstocks, along with heat generating material (HGM) loaded with the catalyst to enhance selectivity and yield of CATOFIN units.
Albemarle chairman, president and CEOLuke Kissam said: “The sale of this portion of our performance catalysts solutions business shows our continued commitment to portfolio management that is in the best interest of our shareholders and employees.
8 • December 2017
Chemical Engineering World
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CEW News Features
Khimia 2017: Post Event Report
K
himia 2017, held on 23-26 October 2017 at Expocentre Fairgrounds, Moscow, Russia, covered all sectors of the chemical industry and brought together representatives of business, industry, science and authorities from all over the world. The event organized by Expocentre AO was supported by the Russian Ministry of Industry and Trade, Russian Chemists Union, NIITEKHIM OAO, Mendeleev University of Chemical Technology of Russia, Mendeleev Russian Chemical Society, Chemical Department of Lomonosov Moscow State University. “This oldest trade show of achievements in the chemical industry, which has run for over fifty years in this country, has become a worldclass event. It draws much attention of Russian and foreign professionals. They traditionally showcase the latest accomplishments in the chemical industry and sign win-win contracts here.” said Mr Dmitry Medvedev, Prime Minister of the Russian Federation
Show Highlights • The URALCHEM Group signed an agreement with Gazprom Sera on supply of sulfur to industrial enterprises of the group. • The first Startup Chemzone presented 14 companies to help them show their new developments and find investors. They included Binakor-HT, Innovative Machinery and Technology OOO, Nanomaterials OOO, Engineering Centre of Inorganic Materials, MIP New Solutions, Poliofit OOO, Enterprise of Sustainable Growth, Stimul Growth OOO, Ferrit NPO, etc. • Expocentre continued its Expocentre for Counterfeit-Free Exhibitions Project aimed to minimize counterfeit products showcased at exhibitions through providing consultations and clarifications regarding intellectual property, and rendering assistance in solving conflicts connected with violations of exclusive rights. • The participants in the Centre of Science and Education were the Lomonosov Moscow State University, Mendeleev University of Chemical Technology of Russia, Tomsk State University, St. Petersburg State Technological Institute, Tver State University, Ural Federal University, etc. Supporting Events • The first Foresight Session on Industry 4.0 Technologies for the Chemical Industry was organized by the Expocentre Chemical and Technological Exhibitions Division with 10 • December 2017
support of the Russian Ministry of Industry and Trade, NIITEKHIM and Avtomethim. • The 5th edition of the Moscow International Chemical Forum was organized by the Russian Chemists Union and Expocentre AO. • The Indo-Russian Seminar was organized by the Chemical and Technological Exhibitions Division of Expocentre AO and India’s leading industry association CHEMTECH Foundation. • Deputy General Director of Expocentre AO Mikhail Tolkachev welcomed the participants and said that foreign companies chose Expocentre Fairgrounds as a platform to show their products and technologies and to enter the Russian market. He encouraged Indian companies to use this great tool to develop their business in Russia. Councillor of the Economy and Commerce Department of the Indian Embassy in Russia Inbasekar Sundaramurthy noted that India was looking forward to expanding its cooperation with Russia. “We are interested in Russian investments, Russian business, development of cooperation and partnership,” said Mr. Sundaramurthy expressing his confidence the seminar would give a boost to it. The Indian participating companies included Adventz Group- Fertilizer Business, Lasern&Toubro Ltd, and Simon India Ltd. • The Consulting Session on Russian Export Center: Tools for Promotion of Export of Chemical Products was organized by the Russian Chamber of Commerce and Industry, Expocentre AO and Russian Export Center AO. The session was moderated by the Chamber’s Vice President Vladimir Dmitriev. He noted the importance of holding such events during the largest trade shows of Expocentre. Their participants are already working on exporting their products abroad. Deputy General Director of Expocentre AO Nikolay Gusev said, “We are happy to see these sessions at Expocentre Fairgrounds. We will continue to create the best environment for such meetings.” According to Deputy Head of the Department of Chemical Engineering and Timber Processing Complex of the Russian Ministry of Industry and Trade Aleksandr Orlov, Russian chemical enterprises have large export potential. Production of chemical products is growing, and their export exceeds import. Representative of the Russian Export Center Elvira Chernysheva talked about many support instruments for export projects provided by the Russian Export Center
Group, which together with the Russian Export Center includes the Russian Agency for Export Credit and Investment Insurance (EXIAR), and Roseximbank. The Group offers Russian exporters insurance and credit support. Roseximbank gives credits to participants of export related agreements, including foreign buyers of Russian products. • The Association of Recruitment Consultants, CHOICE Recruitment Agency and Expocentre AO organized two projects: the Employment Centre and the Expert Session: HR Solutions for Business. • The Conference on Innovative Development of Chemical and Petrochemical Industries. Paths, Opportunities, Prospects and the Road of Innovations Award were organized by the Centre of Communications Development FEC. • A series of sessions and seminar on support of small and medium businesses in the chemical and petrochemical industries of Moscow were organized by the Small Business of Moscow State Agency. • The first Round Table on Providing Perfume and Cosmetic Manufacturers with Chemical Raw Materials and Polymer Packaging was organized by the Chemical, Technological and Timber Department of the Russian Ministry of Industry and Trade with support of Expocentre AO. More than 30 companies took part in the event. • Other events included the 8th International Conference on Resource Saving and Energy Technology in the Chemical and Petrochemical Industries organized by the Mendeleev Russian Chemical Society, the 7th Conference on Advanced Technology for Water Conditioning and Corrosion and Scaling Protection for Equipment organized by Roshimreaktiv Nonprofit Partnership, Travers and Expocentre AO, as well as events devoted to technologies of green chemistry, industrial biotechnologies and other issues. • The Zone of presentations of Khimia 2017 offered the exhibitors an opportunity to demonstrate their new products and solutions. • The 11th Competition of Young Scientists was organized by the Mendeleev Russian Chemical Society, the Russian Chemists Union, and the Mendeleev University of Chemical Technology of Russia. The next edition of the Khimia International Exhibition will run at Expocentre Fairgrounds on October 29 through November 1, 2018. Chemical Engineering World
CEW Features
Industry 4.0 and IIOT, Its Impact on the Industrial Scenario The Industry 4.0 had put a new dimension on the way things may work. It had ushered in Disruptive Technologies like IOT & New Packaging of Concepts to work in a different platform. Now inanimate objects are made intelligent and web enabled with its own Analytic tool to participate in a global network. As a result Business Analysis, Shop floor production, quality, reliability & supply chain management operate in a coherent mode .This results in, better quality, on time delivery, optimized Cost, plant efficiency & reliability excellent working condition, new area of business & protection of environment, safety & health.
I
ndustry 4.0 had ushered in a new generation Technology to work in a collaborative Platform. The first industrial revolution started with the invention of steam engine, which replaced human labor with mechanization driven by the power of steam. With the invention of electricity, industry progressed one step further, ushering in large scale production and enhancement of scale production. Then with the introduction of Electronic devices, computers, and Programmable Logic Controllers (PLC) the third industrial revolution came putting automated production which resulted in better quality, better control of the process & reduction in reduction of wastages and hence better cost. The fourth industrial revolution came, when the Internet technology was adopted establishing connectivity of smart devices with technology to communicate and sense or interact with their internal states or the external environment. Industry 4.0 introduced Internet technology, Robotic Tools, Big Data Analytics which introduced smart production matching with latest state of the art requirement of the 21 st century and putting more value to products & services Thus to understand the impact of Industry 4.0 on Industry, a deep understanding of IOT (Internet of Things) is required. The Internet of Things (IOT) is an environment where physical objects (often termed smart objects) are connected by Internet enabled networks. In practice it consists of web enabled sensors embedded 12 • December 2017
in various processes, machines and devices that share information on web for monitoring, controlling & also creating database for future use in Cyberspace. Thus in IIOT Packaging of New Technologies, Open Standards, Pervasive Communication, Computing including Cloud Computing & Embedded Computing, Sensing Devices including GPS devices are driving the growth and creating Innovating Products. To introduce IOT some readily referred terms which are the integral part of IIOT need to be considered. They are the followings: Cloud Storage. In cloud storage arrangement for subscribed storage of data in remote servers designated as clouds are offered as a storage medium of big data and managed by service providers for integrity & security and accessible through the internet,. Cloud Computing: Cloud computing ensures implementation of various diverse operations like computing and data analytics in time sharing mode through resources available in the cloud as a service. It enables shared computing functions & dynamic storage facilities. This concept eliminates capital investment and introduces Pay as one derives the services, i.e. shared facilities. Cloud Analytics: In this system Predictive Maintenance, Advanced Computation
driven results and decisions, Optimization of Systems etc. are undertaken, without investing on local dedicated system. The Analytic software ensures fast and secure procedures for searching , analyzing and visualizing the enormous streams of physical system data generated by process & also other related & unrelated disparate data . It also supports working in technology infrastructure, physical & virtual environment in the cloud. IIOT: High Volume Internet of things products and applications are driving with creation of low cost, high power Micro Computers & Integrated Circuits (IC) with Integrated Communication and low cost Sensors to interface with Cyber Physical System. Edge Computing: Edge devices are those devices which captures information from the process or environment. These edge-of-network devices apart from data collection also have storage and incorporate open, embedded computing platforms to take executable decision at the edge level & also control structured flow of information as considered appropriate to other elements of the network. Embedded Analytic tools also embedded on the edge devices operate to remotely carry out analytical functions like analyzing and transmitting to remote control centers about the conditions of various lifesaving parameters of an expensive and crucial equipment like big motors/ rotating equipment. Chemical Engineering World
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CEW Features Model and executing Condition Monitoring of a variety of System , resulting : • Web based access to get visibility on Process Condition & Asset Health and performance of all types of assets. • Asset Reliability by analyzing Asset Status & Evolving maintenance strategy to eliminate Unplanned Shutdown. • Working on Big data Analysis and working on Risk based Strategies to Identify Critical Assets , Identifying areas of Improvement on the chain of Assets based on past trends , Reduce Production loss & Improved Efficiency . • Elimination of Human error and equipment malfunctioning by using expert system tools. • Root Cause Analysis on All Incidents applicable for Production, Environment, Health & Safety, Security & Quality & Customer Feedback.
Figure 1: Domain of Internet of Things
Iota is thus a world where anything including an inanimate object or a machine can be connected and can communicate in an intelligent fashion by imparting intelligence by putting embedded sensors, storage & analytical capabilities using cyber physical system. Thus with Internet of Things, the physical world behaves like one big connected system. Thus in IIOT (Industrial Internet of Things) Packaging of New Technologies, Open Standards, Pervasive Communication, Computing including Cloud Computing & Embedded Computing, Sensing Devices including GPS devices are driving the growth and creating Innovating Products
•
• • •
•
results Greater Reliability of Plant & Equipment. Improved Process Efficiency and improved Productivity by optimizing Asset utilization. Reduction of unwanted Wastage of material & Utilities. All these result in reduction of Cost of Production. Efficient handling of diverse task automatically & correlating useful information and creating more opportunity in the system. Consolidation and working on Disparate Data with special tools results in development of more Smart Asset Strategies.
Thus it is evident that IIOT role in industries is substantial. We can broadly describe the role as
IIOT and Asset Management (APM)
• IIOT Platforms by • Tracking the plant information by smart embedded sensors and data eliminates unplanned shut down. This
Asset Performance Management (APM) program is IIOT enabled and works on Special Algorithm for consolidation of Disparate Data , Building Data Analytic
16 • December 2017
Performance
The Culture brought are working with better quality , improved efficiency , minimized downtime , Reliability Safety , Better Environment & Customer satisfaction . IIOT and Product life Cycle The new generation requirement is to continuously update existing product or to launch new product with changing requirements of users. This is a great challenge for a complex product which consists of a great number of components, specifically when the components are manufactured at different locations, which often are globally distributed in various continents. Whenever a product change is initiated with improved features, it triggers a change in various components with reference to shape size, electrical power, hydraulic system and many other parameters. Also the components that are not impacted need to be checked for compatibility with the changed components for coherent functioning. Any Chemical Engineering World
CEW Features • Security of Plant Data & Plant Safety secured communication by proper encryption & secured data storage & handling will ensure confidentiality on private information. Opportunities and Introduced by IIOT
Figure 2: Product Lifecycle Management
inability to meet the above requirement within the dead line will result in failure of launching the product in time resulting in a huge loss in time & cost. Thus a strategy need to be formulated ,to online control & share in 3D graphics , the entire changed engineering process with simulation based checking on compatibility & performance and fitment of changed and retained components packaged in an eye catching design. This involves a synergy between Enterprise Resource Planning (ERP), Material Resource Planning (MRP), 3D automated drawing methods with time scheduling & product costing under the domain of Product life Cycle (PLM). This also ensures on line the transparency in sharing accurate product information, component wise, in the assembly line & information sharing & changed process management & an ecosystem for integrated operating eliminating nonconformance in the product and inculcating a culture of integrated team operation between all the stakeholders. IOT integrates the PLM with other domain of the product value chain and logistics chain. 20 • December 2017
Key Steps to be IIOT Compliance • Tagging: All Raw material, Intermediate Product & Final Product to be identified by separate names and codified by barcode or other methods. Then these can be identified and digitized for further processing. Collection & Analysis of these data will have significant impact on the value chain management. • Measuring: All product components in the value chain to be measured to acquire comprehensive information on the product & the production state. By analyzing these data Product quality, improvement of processing time & cost reduction. • Transmit Connect, Manage & Analyse: Secured data capture and transmission with digitized coded items with digitized information on quality & status. Establish wireless communication through various methods, capture all relevant data, store, analyse in real time for further decision making .Management & maintaining of huge data base and sharing only relevant information with the appropriate program is very important for the process success.
Challenges
The opportunities and challenges faced by any entrepreneur are Globalization, requirement of horizontal & vertical integration to compete with scale of demand & ensuring the value chain, requirement of resource with proper competency, adoption of dynamic product life cycle management & benchmarking the products to ensure quality, price, and delivery in time & adoption of dynamic product upgradability. With all these the entire globe is the market where adopting smart method of manufacturing, Asset Management System , Product Life cycle Management and IIOT based value chain, sustainability in business can be ensured with quality , meeting product demand, on time delivery , competitive price with healthy bottom line .
Author Details
Sugata Bandyopadhyay Discipline Head (Instrumentation & Automation) & Consultant Tata Consulting Engineers Limited Contact: sbandyopadhyay@tce.co.in Chemical Engineering World
CEW Features
Process Monitoring Solutions for Chlor-Alkali Industry For a global production capacity of chlorine at 37.0 Million Tons per Annum, India’s contribution is less than 3% today. Even at this capacity, India’s Chlor-Alkali industrial sector makes an annual turnover of more than ` 3000 Crores. Over the past decade, significant efforts been made to find technological solutions that can provide sustainable growth to this market. This review highlights the recent developments in Process Monitoring Solutions for Chlor-Alkali Industry.
C
hlorine is one of the 15 major elements that constitutes human body. Apart from being the most commonly used bleaching and water disinfection agent around, it is also an important raw material in 80% of modern day pharmaceuticals and drugs. In addition, chlorine is a vital ingredient in manufacturing a variety of products in petroleum as well as paper & pulp industry. On a global scale at present, about 95% of the chlorine is manufactured using an electrochemistry based ChloroAlkali Process. Chlorine is produced simultaneously with caustic soda (NaOH) via controlled electrolysis of a sodium (or potassium) chloride solution (‘Brine’). Caustic soda is a useful by-product in industries producing aluminium, cellulose products, and textiles. The other by-products include hydrogen gas, which has a variety of applications in alternative energy sector and hypochlorite, which is extensively used in modern day bleach solutions. In India, there are 42 major Chlor-Alkali manufacturers providing a total turnover of more than ` 3000 crores per the major contributions of AMAI in the past annum. By 2018, the overall production capacity of India will reach more than 13 lakhs tons per annum for caustic soda and 11.5 lakh tons per annum for chlorine. The Alkali Manufacturer’s Association of India (AMAI) established in 1960 is an Apex body representing Indian Alkali Industry for entities such as Govt. of India and Department of Ministries. One of decade has been the transition of 99% of these facilities towards an environmental friendly “Membrane Cell Process” from an 22 • December 2017
age-old “Mercury Diaphragm Process”. Such an adoption of 3rd to 5th generation electrolyzers was a huge step towards process sustainability, cost-optimization and energy efficiency in this market. This has allowed the minimization in the overall mercury waste by almost 98% Membrane Cell Process The Membrane Cell Process utilize a highly advanced ion-exchange membrane based electrochemical reactor for process efficiency. Such a membrane stands between the anodic and cathodic compartments of the electrolysis cell. It will allow sodium ions (Na+) and water molecules to pass through, but limit chloride and other anions. As a highly purified solution of ‘Brine’ is electrolyzed to Cl2 gas on the anodic side, H2 gas and caustic soda are simultaneously produced in the cathodic compartment. Such ion-exchange membranes are commonly made of per-fluorinated polymers and are generally two layers thick. The membranes must remain stable while being exposed to such aggressive solutions, and have an average lifetime of 3–5 years. The ion exchange efficiency is vital in order to limit impurities in the concentrated caustic product. Partial membrane blockage from precipitation reactions will lead to high operational and / or replacement costs, which are not good for process efficiency and cost optimization. Brine Liquor Purification The ion exchange efficiency and its longevity directly depends on purity of the brine fed to
the electrolytic cell. For the efficiency to reach its maximum, the hardness of the brine liquor along with any other impurities that may affect membrane performance have to be reduced to their minimal content. Typically, a twostage filtration process addresses this issue. The initial stage uses caustic soda (NaOH) and sodium carbonate (Na2CO3) to remove excess hardness (Ca2+, Mg2+) via precipitation reactions. In the second-stage, the purified raw brine is send to an ion-exchange resin unit to minimize trace impurities in brine such as iodide, arsenic and mercury. A vigorous real-time process control is required to monitor species such as carbonates and caustics in brine filtered out from stage 1 followed by calcium, iodide & magnesium in the brine from stage 2. The Cl 2 and H 2 gas produced also needs to be analysed for moisture content. Trace Anion Impurities in Caustic Typically, anionic impurities in 50 wt.-% caustic soda or potash are determined by gravimetric or titration methods which require a variety of reagents with diverse shelf lives and hazards. ASTM method E1787-16 specifies ion chromatography to measure bromide (Br-), chlorate (ClO3-), chloride (Cl-), fluoride (F-), nitrate (NO3-), phosphate (PO43-), and sulphate (SO42-) in concentrated NaOH or KOH solutions. There are variety of IC-based process analytical solutions in the market that can also offer intelligent sample preconditioning techniques (‘matrix elimination’) to conduct fully automated process stream analysis for multiple anion impurities in a simple yet easy fashion (without any human intervention). Chemical Engineering World
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Trace Metal Streams
Analysis
in
Process
In the electrolysis cell, iodide (I-) is oxidized to iodate (IO 3-), which precipitates in the ion exchange membrane and decreases its lifetime. The interaction of alkaline earth metals (Ca2+, Mg2+, others) with iodide at the membrane surface can cause severe damage to the membrane in case of a blockage. Voltammetry Analysis (VA) is an ideal solution to quantify selected trace metals in ppb-ppt range. Apart from iodide, such process based VA systems can conduct voltammetry detection of Pb, Fe, Cu, Zn, As, Hg and Cr in process streams via fully automated standard addition technique.
Moisture Analysis in Chlorine Gas Streams Moisture determination in the produced gases (Cl2, H2) is necessary to overcome corrosion in storage containers and transport pipelines. Vaporization of the gases after storage, without proper removal of moisture beforehand, can also clog the container valves and lead to further handling issues. Determination of moisture content in the gas at different points in the drying process gives information regarding the efficiency of the dryers and the endpoint of the drying process. The NIRS XDS is capable of monitoring nine different process points with the multiplexing capability. Fast, reagent- free analysis is available in a housing suitable for dangerous ATEX environments.
Hypochlorite (ClO-) in brine
Chlorine (Cl2) in brine (Depleted brine)
A certain amount of the formed hydroxide can migrate into the anodic compartment during electrolysis, leading to formation of hypochlorite and chlorate. These impurities can result in a loss of current efficiency of up to 7% in the production of caustic soda. A process-based system capable of conducting basic potentiometric titration is typically an answer to the issue.
Depleted brine can be recycled so that it can be reused in membrane cell electrolysis, which reduces costs incurred during the multiple purification steps of the raw brine. The determination of chlorine (Cl2) in brine is necessary due to the high concentrations, which can be found in the recycled bulk solution. Online monitoring of these levels can lead to more efficient chlorine removal
24 • December 2017
processes, if the analyzer output signals the chemical distribution system in cases of high Cl2 content. Online photometric solutions provide single or multiple stream analysis in low ppb levels. Summary Compared to an expensive yet bench top based ICP-OES or GC-MS systems, such real-time based process analyzers are costeffective and efficient solutions to every other analytical need in Chlor-Alkali industry. Not only are they capable of providing ‘real’ data for control parameters, they also can also be recognized as the future guiding platforms for overall process sustainability.
Author Details
Ritesh N. Vyas Product Manager (Asst.) for Electrochemistry Metrohm India Limited Ritesh.Vyas@Metrohm.in Chemical Engineering World
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Differential Approach in Execution of Mega Projects The Mega Projects are inherently complex due to sheer size, scale & scope. Therefore, risks associated with Mega Projects need to be assessed and approached differently when compared to small & medium scale projects. However, Mega Projects, if executed par excellence, have the potential to bring transformative changes for the organization and the stakeholders at large. While executing mega projects internationally, it is observed that approach and mindset required for successful execution of Mega Projects (>1 BUSD) are substantially different vis-à-vis that for small & medium scale projects. Based on validation through real life mega project execution in L&T Hydrocarbon Engineering Limited, author identified in this article the critical success factors for execution of Mega Projects.
S
ize, scale & scope are the drivers for Mega Projects necessitating differential approach for successful execution. Such differential approach are related to three aspects – People, Process and Leadership. Following critical success factors related to People, Process and Leadership have been validated while executing mega projects successfully.
Differential Approach Related to People: • Alignment of Project Team Unlike small & medium scale projects, execution of Mega Projects requires large number of team members having diverse expertise and experience. Often such project team will comprise of people from multiple Business Verticals within organization having various nationalities and located across different countries having different time zones. Such project team is akin to the team involving several functions required for running a business as against a project. Integration amongst the team members and alignment of the team with project goals become the determining factor for transforming the task force into high performing team. In order to overcome such challenges, approach practiced 28 • December 2017
in mega projects which resulted in an integrated, high-performing team drawing the benefit of diversity as against its perceived drags has been detailed in Figure 1. • People Engagement Typically the duration of Mega Projects is two to three times of duration of small projects and therefore, majority of times it becomes a challenge to keep the team members engaged and motivated. Any drop in team morale poses a significant risk to the project performance and delivery. In order to tackle this challenge, multiple innovative initiatives were implemented in mega projects. From the beginning of the project, practice of publishing a project specific newsletter was established which highlighted latest happenings in the project, HSSE alerts and stories of accomplishment by project team members. Employee engagement surveys were also conducted on half-yearly basis and the feedback received was utilized to take appropriate
steps to enhance the engagement of project team members in their work. Project Leadership Team conducted multiple town hall meetings with team members which provided the team members bigger picture of the project performance. The Client’s feedback on the team’s performance was also shared with team members during such meetings which enabled the team to maintain and further improve their performance. With above efforts, the motivation levels and commitment of the team to successful delivery of the project was taken to substantially higher level and maintained throughout the project cycle.
Differential Approach Related to Process: • Structured Review Making Process
and
Decision
Another major difference between small / medium size projects and Mega
“Typically the duration of Mega Projects is two to three times of duration of small projects and therefore, majority of times it becomes a challenge to keep the team members engaged and motivated. Any drop in team morale poses a significant risk to the project performance and delivery.” Chemical Engineering World
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CEW Features
Figure 1: Alignment of People towards Project Goal
Projects is the project organizational setup. Compared to mega projects, small projects organization structure are flatter. Due to multiple layers in Mega Projects, final decision making authority is often more remote from the action resulting in slowdown in decision making process which leads to longer time & higher cost of decisions. While executing the Mega Project, a structured review calendar was established wherein Project Leadership Team interacted with execution members on weekly basis. Such approach not only lead to faster decision making and timely resolution of issues but also minimized the cost associated with such decisions. It also ensured better coordination across Project Value Chain. The faster decision making also boosted the morale of the execution team and encouraged them to put more efforts to complete the tasks at hand. • Monitoring & Control
activities only while other activities are noticed only when they are delayed and start affecting the project performance thereby providing very little time for course correction. In order to avoid such scenario, instead of categorizing and focusing only on key activities, Progress Dashboards approach was adopted to report the progress of each function. Such dashboards were creatively generated for various responsibility levels (e.g. Dashboard for supervisors to Project Leadership to Organisation Leadership). This approach ensured raising of coloured flags depending on the defined criticality (e.g. Green, Amber, Red) and divulged factually the health of the project & also the exceptions. The rundown and recovery plan was prepared for each of the delayed activity along with identification of specific crack team to implement such plan. In this manner, any adverse impact of delayed activities on project performance was minimized ensuring project progress as per schedule. • Scenario Planning
Due to vast scope and large number of concurrent activities in Mega Projects, the focus is often on progress of major 30 • December 2017
While small projects involve limited number of key activities, execution
of Mega Projects includes large number of activities and complex interdependencies. Any slippage affects performance of all interlinked activities thereby affecting project performance. The complex nature of project and involvement of multiple agencies also lead to emergence of many risks during project execution. In such scenario, thinking ahead of time and analysis of all probable scenarios involving “known – known”, “known – unknown” and also stretching the mind to judge maximum of “unknown – unknown” become necessary. In addition to robust risk management process, “What – If Scenario Analysis” workshops were conducted during each critical phase of Mega Project which were structured in manner depicted in Figure 2 to encourage team members to develop & identify Plan B for various scenarios. The above approach enabled the project team to react quickly to any challenge which was posed during execution and minimize the impact of any slippage on project performance. Chemical Engineering World
CEW Features
Figure 2: “What-If” Scenario Analysis
Differential Approach Related to Leadership: • Collaborative Approach with Partners Large number of vendors and subcontractors are involved in execution of Mega Projects whose performance is directly linked to the successful delivery of the project. In the event, any partner becomes weak link, it may pose serious risk to the entire project. Therefore, it is imperative that special focus is maintained on the progress and performance of such partners who are supplying bought out item and / or providing services to the execution of mega project. To ensure effective monitoring of vendor performance, dedicated task force was constituted for Post Order Management. Specific crack team was assigned to each of the bought out items. The project specific procedures developed by the team were shared with subcontractors to ensure their performance is in accordance with the requirements of the client. Progress and financial health of such Vendors and Subcontractors were reviewed periodically by Project Leadership. 32 • December 2017
With the above approach, effective business partnership was established with vendors and subcontractors based on joint problem solving attitude and on the principle of “we win together” leading to enhanced performance by vendors and subcontractors. • Leadership
While the immediate benefit of the processes was successful execution of Mega Project, consistent focus by leadership team on institutionalization has ensured the processes are implemented in other projects as well resulting in transformative changes which will be lasting beyond the project horizon.
While established processes and systems may ensure success in execution of small projects, success of Mega Projects is also dependent upon the leadership involved in execution of Mega Projects. In case of Mega Projects, the leader has to consistently analyze the benefits and limitations of established processes & systems and must intervene at appropriate junctures to ensure project success. In recent Mega Project, the leadership team not only focused on enhancing the effectiveness of existing processes such as risk management but also developed structured processes for change management, post-order delivery management and progress / exception reporting.
Author Details
Parthasarathi Chatterjee Vice President L&T Hydrocarbon Engineering Limited Chemical Engineering World
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Failure of Double Wall Jacketed Piping in Refineries: Causes and Prevention The application of double wall jacketed pipeline in sulfur recovery units of refinery plays a major role in productivity of sulfur. The sulfur content in crude oil may contain 0.22 wt% as obtained by detailed assay report. This sulfur has been extracted from various hydrocarbon processing units as sour water. Further the sour water processed in sulfur recovery unit to produce sulfur in solid powder form. The molten sulfur condenses via sulfur condensers to produce solid sulfur. The molten sulfur transferred to double wall jacketed pipeline and its failure case study is discussed. An improper design results in internal and external corrosion of internal core pipe deteriorate the pipe within five years. Root cause is analyzed and possible ways to mitigate similar failures is suggested.
T
he double wall pipeline is utilized in petroleum refineries and chemical process industries for maintaining liquid sulfur in melting temperature or not below sulfur condense temperature within internal pipe or similar fluid services in similar piping. The low pressure steam supplied within external pipe transfers heat to internal pipe through its wall thickness. Heat transfer depend wall thickness, corrosion scale deposit on inner and outer surfaces of internal pipe, steam temperature, sulfur temperature and material of pipe. One such jacketed pipeline was failed during service is discussed in this short technical paper. The inner pipe contains molten liquid sulfur and outer pipe contains low pressure steam. The nominal pipe size of inner pipe and outer pipe is 50 mm and 75 mm respectively. Both the pipes were made up of ASTM SA106 Grade B carbon steel with design pressure of 0.9 kg/cm2 and design temperature of 250 deg C. The pipelines were operated at 0.11 kg/cm2 pressure and 160 deg C temperature. Frequent failures were observed on double wall piping system and new pipes were installed. It constitutes major breakdown of units and loss of revenue. The insulation was provided for complete double wall piping network. The failure was confirmed by pressure drop within internal pipe due to molten sulfur clogging resulted in reduction of pipe area for fluid to flow. No external steam leakage was observed. This short review paper discusses the causes, analysis and prevention of failure. Failure Causes and Analysis A 2 inch inner pipe weld with 3 inch outer steam jacket pipe carries liquid sulfur from coalescer gas vessel to sulfur locks. The location of failure is observed on cross connection of double wall pipe shown in figure1. A 2 inch inner pipe of 5.54 mm thickness has corrosion allowance of
34 • December 2017
3 mm. The inner pipe wall thickness reduces and fails due to corrosion. However, it is difficult to determine a failure due to internal or external corrosion. Both the corrosion may have occurred possibly for cross connection failure. The failure pattern is due to poor design subsequently resulted in metallurgical prone corrosion failure. External Corrosion on Inner Pipe: The low pressure steam condensate traps within external pipe could not able to drain since non availability of separate drain line. The absence of wear plate on inner pipe further erodes eventually. Internal Corrosion on Inner Pipe: The forged cross connection pipes were not used during erection and instead cross connection fabricated locally from sub-standard pipes by unqualified welders or fabricators was observed initially for fabricating T-joint from records and documents. This may lead to non uniform inner surface of internal pipe particularly at weld joints location conducive for stagnant molten sulfur deposits. This sulfur deposited in stagnant locations further build up deposits and alters the localized electrochemical reactions of internal pipe at those sulfur deposited area locations. This localized electrochemical alterations attack the inner surface wall on or near the weld joint. Further reactive process gas agents like hydrogen sulfide present in liquid sulfur increases deterioration of internal pipe. After internal pipe perforates, the steam from outer pipe enters into internal pipe through perforated area, mixed with molten sulfur. A mixing cools liquid sulfur suddenly and solid sulfur formed subsequently clogged the internal pipe completely. These have been indicated by pressure gauges installed in those piping as action of sudden pressure drop which was noted.
Internal Corrosion of Outer Pipe: No leakage of steam from outer jacketed pipe was reported. Prior history confirms no such leakage observed till now from construction. Welding Procedure and Non Destructive examination during and after Fabrication The welding of failed cross connection was fabricated as mentioned below. All the weld joints were fabricated by fillet weld and no other joint design (single v groove) were used. 1. Welding one end flange into inner pipe 2. Guide strip of equal circumference were divided for fillet joint between inner and outer pipe 3. Welding wear plate into inner pipe where steam impinges an external surface of inner pipe 4. Welding remaining section of inner pipe to outer pipe 5. Welding outer pipe to inner pipe on remaining three flange connections 6. Performed liquid penetrant test and hydro test on inner pipe at 3.0 kg per sq.cm 7. Liquid penetrant and hydro test were conducted on outer pipe at 12.0 kg per sq.cm It was observed that no defects were found from fabrication during initial welding construction. No significant observations were recorded during initial fabrication. The fillet root pass welded with E70XX series welding rod and no post weld heat treatment was done. The pre heating before welding was maintained at 150 deg C to avoid hydrogen dissolution in welded joints. This may cause hydrogen embrittlement of fillet welding. The hot and subsequent passes were welded by E-60XX series welding rods. Chemical Engineering World
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CEW Features
Figure 1: Shows cross connection of jacketed double wall piping in sulfur recovery units and its geometric features
Discussion The phenomenon of failure is due to inadequate condensate draining of steam on external jacketed pipe and sharp edge of inner core pipe at cross junction. Inadequate draining causes cavitation damage on external surface of inner core pipe where condensate impinges. Also inner cross connection having sharp edges acting as stress raisers and it leads to sudden changes in flow pattern of molten sulfur resulted in localized erosion corrosion. Cumulative effect of aforementioned mechanisms may results in failure of jacketed pipe. The condensate drain line was not provided separately in an external pipe design and it is considered design defect. Therefore both internal and external corrosion contributes metallurgical prone effect on material corrosion in inner pipe due to design deficiency. The failed portion did not confirm to any standard specification. The standard cross connection is shown in figure 1 which has design for smooth laminar molten sulfur flow pattern in internal pipe at cross connections. However, right shown figure were not constructed as per design shown in left figure and pressure drop was found in the right shown cross connection figure which was failed. Recommendations to avoid Failure • An inner bar shall be fixed during fit up fabrication for maintaining proper concentricity between inner core and outer jacketed pipe. It may lead to uniform load distribution on effective area of welded joint between inner and outer pipe. • The wear plate shall be installed on inner core pipe. This certainly avoids the inner 36 • December 2017
•
•
•
• •
•
•
•
•
•
pipe from erosion since steam impinging on external surface of inner core is severe. The condensate drain lines shall be provided on outer jacketed pipeline as a provision for draining the condensate available in steam. Otherwise condensate trapped within jacketed pipe gradually settles inside shell and corrode further an inner pipe. Before taking shut down of steam jacketed lines, the condensate trapped within shell shall be drained out completely. Proper guide strip shall be provided on inner pipe for uniform steam distribution to avoid process fluid concealing. The venting holes shall be provided on outer pipe to empty out residual water. The cross connection edge corners shall be provided with smooth surfaces such that smooth laminar flow may occur on cross connections. The maximum the smooth minimum the damage on inner core pipe. Hydro test shall be carried out for every 5 years on internal pipe and outer jacketed pipe which assure structural integrity. The inner pipe shall be flushed properly to remove stagnant sulphur deposits if any present which further avoids under deposits like active sulphur agents and prevent from under deposit corrosion. Low pressure steam in outer jacketed pipe shall be shut off when the jacketed lines are shut down. Construction of steam jacketed lines shall be conformance international and national code standard specifications Epoxy internal coated inner pipe shall be used for inner core pipe which exhibits corrosion resistance at 150 deg C for molten liquid sulfur.
Conclusions The cross connection pipe clogged with sulfur deposits were analyzed and it is observed inner core pipe failed at fillet weld joint between inner core pipe and external jacketed pipe. It is concluded as design defect and further recommendations were provided to improve the design of those pipelines. Improved design pipe cross connection were replaced after this failure and author experiences no leakage was obtained even after 5 years. No pressure drop was observed in those piping systems. References 1. ASME Boiler and Pressure Vessel code, American Society of Mechanical Engineers ASME Sec IX, USA 2. SME Boiler and Pressure Vessel code, American Society of Mechanical Engineers ASME Sec II A, USA 3. ASME Boiler and Pressure Vessel code, American Society of Mechanical Engineers ASME Sec V, USA 4. ASME Code for Pressure Piping, American Society of Mechanical Engineers ASME B31.3, USA Author Details
S Chidambaram Officer Inspection and Metallurgy Inspection Department Numaligarh Refinery Limited Contact: chidambaram.s@nrl.co.in Chemical Engineering World
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Concept of Integrated Technologies in Wastewater Treatment This article deals with advanced technological solutions for the treatment of industrial wastewater. Wastewater from pharmaceutical, chemical and petrochemical industries as well as landfill leachates are specifically considered as representative of major problems encountered when treating industrial streams. The economic and environmental sustainability of the above solutions are also reported in this article.
W
astewater treatment processes are very important for environmental conservation. Increasing industrialisation and population in India has created huge potential in the area of wastewater management. Wastewater treatment market in India is still in the process of finding innovative technologies/solutions required for specific industry. The level and composition of pollutants varies for different industries. In many cases, industries are exploring applicability of processes for recovering specialty chemicals from their wastewater. These solutions have been fuelled by increasing need for conserving and reusing/ recycling water processes.
Increased
environmental awareness, public awareness and social responsibilities have raised the need to generate new wastewater treatment technologies with specific programs in this sector. At the same juncture, most of the industries
prefer
system
supplies
capable of providing energy-efficient technology at competitive price/low cost. The equilibrium between low cost and efficient performance, limits the flexibility of the technical operation. Membrane Separation Laboratory at CSIR-IICT, Hyderabad has developed tailor-made processes for water treatment at low cost. The technology 40 • December 2017
is highly efficient, effective and economical for treatment of wastewater from specific industries like Dairy, Kitchen, Pharma and Coffee. Dr. S. Sridhar, Principal Scientist and Project leader of this group says the integrated process with pre-treatment + Membrane Bioreactor (MBR) + Reverse Osmosis (RO) can meet Zero Liquid Discharge (ZLD) for wastewater treatment. Dr. Nivedita Sahu, Sr. Scientist from the group has developed unique microbial cultures for treating many of these effluents by breaking down the Chemical Oxygen Demand (COD). With her background on phycology, she plans to carryout algal-based phycoremediation to enhance treatment efficiency and improve percentage water recovery. Dr. Sridhar adds that in present scenario, it is also necessary to provide value addition to reduce the total cost of operations while fulfilling the existing criteria. The group, at IICT has successfully commissioned membrane based pilot plants of 7,500 L/day to 1.10 lakh L/day for processing effluents from acrylic fiber industry, pharmaceutical producers and steel
manufacturers to recover valuable solvents and water. The technology developed at Membrane Separation Laboratory, CSIR-IICT is a novel membrane based integrated process that combines chemical coagulation, microbial degradation, membrane separation and if necessary, post treatment by UV, ozonation or activated carbon. MBR is a device which combines microbial action with membrane separation to eliminate secondary clarifier and achieve process intensification. MBRs can be operated in aerobic and anaerobic mode depending upon effluent characteristics, with the latter involving simultaneous generation of energy in the form of biogas apart from facilitating water reclamation. Usually MBR is incorporated with MF or UF membranes to clarify and disinfect the water and make it fit for reuse or utilization in irrigation. If higher water purity is desired, MBR can be combined with RO. Unlike, MBR, in moving bed bioreactor (MBBR) configuration, the entire mixed liquor suspended solids (MLSS) need not be recirculated through the membrane assembly and
Increasing industrialisation and population in India has created huge potential in the area of wastewater management. Wastewater treatment market in India is still in the process of finding innovative technologies/solutions required for specific industry. Chemical Engineering World
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Figure 1: Membrane Filtration Integrated Process
only the overflow water from reactor is processed by microfiltration (MF) or ultrafiltration (UF) before reclamation. MBBR could be useful for effluents which are less biodegradable and need aeration or activated process. The possibility of using MBR integrated with RO can be considered an effective and easy process for the de-colorization and de-odorization of these waste streams. The process is safe, rapid and does not generate any pollutants. The graphical sketch shows the types of approaches adopted during treatment. Impact of Innovations in Wastewater Treatment Dr. S. Sridhar feels that, the developments in the industrial wastewater sector in India are experiencing tough regulations. The presence of numerous industries and
of handling equipment, (b) effective removal of recalcitrant components, (c) efficiency in selective applications like recovery of specialty chemicals for specific needs in industries, (e) equitable water distribution and utilization, and (f) economy. The industries get benefited by adopting hybrid/integrated technologies with chemical treatment/ pretreatment+MBR+RO, Zero Liquid Discharge (ZLD), etc for wastewater reuse.
the industrial sector will define enhance scope for effective and economical treatment of wastewater to achieve ZLD and conserve water.
Author Details
Key Challenges Industry’s acceptance to adopt new technology is a key challenge for technology providers. Future Scope
Dr. Nivedita Sahu Sr. Scientist CSIR-Indian Institute of Chemical Technology, Hyderabad
shift in wastewater treatment is towards
Water scarcity is a global issue/concern. Conventional technologies for treatments are well proven but more technologies
the concept of ZLD has led to process
with less energy consuming based on
and system design with equipment such
3E’s concept (“efficient, effective and
S. Sridhar
as MBR, RO, UF, NF with chemical treatment/ pre-treatment. Membrane based integrated processes provide better solution for ETPs and STPs. The key benefits are: (a) ease and safety
economy”) need to be showcased. MBR
Principal Scientist and Project leader
+ RO/UF/NF and MBBR + RO/UF/NF
Membrane Separations Laboratory,
are such technologies which are finding
Chemical Engineering Division
prominence in wastewater treatment. The adoption of these technologies in
CSIR-Indian Institute of Chemical
42 • December 2017
Technology, Hyderabad Chemical Engineering World
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Water Management Using Membranes: Forward Osmosis and Pressure Retarded Osmosis as Technologies of Future Nobel Laureate Richard Smalley listed the Top 10 global challenges which he predicted will haunt the human race in the coming decades. Energy and water topped the list with ranks 1 and 2, respectively. All the other cited challenges, e.g., food, environment, poverty, terrorism, etc either can directly or indirectly be related to either energy or water. The recent crisis in Syria is an example of water crisis (drought) affecting an already unstable region. Thus, it is imperative to understand the effect of water crisis and its impact on human civilization. In this regard, the present article focuses on two technologies – forward osmosis and pressure retarded osmosis. Whereas FO is being vouched as low energy intensive process for water treatment (industrial or drinking water), PRO is being looked into a green and sustainable technology for power generation from water mixing.
F
orward osmosis is one of the most promising technologies for seawater desalination with less energy consumption. In a scenario of rising population and limited energy resources forward osmosis is being “tipped” as the technology which can help diminish the offset between the supply and demand of drinking water requirement. Forward osmosis (FO) is essentially an osmotic pressure driven process in which a semipermeable membrane is used which separates dissolved solutes and pure water (Fig. 1). In principle, a “draw” solution having higher concentration relative to feed solution is selected which generates a osmotic pressure gradient across membrane. The pure water permeates through the membrane while retaining the dissolved solutes osmotic pressure gradient vanishes. This process is in contrast to reverse osmosis (RO) technology which uses hydraulic pressure as the driving force (working against the osmotic pressure) for separation of solute and fresh water. Thus, RO energy requirement is significantly higher than FO process. Since FO is driven by osmotic pressure difference, thereby it is less susceptible to membrane fouling compared to traditional hydraulic pressure driven membranes like RO.
44 • December 2017
FO is enjoying great popularity and has garnered lot of attention in food processing industry, power generation sector and waste water treatment plants. The significant player which influences the efficiency in FO process is membrane selection and draw solution. There have been a lot of recent advancements in improving the flux across membrane including development of FO-ultrafiltration system and development of FO hybrid membranes using hydrophilic nano-sized particle with polyacrylic acid as draw solute. Generally FO membranes can be categorized into three classification on the basis of synthesis, e.g., cellulosic , thin-film composite (TFC) and chemically reformed membranes. There are currently
two types of commercially available TFC membranes in market which is extensively used in FO study and research. A recent nanofiber TFC-FO membrane has been developed by Electrospinning and interfacial polymerization. This has increased the FO performance due to high porosity and low tortuosity. The support layers of commercially available TFC membranes can be modified by Polydopamine (PDA) for engineered osmosis application. Enormous research and publications on FO for desalination have been carried out in past 20 years (general schematic in Fig. 2). But development of economically viable membrane
Figure 1: FO process Chemical Engineering World
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CEW Features
Figure 2: FO assisted desalination
from experimental studies is crucial to attain sustainable FO applications. For optimization of desalination efficiency the FO membranes should be chemically and mechanically stable with minimal internal concentration polarization and negligible reverse solute flux. The draw solutes for future desalination application should be easily regenerated with minimum energy requirement. Thus looking ahead, there is huge potential in FO technology in coming future .The overall energy requirement of FO can further be minimized by integrating both FO and RO for water purification thereby designing a hybrid system. Harvesting Salinity Gradient Renewable Energy Generation
For
Since time immemorial, the debate of renewable energy methods has been troubling academics and industry likewise. There have been the clichéd methods such as solar, wind, geothermal and such, but one that has not been given its due share of academic investigation is that 46 • December 2017
of Pressure Retarded Osmosis (PRO). It is an oft overlooked method that caught the academia off guard when Statkraft, Europe’s largest supplier of renewable energy and Norway’s leading power company shut down their PRO operation in 2012, reaching to the conclusion that it wasn’t economically viable to operate the plant. PRO was first developed in the early 70s as a clean way to utilise osmotic pressure for the generation of electrical power (Fig. 3). It involves using a very large semipermeable membrane to allow two streams, one being fresh river water, to flow into a more concentrated and pressurized solution, such as sea water. Salt molecules pull the fresh water through the one-way membrane as a result of osmotic pressure gradient that developed across the membrane, and cause an increase in pressure, which is harvested by a turbine to generate power. It has been estimated that utilization of osmotic potentials between rivers and oceans across the globe represents an energy potential of 1600-2000 TWh
(corresponding to approximately 1% of the World energy consumption). This process has no carbon footprint, and the full-scale process plant will have only brackish water as the by-product. It is well known, that energy and water are two of the top concerns in the near future. The goal needs to be to manage this resource in the most efficient and sustainable way possible. Obtaining usable work from a renewable and clean energy generation process is a step in this direction - that hits both birds with one stone! For an energy deficient country like India, looking towards novel and alternate options and tapping such sources is one of our best bets towards solving the energy crisis. The Indian peninsula is strategically located in the Asian subcontinent with Himalayas to the North and Oceans surrounding the other three directions with annual monsoons taking care of water supply to the perennial rivers. The total river water discharge into the Bay of Bengal and Arabian Sea is 628 km3/year and 274 km3/year, respectively. Thus, huge volumes of fresh water meet saline water and this mixing Chemical Engineering World
CEW Features
Figure 3: Pressure Retarded Osmosis Power Generation
of two streams of dissimilar salinity gives rise to colossal mixing energies which can be harvested for usable work for various purposes like energy generation using the novel method of Pressure Retarded Osmosis. Harvesting energy from such an option is certainly new in the Indian subcontinent. However, it has been significantly researched upon and eventually implemented, if not successfully
Interest in PRO has been growing internationally, such that researchers at NASA have been studying use of such process that can purify water and generate energy at the same time. With the need for renewable and clean energy alternatives greater than ever before, this could be a topic that would get picked in the near future with tremendous application that can benefit all.
Theoretical studies confirm that higher the salinity difference among the two streams better is the rate of energy production. The concerns however, for PRO have been raised when in 2012, Statkraft concluded that one of the major challenges to having an economically viable full-scale PRO plant was the unavailability of the advancements in the domain of membrane technology to enable manufacturing of high performing and inexpensive bulk membranes. Another concern that has caught the attention of researchers and environmentalists alike, is that concerning the future largescale operations of PRO and their effect on salinity levels or how pre-treatment processes might impact local marine life.
Conclusion Keeping in mind India’s economic growth and recent initiatives like “Make in India”, it is important to start concentrating on striking a balance between conserving and harvesting an important resource like water. It is of utmost importance that while recycle and reuse of water should be encouraged, however compensating the offset between supply and demand of water should be addressed with potentially sustainable technologies like Forward Osmosis. Also research into harvesting energy from mixing energies of sea-water and river water should also be initiated as India is geographically well positioned to benefit from such technologies.
48 • December 2017
Author Details
Arijit Chakraborty Undergraduate Department of Chemical Engineering BITS Pilani Goa
Ridhish Kumar Undergraduate Department of Chemical Engineering BITS Pilani Goa
Anirban Roy Assistant Professor Department of Chemical Engineering BITS Pilani Goa Chemical Engineering World
Beda_AP_15 Dec 14.indd 1
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CEW Features
A Roadmap to Unlock Future Growth Opportunities of Plastic Processing Sector in North East India Plastic Processing Sector has become the ubiquitous workhorse of the modern economy – manufacturing products with peerless functional properties and optimum cost. The uses of plastic products have increased ten-fold in the last two decades and is expected to double again in the next five years. While delivering many benefits, the current plastics processing sector has drawbacks that are becoming more apparent by the day. This sector offers a new vision and roadmap to overcome the boundaries of today’s incremental improvements and fragmented initiatives which will align with the principles of the circular economy, to unlock future growth opportunities with an unequivocally systemic and shared approach. The aim of this sector is to move the plastics value chain into a positive spiral of stronger economics, capture value and better environmental outcome- while creating a shared sense of direction and igniting the spark of innovation. This article outlines the potential of the Plastic manufacturing sector to transform the scenario and thereby usher in the New Plastics Era of North-East India.
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lobally, the manufacturing sector is changing rapidly, driven by changing trends and emerging technologies. With the global petrochemical feedstock slate becoming more diverse, understanding the complex petrochemical markets has become essential in gaining a competitive advantage, and in order to understand the supply-demand scenario, the polymerproducing petrochemicals are digging deeper. It is important to track the global
trade flows and keep in line with the longterm and short-term changes in the global and regional market. The Indian plastic industry has a considerable involvement in the economic development of the country along with its association with the development of other key-sectors like construction, automotives, electronics, etc. The plastic processing sector is gaining notable importance, with developments in the petrochemical sector, and strengthening the capacities to cater
the domestic as well as the overseas market. Development of various new applications has provided an impetus to the growth of the plastic industry, and with the growing demand in end-use industries for existing applications, the potential to contribute in bringing foreign investments has also increased. The Indian plastics processing industry has grown at a CAGR of 10% in volume terms from 8.3 MMTPA in FY10 to 13.4 MMTPA in FY15 and is expected to grow at a CAGR
Figure 1: Overview of per capita consumption of plastics in North-East India with respect to global consumption 52 • December 2017
Chemical Engineering World
CEW Features Changing landscape of Plastic Industry in North-East Considering the economic and demographic features of the North-Eastern states, in comparison to the rest of the country, the prospects for increased consumption of polymer products than the present levels appear bright. Cross-border trades with Myanmar and Bangladesh, and the India– Myanmar–Thailand Trilateral Highway which is expected to be a boon to the growth of the polymer sector in the NE region, all offers immense trade potential for the NER in the years to come.
Figure 2: Growth in polyethylene and polypropylene capacities in India
of approximately 10.5% from FY15 to FY20 to reach 22 MMTPA. The current percapita consumption of plastics in the U.S. is 109 kg, 38 kg in China, 11 kg in India, and 4 kg in North-East region. While the outlook for plastics processing in the Indian subcontinent is positive, the industry still faces many challenges. Being tucked away in a landlocked corner with limited infrastructure and limited connectivity with the rest of India, the Petrochemicals & Plastic Industry in North-East India are exposed to changing environment, increased globalization of markets, public expectations for improved environmental performance, 54 • December 2017
and the need for increased profitability and productivity. Usually petrochemical industries are primarily located nearer to sea-ports which facilitate coordinated and planned movement of goods and materials. The North-Eastern region has the inherent disadvantage of being located far away from any of the Indian sea-ports due to which supply of feedstock and materials from other parts of the country is a herculean-task which involves time and cost-overrun. On a positive note, the situation also created platform in making domestic downstream plastic processing industries more competitive thereby providing significant opportunity for entrepreneurs.
Domestic manufacturing is now being promoted through a new policy of the Government for setting up National Investment and Manufacturing Zones (NIMZs) which are a combination of production units, public utilities, logistics, residential areas and administrative services. Keeping in line with the Centre’s vision of Hydrocarbon-2030, the government has called upon entrepreneurs to invest in plastic industry. The government has also passed the Easeof-Doing Business Bill-2016, creating possibilities of a single-window clearance system for fast-tracking business projects in the state. The focus is on promoting and attracting plastic-based downstream industries which will not only bring in large amount of investments but also generate huge employment opportunities and socioeconomic development in the region. Opportune Moment to Act is Now The plastic industry in the region, at present, is witnessing a dramatic transformation from a low-profile production base accounted for by the local entrepreneurs, to a scenario in which the major-players in the field in the country are focusing on investments opportunities in the region. The major petrochemical players in the region are committed to establish significant presence in the north-east region in petrochemical sector by way of production or sourcing and marketing of quality products, deploying Chemical Engineering World
CEW Features
Figure 3 : Key growth drivers for North-East
efficient distribution and marketing channels to cater to the needs of target customers. Opportunity of exporting desired PE/PP grades in the adjoining countries is also being explored for expanding market footprints of the Plastic Industry in next few years. Coupled with local availability of raw material, campaigns like “Startup-India” launched by the Government are expected to give a further boost to setting up of plastic-processing units in the region. An integrated plastic-park is being set up at Tinsukia, Assam, which is expected to attract entrepreneurs to setup downstream plastic processing units to utilize the polymers produced in the region. The market 56 • December 2017
prospects in the region are promising with around 136 plastic processing industries consuming approximately 1.1 lakhs TPA of polymer which was earlier sourced from outside the region. With the implementation of economic reforms, India’s overall outlook remains positive with a GDP of approximately 7%. This is a positive indication for the Polymer sector, which plays vital role for growth on the overall economic development. In the journey towards sustainable production, the existing petrochemicals have formulated souring and marketing strategies towards “Make-in-India” through boosting entrepreneurship, technology and research and development along with unlocking latent demand in downstream industries.
New Plastics Era Demands New Way of Thinking An organized development addressing cost-effective plastic processing along with streamlining operations of plastics could pave a growth path for downstream plastic manufacturers in North-East India. Demand for performance plastics such as biodegradable polymers is expected to be on rise across the world including India. Focus areas are going to be modern farming through Plasticulture, packaging for processed food & non-durables, better plastics for Automobiles, infrastructure development, innovative products for Telecommunication and IT sectors. Plasticulture can significantly benefit agriculture by its wide applications in all the Chemical Engineering World
CEW Features areas of farming. It can be used to tackle the specific problems faced by North-East regions.
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Most of the actions listed above require a collaborative effort and in order to accelerate or improve the impact of these actions, a number of considerations must be contemplated to identify the most efficient and effective implementation approach. These considerations may also include acknowledging the pace of cultural change in North-East Regions, and tailoring solutions for SMEs. The agility and specialization of SMEs will be critical in achieving the visions for NorthEast Regions and while implementing the suggested actions, it is important to ensure solutions are valuable and accessible to SMEs.
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In order to move beyond small-scale and incremental improvements, and achieve a systemic shift for unlocking the future growth opportunities, existing improvement initiatives would need to be complemented and guided by a concerted collaboration initiative that matches the scale of challenges and opportunities. Standard protocols needs to be established built on the following elements: • Continuous efforts to develop and facilitate adoption of globally recognized standards. • Redesigning a set of clearly defined collection and sorting archetypes, allowing for continued innovation and regional variation. • Developing insights and building an economic and scientific base which accesses the socio-economic impact of the plastic materials. • Engaging policy-makers, in a common vision towards a more effective system, and provide them with relevant tools, data and insights related to plastics processing. • The leading stakeholders need to come together and define “moon-shot” innovations: which are focused and have practical initiatives with a high potential for significant impact at scale.
Transforming North-East Petrochemical and Plastic Industry for sustainable competitiveness is not a short-term process, and a consistent and supportive policy environment is required over the next decade to provide businesses with stability and allow them to execute longterm strategies. Significant efforts are being made by all the stakeholders to realize the real potential of this industry, and position the North-East Petrochemical and Plastic Industry as a eminent economic player in the region.
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Growth and Opportunities in Plastic Industry of India Indian Plastics Industry has taken great strides. As shared by Shri Arvind Mehta, Chairman & Managing Director, Welset Plast Extrusions Pvt. Ltd., plastics will be called on to play a vital role in this changing region and the plastics industry will benefit from national efforts to encourage and improve manufacturing and processing in plastics.
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ndia is one of the oldest civilizations, with a population of over one billion (17% of World Population). India has consistently shown a GDP Growth of more than 6%, since the introduction of economic reforms in 1991. The global demand for plastics increased after 21 st century and it continues to increase over the years. The Indian sub-continent has established itself as the most exciting and dynamic emerging market in the world and is one full of potential and investment opportunities. India is one of the largest producers of Plastics in the world and is expected to become 3 rd largest plastics manufacturer by 2020 . In context of Growth Drivers in Plastics Industry, India’s booming progress in
various fields has given a kick start to the growth spree of the Indian Plastics and Polymer industry. These have laid down a positive path for the plastics and polymers growth story in the country. The Development in the Indian Polymer Packaging Products has brought in the revolution with more than 60% of the polymers consumed in India being consumed for packaging applications. With the polymer consumption in packaging being at 5.3 Mn Mt in 2011, it is slated to reach 10 Mn Mt by 2020. Another driving force behind the success of the plastics industry is the Indian appliance industry which is growing at 15% Y-o-Y. Other significant
contributors to the progress of the industry are the healthcare domain, which is increasingly resorting to plastics in terms of syringes, IV fluid bottles, , Modern Medical Equipment & Implants, Artificial body parts etc. The plastics industry in India is poised to grow multifold in the years to come. In terms of Market Development, India’s Gross Domestic Product (GDP) grew only by 5.7% year-on-year in April-June, 2017 quarters as per OECD Economic Survey of India, 2017. Indian economy is expected to grow at a rate of 6.7 per cent in the year 2017-18 and in the next financial year 2018-19 the economy is expected to grow at a rate of 7.2 per
Figure 1: Plastics Products Demand Growth Drivers 60 • December 2017
Chemical Engineering World
CEW Features Key Roles
2005
2015
@15% CAGR, Consumption of Plastic Polymers
4.7 Million Tonnes
18.9 Million Tonnes
Employment in Plastics Industry (Direct + Indirect)
2.5 Million
9.5 Million
Plastics Industry’s Turnover
` 35,000 Crores
` 1,33,245 Crores
Export of Plastics Products @30% CAGR
USD 1900 Millions
USD 10,215 Millions
Contribution of Polymers and Plastics Products to the ` 6,200 Crores Exchequer
` 15,990 Crores
Table 1
cent. With a focus on expandable market capitalization of plastics industry, the per capita consumption of plastic products in India is growing and is moving towards 8% GDP Growth. The phenomenon rise in the plastics industry sector of India is coupled with the developments in the petrochemical sector and plastic processing sector, which has facilitated the plastics industries to build capacities for the service of both the domestic market and overseas market. Today, Indian Plastics Processing sector comprises of over 30,000 units involved in producing a variety of items through injection moulding, blow moulding, extrusion and calendaring etc. The capacity built in most segments of this industry coupled with inherent capabilities has made Indian plastic industries capable of servicing the overseas markets. The above table mentions about the key roles played by the plastics industry between the timeframe of 10 years (2005 – 2015) in the Indian economy. One of the major factors leading to technological skill enhancement and growing education standards through various sector focused institutions in the field of plastics, has resulted in creating abundant employment opportunities in last 10 years for the Indian youths. With a growing demand of plastic materials and its uses in various other industries, 62 • December 2017
a diversified need was realized by the plastic industries to serve the nation’s demand, resulting a turnover growth of about ` 98,245 Crores between the time period of 10 years. In view of Wide Ranging reforms in the field of plastics industry, India is one of the most promising exporters of plastics among developing countries. The Indian plastics industry produces and exports a wide range of raw materials, plastic moulded extruded goods, polyester films, laminates, moulded/soft luggage items, writing instruments, plastic woven sacks and bags etc. As manufacturers increasingly focus on customising products in accordance with end-user needs, the Indian plastics industry has also started developing specific items to suit customer requirements, including supplies to original equipment manufacturers (OEMS). The design, style, as well as the pattern, is decided according to the requirement of the customer in the export market. The micro, small and medium plastics processing units (~75-80% of the total plastic processing units) contribute just about 25% of polymer consumption. The industry also consumes recycled plastics, which constitutes about 30% of the total consumption.
In addition with the government’s renewed focus on providing clean water for drinking and improving sanitation facilities through the construction of individual household toilets, cluster toilets and community toilets under Swachh Bharat Mission, PVC and Chlorinated polyvinyl chloride (CPVC) plays important role in the sustainable management of these sectors through various plastic allied products. The huge allocation to infrastructure sector, higher focus on water management and on improvement in sanitation facilities provide huge growth potential for plastic manufacturers which has significant presence in these areas. As per the growing demand of consumer products by Indian citizens, Indian consumers segment is broadly segregated into urban and rural markets, and is attracting marketers from across the world. “Smart cities, rapid urbanisation, increase in sale of packaged products through retail and ecommerce mode, low per capita consumption, shifting consumer lifestyles, large young population, majority of population of middle income group, many manufacturing segments adopting higher percentage of plastics, etc. are contributing towards the growth of plastics industry,” and resulting to the
“Slowly but surely India is overtaking all the other countries in the region as the future plastics growth center of not only AsiaPacific, but of the world.” Chemical Engineering World
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Figure 2 Source: Tata Strategic Analysis Report, Tata Strategic Management Group, February, 2017
growing demand of plastic consumable products among Indian citizens. In comparison of growing Indian plastics industries at global level, plastics are gradually becoming the material of choice for extensive usage due to their unique and diverse set of properties. However, due to low penetration levels of plastic products in the Indian market, especially rural segment, the per capita consumption of plastics is low. As shown in below mentioned figure, with current per capita consumption of plastics in the U.S. at 109 kg and in China at 38 kg, India at 11 kg has a long way to go. The low consumption level indicates an enormous growth potential for the plastics sector. Due to increasing domestic consumption and high potential, India is emerging as one of the focus destinations for plastics and downstream players worldwide. Key Facts about Welset Plast Extrusions Pvt. Ltd. Welset is a well-known and highly trusted name in plastics industry making available 64 • December 2017
a wide range of colouring and compounding solutions to the industry. Welset has entrenched its name as a high quality manufacturer and supplier of a wide range of Colour, White, Black Master Batches, Anti-fibrillation/Filler Master Batches, and full range of Additive Master Batches for Plastics Industry. Welset is equipped with technologically most advanced ISO 9001-2008 certified facility to produce full range of PVC compounds, master batches, niche medical grades and specialty products like tubings and sheetings. The facility is fully automated with clean room having class 100,000 environment. With a vision to be the market leader in compounding by offering innovative colour and compounding solutions and to achieve higher levels of growth and excellence to attain leadership and set a benchmark of quality service at the National level
and be recognized globally, Welset Plast Extrusions Pvt. Ltd., is today one of the leading companies in the business of colouring and compounding solutions for plastics industry. Welset Plast Extrusions Pvt. Ltd. has achieved various milestones in its ongoing journey since the inception of the firm in the year 1968.
Author Details
Arvind Mehta Chairman & Managing Director Welset Plast Extrusions Pvt. Ltd Chemical Engineering World
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Ecological Sustainability for Economic Upliftment This article talks about need for a sustainable model of development in order to overcome environmental pollution, water scarcity and rising temperatures. It also delves upon the concept of circular economy.
I
n April, IMF estimated that Indian economy is set to leapfrog Germany to rank fourth globally by 2022. The World Bank agrees and predicts India has the potential to be the world’s 3rd largest economy within the next 10 years. GDP is expected to grow between 7.5% and 8.3% for the coming years. If India continues its current high growth path, incomes will triple over the next two decades and the country will become the world’s fifth–largest consumer market by 2025. The need for a sustainable model of development has never been more urgent, as the world’s fastest growing economy battles environmental pollution, water scarcity and rising temperatures. In line with the UN Sustainability Development Goals 2030, India too set its Sustainability Goals and solemnly pledged for a safer environment. According to a research released by the United Nations, named the Climate Action Tracker (CAT), India is likely to reduce projected global carbon emissions growth by roughly two to three billion tonnes by 2030 compared to forecasts made a year ago. However, for a nation as vast and populous as India, implementation at the grassroots level will require time and sustained effort. Emergence of technologies
smart
manufacturing
India can benefit from accessing technological advancements implemented across other industries. Further efficient use of resources is of crucial importance as initiatives like Make in India, Smart Manufacturing and Skill India are gaining momentum and building in scale on a low base. 66 • December 2017
Consider Manufacturing, there is need for an advanced production optimisation tool that supports timely execution of production processes and that guides companies in real time to reduce nonvalue-adding activities thereby enhancing productivity and enabling them to achieve operational excellence. Industrial development using sustainable practices India’s contribution in the formation of the International Solar Alliance and efforts to harness solar energy to address the power deficits in the country are already reaping rewards. India had targeted installation of 4 GW of wind capacity and 12 GW of solar capacity, the two largest contributors to the renewables basket, in 2016-17. India has achieved about 40% of its wind energy target and about 17.5% of its solar energy target. One of the most critical pieces of the sustainability puzzle is harvesting of water for appropriate use for individual consumption, agriculture, industries etc. For many municipalities across the world the fear is primarily floods or scarcity because of heavy usage of water for industrial purposes. The industries are chiefly concerned with the latter. To avoid or mitigate such impacts, energy efficiency, emissions control, and reuse are destined to become the norm across the board, by choice or by mandate. As a result of this many businesses in India are working towards closed-loop water management systems. Manufacturing is one of the sectors vulnerable to water shortages. According
to McKinsey, the global water demand for manufacturing is anticipated to increase by 400 percent from 2000 to 2050. Maximizing the efficient use of water by industry is a critical step in the right direction — for both the environment and the bottom line. To prepare against impending cuts on water supplied to industrial belts which could pull down Index of Industrial Production (IIP) growth by around 40-50 basis points, it is imperative that industries review their water management systems critically. Technologies that enable Minimum Liquid Discharge (MLD), which are not mandated by government in most industries can be easily blended, with minimum injury to the bottom-line. According to a study conducted by IndiaSpend earlier in 2017, 75% to 80% of water pollution is from domestic sewage, discharged untreated into local water bodies. The report also mentions that untreated sewage is dumped directly into water bodies, polluting three-fourth of India’s surface water resources which implies that almost 80% of the water bodies in the country are polluted. Welcoming the circular economy model It is critical for us, as an industry to commit to preserving our diminishing natural resources by moving away from linear consumption model to reduce-recyclereuse model of circular economy. Adopting the Circular Economy Model that promotes the use and reuse of resources, will bring in healthy practices of consumption of non-renewable resources. A research by the Ellen MacArthur Foundation on Circular Economy confirms that the circular economic model could bring India annual Chemical Engineering World
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CEW Features benefits of INR 40 lakh crore (US$ 624 billion) in 2050 compared with the current linear model – a benefit equivalent to 30% of India’s current GDP. To make this a reality, we need to establish the need for industry-government collaborations and jointly prepare a road map to success. A common standard for environmental regulations and policies must be devised and strictly implemented so that all industries, irrespective of their size and economic strength, can make efforts to protect the environment. Collaboration The intent and aspiration to align economic efforts with the environment should not be restricted to the government. Collaboration between the industry, government and regulatory bodies will help in evaluating decisions on economic viability and environmental benefits. For
instance, being the authoritative body to safeguard the environment, the Ministry of Environment, Forest and Climate Change along the National Green Tribunal and industry can bring to steer a giant leap towards adopting sustainable economic models. Making environmental health integral to the national economic growth agenda of the country is the way forward for India. Integrating climate action into economic policies will only lead to greater output and favourable growth prospects. According to the Organization for Economic Co-operation and Development (OECD), major economies could boost their long-term economic growth by 2.8% with policies that lower greenhouse gas emissions and boost resilience to climate change impacts.
into that of services, skipping the process/ requisites of manufacturing completely. As we go forward, policymakers will be challenged to keep India on the path of economic reform while addressing issues in infrastructure and social investment. It is important that we take collaborative and thoughtful efforts to preserve and protect the present.
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Sudhir Shenoy CEO Dow India
The window of opportunity to growth comes with its own set of challenges – India leapfrogged from the era of industrialization
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CEW News Features
GSFC University- Taking a step towards Progressive Future of Engineering The GSFC University has achieved various milestones when it comes to providing students the best of knowledge along with the imparting most practical skills that prepare the students to face every day to day challenge with ease. It strongly believes in making students more industry-ready across various disciplines.
I
n 2015 Gujarat State Fertilizers and Chemicals (GSFC), a leading producer of fertilizers and - chemicals, started a University in their campus in Vadodara, as a CSR initiative. As its seeds were sowed by an industry, it is obvious that it gives equal importance to both, i.e., industrial training and theoretical knowledge. The most important aspect that separates GSFC University from other colleges is the fact that students get intense industrial exposure in the form of internships for one month after each semester. There is no better practical training than doing tasks directly in the industry. It is very important for an engineering student to be exposed to the industrial environment he/she would be working in after graduation. The University has collaboration with IIT RAM and many other local industries like – IOCL, Deepak Nitrite, TRANPEK, OPAL, GUVNL to name a few. It provides B.E. in three undergraduate courses, namely - Civil, Chemical and Mechanical; B.Sc and M.Sc courses in Chemistry and Biology; Bachelor courses in HR, Marketing, Finance, and Office Management. The faculties are also the best in class as the professors are recruited through a rigorous industry like four stage process, comprising of – online test, ability to teach assessed by students, ability to use plant and machinery to demonstrate practical from syllabus and finally interview. All the above make GSFC University a studentfocused “teaching only” university, designed to produce industry-ready manpower in various discipline. As the Director (Admin & EF) of GSFC University, Mr Ravindra Mohan is dedicated
70 • December 2017
to mentoring students to learn contemporary techniques and best practices and build their knowledge and skills in a real world context. “The teaching at GSFC University is modelled on lines of medical education. In case of a Medical College, students learn to apply theoretical knowledge to practical aspects of medical treatment in hospital attached to it. Here our University is housed at handshaking distance from GSFC’s 22 plants, where students acquire practical aspects of engineering,” Mr Mohan tells Chemical Engineering World. “The GSFC University is being modelled as a boutique university to produce 100% industry ready manpower with 80% students getting employment,” he continues. It offers students a platform and tools to develop skills needed for their professional success. Courses are firmly anchored in their hands-on, practice-based approach and aim to equip students with practical experiences and knowledge, preparing them to meaningfully engage with their future employers. The University strives to inculcate in students; • Value for hard work, i.e., ability to use his/ her hands – through projects, assignments, internship / industrial training • Safety consciousness … making safety a habit • Quality of a good team player , i.e., by being - compassionate towards others, punctual, ethical, honest, proactive and having impeccable integrity • To develop an enquiring mind and willingness to learn • To be able to apply scientific methods by application of knowledge or skills gained from one area to other area
• To be good communicator, preferably in English • To respect gender differences “Thus students get 8 months working experience in industry and - are able to become productive much earlier in organization they join. Also, organizations are able to assess the candidates much better having seen them for a prolonged time,” Mr Mohan states. Intrinsic link between the industry, government and academia “Industry, Government and Educational Institutions; all three are stake holders in nurturing the young minds, so that they get crafted to engage in development of the chemical and petrochemical sector, which is an essential part of infrastructure development of a country. Oil & gas, energy, pharmaceuticals, petrochemicals are critical to meet the basic needs of citizens of a country at large,” observes Mr Mohan. Industry is the harbinger of the progress and a vibrant industry provides jobs to people to run the industrial establishment thus leading to progress of the country in various fields to become leader. Educational institutions are tasked to nurture, develop and supply to industry young minds, inquisitive and innovative. “The Government role is of an enabler through regulations and providing critical impetus to both industry and educational institution so as to give an enabling environment. Another critical role is to nudge the industry in the right direction so that inclusive growth happens and citizens are prosperous ‘year-on-year’,” Mr Mohan notes . Chemical Engineering World
News Features CEW Practical and collaborative learning A four pillar approach is adopted so that theoretical knowledge as applied in day-today working of the organizations / industries is practiced. GSFC plants are used to impart collaborative learning to students.
Internship programs and student placement The governing body of GSFC university comprises of industrialists, educationists, finance and legal experts, and representatives from the social sector.
First pillar is e-enabled virtual labs, where students grapple with various aspects of virtual instruments and carry our experiments a number of times and understand ‘why’ of theory.
Further, GSFC being one of the top stateowned company with over 50 years of legacy means, that it is in tune with the latest trends and opportunities across various disciplines.
Second pillar is physical labs where students perform same experiments in physical world with real fluids and lab model equipment. Third pillar is their exposure to real plant and machineries to full scale sizes. Thus full understanding of theories thought in classrooms as applied to industry is developed by students. Fourth pillar is 4 weeks internship after every semester where he / she is expected to deep dive and understands the nitty gritty of plant and machinery, processes etc.
GSFC University has made Industrial Training (internship) a part of continuous education by, • Having four weeks (per session) of handson industrial training / internship after each semester, i.e., spending approximately 15 20% of total duration of the courses
2019 and many organizations where students are taking industrial internship have shown interest to absorb them,” proudly acclaims Mr Mohan. He adds that GSFC has been organizing lectures on current issues relevant to the local industry by inviting industry leaders and their interaction with students, thus familiarizing students with the trends with in the industry. “In next academic year we will work with local industry and keep refining our syllabus. Thus, providing them the requisite talent at the door step ,” concludes Mr Mohan.
• Having a syllabus for each session with defined outcomes • Assessment having a weightage of 2 credits for each internship, i.e., 15 – 20% of overall weightage in marks “Our first batch of engineers will pass-out in
Author Details
Mr. Ravindra Mohan Director (Admin & EF) GSFC University
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CEW
Marketing Initiatives
B&R integrates vision into machine automation Automation specialist introduces image processing solution
B
&R makes machine vision an integral element of the automation ecosystem. At this year's SPS IPC Drives, B&R introduced the world's first image processing solution to be seamlessly incorporated in the automation system. The solution comprises cameras, software and lighting accessories. At the heart of the solution is a broad selection of intelligent camera technology. Options at the lower end will replace simple machine vision sensors, while the top of the range will harness the full potential of high-end smart cameras. Ready-made software components are available for creating applications with minimal new programming.
Intelligent lighting Lighting elements are available integrated in the camera, as an exter nal device, or even as a combination of the two. Extremely precise synchronization for high-speed image capture and objectspecific functions such as bright-field or dar k-field illumination are easy to implement. Image triggers and lighting control can be synchronized with the rest of the automation system in hard real time and with sub-microsecond precision. B&R's machine vision system is integrated on every level: the engineering tool, the r e a l - t i m e o p e ra t i n g s y s - t e m a n d t h e application software. With a single d eve l o p m e n t e n v i r o n m e n t fo r eve r y
B&R's machine vision portfolio ranges from simple vision sensors to high-end smart cameras. 72 • December 2017
aspect of automation, controls engineers w i l l n ow b e a bl e t o i m p l e m e n t m a ny machine vision tasks on their own. B&R's machine vision por tfolio ranges from simple vision sensors to high-end smart cameras. About B&R B&R is an innovative automation company with headquarters in Austria and offices all around the world. On July 6, 2017, B&R became a business unit of the ABB Group. As a global leader in industrial automation, B&R combines state-of-the-art technology with advanced engineering to provide customers in vir tually ever y industr y w i t h c o m p l e t e s o l u t i o n s fo r m a c h i n e and factory automation, motion control, HMI and integrated safety technology. With Industrial IoT communication standards like OPC UA, POWERLINK and openSAFETY as well as the powerful Automation Studio software development environment, B&R is constantly redefining the future of automation engineering. The innovative spirit that keeps B&R at the forefront of industrial automation is driven by a commitment to simplifying processes and exceeding customer expectations.
Contact Details: B&R Industrial Automation B&R Strasse 1, 5142 Eggelsberg, Austria T+43 7748 6586-0 press@br-automation.com Chemical Engineering World
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Marketing Initiatives
Batch-of-one flexibility meets mass-production efficiency New transport system boosts overall equipment effectiveness (OEE)
A
t the SPS IPC Drives exhibition in Nuremberg, B&R unveiled its new intelligent transport system: ACOPOStrak. ACOPOStrak is the first system in the world to extend the economies of mass production down to batches of one. Divide and merge product flows
at full production speed. "It becomes possible to perform product changeover with zero downtime," explained B&R's mechatronics manager Robert Kickinger at the spectacular unveiling event that kicked off the exhibi-tion. Highly dynamic and flexible
The purely electromagnetic ACOPOStrak d i ve r t e r s d i v i d e a n d m e r g e p r o d u c t flows at full production speed. Among their many advantages is the ability to include a pit lane in the track layout. New shuttles are mount-ed on the pit lane and then channeled onto the track's actual production lines via a diverter. In the same way, any shuttles that are no longer needed can simply be rerouted to the pit lane. All of this takes place
ACOPOStrak's absolute design flexibility allows it to morph into all types of open and closed layouts by arranging different combinations of track segments. The system is capable of 5 g acceleration and reaches top speeds in excess of 4 meters per second with a minimum product pitch of only 50 millimeters. These performance numbers, together with the benefits of the diver ters and the extreme design
B&R's machine vision portfolio ranges from simple vision sensors to high-end smart cameras. Chemical Engineering World
flexibility, form a total package like the market has never seen. To switch products, the operator simply places the wheels of a new shuttle on the guides of the pit lane, while production continues at full speed on the rest of the track. About B&R B&R is an innovative automation company with headquar ters in Austria and offices all around the wor ld. On July 6, 2017, B&R became a business u n i t o f t h e A B B G r o u p. A s a g l o b a l leader in industr ial automation, B&R combines state-of-the-ar t technology with advanced engineering to provide customers in vir tually ever y industr y w i t h c o m p l e t e s o l u t i o n s fo r m a c h i n e and factory automation, motion control, HMI and integrated safety technology. With Industrial IoT communication standards like OPC UA, POWERLINK and openSAFETY as well as the powerful Automation Studio software development environment, B&R is constantly redefining the future of automation engineering. The innovative spirit that keeps B&R at the forefront of industrial automation is driven by a commitment to simplifying processes and exceeding customer expectations.
Contact Details: B&R Industrial Automation B&R Strasse 1, 5142 Eggelsberg, Austria T +43 7748 6586-0 press@br-automation.com December 2017 • 73
CEW Products Condensors
VOC Sensors
The condensor helps in reducing the process time of drying, distillation, etc, by effectively condensing the condensbable vapours.The condensor has been standardised with 1.5-m 2², 3-m 2² and 6-m 2² cooling surface area. The Material of Construction (MoC) can be given in Mild Steel / SS-304 / SS-316 for Shell and Copper / Cu Nickel / SS304 / SS-316 for the cooling coil.
Alphasense offers a new sensor for the measurement of VOCs (volatile organic compounds). The new p-type metal oxide sensor is a broadband total VOC detector with a range of 0 to 100 ppm (isobutylene) and 10-50 ppb detection limit, depending on the VOC. The new VOC sensor will be of particular interest to manufacturers and developers of instruments and monitoring systems for applications such as process monitoring, occupational safety, leak detection and environmental monitoring. Typical VOCs measured by the sensor include solvents, sterilants and petrochemicals.
For details contact: Toshniwal Instruments (Madras) Pvt Ltd 267 Kilpauk Garden Road, Chennai 600 010 Tel: 044-26448983, 26448558, Fax: 91-044-26441820 E-mail: sales@toshniwal.net
For details contact: Alphasense Ltd Sensor Technology House, 300 Avenue West, Skyline 120 Great Notley, Essex CM77 7AA, U.K. Tel: +44 (0) 1376 556 700, Fax: +44 (0) 1376 335 899
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Level Indicators Visual level indicators combine up to three functions in one instrument: level indicator, level switch and level transmitter. The display that can be read even over large distances works without energy and automatically as a result of the physical law of liquids in communicating vessels. The WEKA visual level indicators are characterized by their compact design and the wide range of applications. Operating pressures can range from a vacuum up to 500 bar as well as calculation pressures for the float standpipe up to the nominal pressure PN 630. Liquid densities >0.27 g/cm3 as well as a temperature range from 77 K to 673 K (-196°C to 400°C) allow use in applications for cryogenic liquid gases as well as in water hydraulics and steam boilers. Hermetically sealed floats for condensing media are available up to a max operating pressure of 320 bar. Flexibility through choice of suitable materials - standard materials: 316/316L 1.4435/1.4404, Group A4 stainless austenitic steel. Other possible stainless austenitic steels: 304/304L 1.4301/1.4306, 1.4571, 321, 1.4541. The WEKA visual level indicator is ideal for the commissioning of systems. The display works without energy and automatically as a result of the physical law of liquids in communicating vessels. Independent of a controller - and thus also independent in the event of a power supply failure - visual level indication on site is ensured. The wide, red- and silver-colored flag indicator system is easily and clearly readable, even from over large distances. The fully transparent flag indicator system made of polycarbonate (PC) also ensures readability from the side. The liquids, which are not always unproblematic and sometimes also hazardous, are safely enclosed in the dense and pressure-tight float standpipe and separated from the indicator. WEKA visual level indicators offer the ideal solution for almost all operating conditions. For most applications, you will find a suitable device from our standard program. Again and again, however, customized solutions are also required for special operating conditions. Many designs can, eg, also be used in hazardous areas according to ATEX or IECEx (ATEX is a widely used synonym for the ATEX guidelines of the European Union). The designation ATEX is derived from the french abbreviation for atmosphere explosibles. Toshniwal’s instruments can thus also be used in potentially explosive atmospheres. It finds application in explosion-proof plants, mechanical and plant engineering, water management, ship building, energy, space and research. For details contact Toshniwal Hyvac Pvt Ltd 267 Kilpauk Garden Road, Chennai 600 010 Tel: 044 26445626, 26448983 E-mail: sales@toshniwal.net or Circle Readers’ Service Card 03
74 • December 2017
Chemical Engineering World
Products CEW Water Meter Toshniwal provides a comprehensive residential meter portfolio to meet the world’s water utility requirements. Toshniwal’s Series continues to be in the water industry standards. Their quiet, rugged and reliable industrial and domestic water meter achieve ultra low flow measurement and meet or exceeds all standards. The ISO Standard assures you that they have achieved the highest possible standards for both manufacturing and customer service quality. It is easy to install even on existing pipelines and is highly accurate and reliable. Find out by trying their domestic water meter and calculate your water consumption.Lifestyle choices, population growth and climate change are placing increasing demands on our water supplies. It is important that we do not take this precious resource for granted and that we all use water wisely to ensure that there is enough for everyone in years to come. Water saving habits started now will become a way of life for the future. For details contact Toshniwal Hyvac Pvt Ltd 267 Kilpauk Garden Road, Chennai 600 010 Tel: 044-26445626, 26448983 E-mail: sales@toshniwal.net or Circle Readers’ Service Card 04
Shipping Solution for Temperature-sensitive Payloads ACH Foam Technologies’ DuraTherm PLUS+ is an advanced cold chain shipping solution that assures payload temperatures remain between 2 o to 8 oC for a 24-hour delivery window. Validated to International Safe Transit Association (ISTA) 7D Standards, DuraTherm PLUS+ is available in summer and winter profiles to accommodate off-the-shelf seasonal packout solutions for pharma and other products with acute temperature sensitivity. ISTA’s rigorous testing assures that product temperatures can be controlled within a very narrow range for up to 24-hours. DuraTherm PLUS+ is also pre-qualified to ISTA 7E for summer and winter profiles. A key facet of DuraTherm PLUS+’s ability to maintain near-constant temperatures is the expanded polystyrene (EPS) foam cooler core, which boasts superior insulation properties. ACH Foam Technologies’ laboratory developed packaging kit includes the DuraTherm PLUS+ cooler, inner payload packaging, gel pack refrigerants, outer corrugated shipping box, and precise packout instructions. ACH Foam Technologies manufactures cold chain and protective packaging to architectural insulation and industrial applications. For details contact: ACH Foam Technologies 8700 Turnpike Drive, Suite 400 Westminster, CO 80031, U.S.A. Tel: 855-597-4427, Fax: (303) 428-2595 E-mail: mburk@achfoam.com or Circle Readers’ Service Card 05
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December 2017 • 75
CEW Products Semiconductor OEM Module
Syphon
LumaSense Technologies, Inc offers the m924 (4-channel) and m922 (2-channel) semiconductor OEM modules, designed for electrostatic chuck, chamber and other device temperature monitoring during etching and wafer fabrication processes.The LumaSense solution provides advanced and reliable temperature monitoring up to 330°C. The new m924 Semiconductor OEM module sampling rate is five times faster than most other modules or converters, and provides +/-0.1C high accuracy measurements with a wide range of industry specific communication capabilities. These combined features provide users with better and more accurate temperature measurements to improve process control. This new product provides temperature monitoring for smaller linewidth devices at higher and wider temperature ranges with significantly faster sampling rates needed in semiconductor wafer process measurements.
Excel Metal & Engg Industries offers wide range of instrumentation fitting and valves for use in diverse range of industries and are capable to provide their customers with best possible solutions to meet their various requirements. The production process followed is of higher standards with its modern production and quality assurance facilities where due attention is paid at every level with max resource utilization. Excel Metal & Engg Industries offers U & O Type Syphon in1/8 to 2 in size in SS, carbon steel, etc; end connection: BSP/NPT or as per request.
For details contact: LumaSense Technologies 514, A Wing, Sagar Tech Plaza Saki Naka Junction, Andheri Kurla Road Andheri (E), Mumbai 400 072 Tel: 022-67419203, Fax: 91-022-67419201 E-mail: info@lumasenseinc.com or Circle Readers’ Service Card 06
For details contact: Excel Metal & Engg Industries 177/181 J T Bldg 3 rd Kumbharwada Lane Mumbai 400 004 Tel: 022-23892476, 66394004 Fax: 91-022-23884109 E-mail: info@excelmetal.net / excelmetal@mtnl.net.in
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Liquid & Solid Level Measurement KROHNE, Inc offers a new generation of liquid and solids level measurement products featuring better measurement performance, enhanced software and an improved and more powerful signal processor. The new product families include both 24 and 80 GHz versions, which further increase the accuracy and range of measurement on the devices. Antennas for each model are designed to meet application-specific installations. Also available is a retrofit path for those with older style models who want to keep their existing antennas and upgrade electronics without losing the hermetic seal on the tank.New liquid level measurement devices include OPTIWAVE 5400 (24 GHz) for liquids in basic process applications; OPTWAVE 7400 (24 GHz) for agitated and corrosive liquids; OPTIWAVE 7500 (80 GHz) for liquids in narrow tanks with internal obstructions; and OPTIWAVE 3500 (80 GHz) for liquids with hygienic requirements. These replace the OPTIWAVE 7300.Solids level measurement devices include OPTIWAVE 6400 (24 GHz) for solids ranging from granulates to rocks and OPTIWAVE 6500 (80 GHz) for powders and dusty atmospheres. These are new devices for replacing the OPTIWAVE 6300 in the product line.KROHNE is also providing an upgrade path that enables users with an older style OPTIWAVE 7300 to leave the radar antenna installed on the tank top. Users simply plug in new electronics – with no loss of hermetic seal between the tank top and electronics. For details contact: KROHNE, Inc 7 Dearborn Road Peabody, MA 01960, U.S.A. Tel: +1 978 535 6060 Fax: +1 978 535 1720 E-mail: info@krohne.com or Circle Readers’ Service Card 08
76 • December 2017
Chemical Engineering World
Products CEW New Motors ¬ This new complete and homogeneous range dedicated to explosive, gas and dust atmospheres provides a safe and energy saving response for zones 1 and 2 as well as zones 21 and 22. Fixed and variable speed-compatible, the new motors are suitable for all ATEX markets where quality, performance, risk management and compliance with standards are essential. Covering power ranges from 0.75 to 200/400 kW according to models, they have been developed to meet manufacturing and process industry requirements, for the most demanding users and the most innovative machine manufacturers. For details contact: LEROY-SOMER Motors & Drives C/o Control Techniques India Pvt Ltd 117B Developed Plot, Indl Estate Chennai 600 096 Tel: 044-66918402 E-mail: rengan.rajan@mail.nidec.com
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Extruded Profiles (Silicone/Viton/EPDM) APPL offers a wide range of silicone extruded gaskets in more than 1,000 different shapes and designs (in round and square types). APPL’s extruded gaskets (Autoclave) are made from Food-Pharma Grade pure silicone rubber which can easily withstand a temperature range of -80 to +250oC. Extruded gaskets are available in square cross-sections like 6 x 6 mm, 8 x 8 mm, 10 x 10 mm, 20 x 20 mm, 25 x 25 mm, etc, with or without hollow. These extruded gaskets are available in red, white, orange or any colour as per customer’s requirement. These extruded gaskets are manufactured from fully automatic microwave continuous curing system which ensures accurate dimensional properties, glossy surface finishes and aesthetically beautiful colours. Extruded gaskets can be used in clean room doors, telecom shelters, air tight door seal application, bakery ovens, freeze doors, pharma processing machine’s doors, autoclaves, isolators, dry heat sterilizers, etc. For details contact: Ami Polymer Pvt Ltd 319 Mahesh Industrial Estate Opp: Silver Park, Mira-Bhayander Rd, Mira Road (E) Thane, Maharashtra 401 104 Tel.: 022-28555107, 28555631, 28555 914 Email: mktg@amipolymer.com or Circle Readers’ Service Card 10
Chemical Engineering World
December 2017 • 77
CEW Products Vacuum Dryer
Mass Flow Controller
Toshniwal offers rotary double cone dryer designed for drying and mixing of powdery and granular materials used in pharma, food and chemical industries, especially suitable for the special requirements such as thermal sensitive raw materials; easily oxidized hazardous materials; materials with requirements in crystal shape; materials whose solvent should be recovered; materials requiring low-content of residue volatile matter; etc. The dryer consists of a conical cylinder provided with a jacket for hot water, steam or oil heating, the indirect heating process is carried out under vacuum, and recovery of solvent is possible by conducting the vapour generated during drying operation. When the dryer rotates rapidly and thorough intermixing of the entire batch brings every particle in contact timely and repeats again and again. With the heated surface for more rapid heat conduction permits high speed drying without raising the drying temperature to the danger-point of the material being processed. The heat efficiency of the drying system is two times greater than the ordinary dryer.
Coriolis mass flow meters are highly appreciated for their accuracy and independence of fluid properties. The direct Coriolis mass flow measuring principle is generally used for higher flow rates. Moreover, mini CORLFLOW instruments have an integrated PID-controller and a batch counter to control the fluid flow. Features direct flow measurement independent of fluid properties; fast response time; high accuracy, excellent repeatability; additional density and temperature output; compact design (same footprint as CORI-FLOW M50 Series); excellent price/performance ratio.
For details contact: Toshniwal 267 Kilpauk Garden Road Chennai 600 010 Tel: 044-26445626, 26448983 E-mail: sales@toshniwal.net or Circle Readers’ Service Card 11
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 or Circle Readers’ Service Card 12
New Motor and Drive Solution Leroy-Somer offers Commander ID300, a new integrated drive for the control of its IMfinity induction motors from 0.25 to 7.5 kW. This all-in-one drive solution has been designed to meet the strategic challenges of increasingly complex and demanding production environments, induced by the transition to Industry 4.0. A decentralized system, the motor and drive assembly offers strong dynamic performance and outstanding efficiency levels for process, manufacturing and intralogistics applications, through an easy to install and easy to set-up package. For a high level of performance, Commander ID300 is provided with advanced features for optimizing machine and process performance: onboard PLC, fieldbus communication, extra input/output or preset configurations such as a pump program for pressure regulation (constant pressure/variable flow). It integrates also onboard safety functions for compliance with SIL3/PLe. Commander ID 300 offers customized solutions thanks to a modular concept. The wide choice of options and adaptations enables configuration in line with machine architecture. The system can also integrate an FFB brake for dynamic braking and/or a gearbox from the helical 3000 range, ensuring max adaptability. Extremely robust, Commander ID300 is an easy-to-use solution, ensuring quick and smooth operation. For details contact: LEROY-SOMER Motors & Drives C/o Control Techniques India Pvt Ltd 117B Developed Plot, Indl Estate, Chennai 600 096 Tel: 044-66918402 E-mail: rengan.rajan@mail.nidec.com or Circle Readers’ Service Card 13
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Products CEW Process Analyzer The 2035 Process Analyzer comes in three basic configurations for potentiometric, photometric, and thermometric measurements. Any of these can be combined with additional measuring techniques such as pH and/or conductivity measurement. Due to modular architecture of the wet part, there is an analyzer configuration for each specific application challenge. A large array of functional modules such as burettes, pumps, vessels, valves, and more is available. Strict separation of wet part and electronics ensures safe operation in harsh environments. The electronics part is housed within non-corrosive epoxy-coated stainless steel. Metrohm Process Analytics provides virtually any sample pre-conditioning system, such as cooling or heating, pressure reduction, degassing, filtration, and more. Ethernet TCP/IP Network communication and remote operation, web services, MODBUS, analog outputs, digital outputs to transmit results, and alarm status signals. Result export to USB. For details contact: Metrohm India Ltd 205/206, Sector III Bldg 5 Millenium Business Park Mahape, Navi Mumbai 400 710 Tel: 022-27781003, 27781026, 27781027 Fax: 91-022-27781028 E-mail: joy@metrohm.in or Circle Readers’ Service Card 14
Environmental Analysis Chromate is useful in many industries – in the production of pigments and dyes for textiles, paints and colored glass, anodized or plated on to metals for surface finishing applications, as an oxidizing agent to tan and process leather, and as a corrosion inhibitor in industrial cooling towers. Chromate easily leaches from soil to ground and surface waters and can enter the air through evaporation and combustion processes. Monitoring waste streams containing chromate is extremely important because chromate is highly toxic even in minute concentrations; a property which is enhanced by the high solubility of chromate and its affinity for leaching. In the method concerned, the target analyte is mixed with reagents in a fully automated procedure, resulting in a soluble product which can be measured photometrically at a wavelength of 560 nm. For details contact: Metrohm India Ltd 205/206, Sector III Bldg 5 Millenium Business Park Mahape, Navi Mumbai 400 710 Tel: 022-27781003, 27781026, 27781027 Fax: 91-022-27781028 E-mail: joy@metrohm.in or Circle Readers’ Service Card 15
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CEW Products High Vacuum Pump (Oil Immersed)
Roots Vacuum Pumps
The compact and quiet in operation, highly reliable and sturdy in design GL Series pump is an oil sealed belt driven pump operating according to the rotary vane principle with gas ballast valve. Oil, which is injected into the pump chamber, is used for sealing lubrication and cooling purpose. It is easy to maintain and guaranteed ultimate vacuum.
The Roots Type pumps belong to the group of positive displacement delivery pumps. Two symmetrical pistons having an eight feature, housed in the pump body, rotate in opposite directions with no contact neither between each other nor with the pump body, meshing continuously. The pistons are driven by a set of gears with synchronised rotation, which guarantees frictionfree movement. During rotation, a progressively growing space is created with corresponds to the suction stage: phases 1 and 2, being gradually decreased phases 3 and 4, compressing the volume of gas. This cycle is repeated four times per each complete rotation of the drive shaft.
Double stage models from 180 m 3/hr to 300 m 3/hr are available to meet wide range of vacuum needs. For details contact: Toshniwal Instruments (Madras) Pvt Ltd 267 Kilpauk Garden Road Chennai 600 010 Tel: 044-26448983, 26448558 E-mail: sales@toshniwal.net or Circle Readers’ Service Card 16
For details contact: Toshniwal Instruments (Madras) Pvt Ltd 267 Kilpauk Garden Road, Chennai 600 010 Tel: 044-26448983, 26448558 Fax: 91-044-26441820 E-mail:sales@toshniwal.net or Circle Readers’ Service Card 17
Online Heat Tracing System Design Tool Thermon offers CompuTrace Express, the latest addition to its industry-leading line of heat trace design software. With this new online tool, users can easily design the optimal heat tracing system using Thermon products. CompuTrace Express was developed to be mobile-friendly, and leverages the power of Thermon’s CompuTrace Design Suite database. It is the new industry standard in heat trace design and primarily supports smaller projects in the industrial sector for maintenance, repair and upgrade expansion projects. Design a system in four simple steps: create project; edit circuit - modify system defaults (eg, change pipe size, circuit length, insulation); create design; and generate bill of materials. Thermon developed this new tool in response to customer requests for an easy-to-use solution that would address smaller heat trace circuit requirements. CompuTrace Express can be operated on a local desktop, tablet or mobile device. The design calculations in Thermon’s CompuTrace program are performed in accordance with generally accepted engineering practices. Designs are based on user-specified input so the user is responsible for the completeness and accuracy of the data. Component lists generated by CompuTrace are based on an estimated number of circuits and do not include an allowance for spares. An engineer who is familiar with heat tracing or is an experienced heat trace designer should perform the actual circuit layout and confirm that the recommended quantity and type of components are appropriate for the application. Products must be installed and used in accordance with Thermon instructions and local codes. Additional information relating to the design, installation and use of Thermon products is available upon request. For details contact: Thermon 100 Thermon Drive San Marcos, Texas 78666, U.S.A. Tel: +1 512-396-5801 Extn: 2239 E-mail: lance.bielke@thermon.com or Circle Readers’ Service Card 18
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Products CEW Mixer Toshniwal offers new generation powder mixer, which gives a homogeneous mix in a very short time (30-60 seconds) for dry powder. The mixer has a facility for spraying liquid to ensure uniform coating on powder/ pellets as well as lump breaker. The other salient features are high degree of precision mixing up to10 PPM, low energy cost per tonne of mix, high production output with a small batch mixer, fast discharge of mixed material through two large Bombay Doors avoiding segregation of mixed material, negligible maintenance, etc. The mixer is ideally suited for food products like instant drinks, coffee/tea vending premix, gulab jamun mix, spices, cereals, bakery premix, etc. For details contact: Toshniwal 267 Kilpauk Garden Road Chennai 600 010 Tel: 044-26448558 / 8983 E-mail: sales@toshniwal.net or Circle Readers’ Service Card 19
Electro Magnetic Meter The instrument works on the principle of Faraday’s law of Electromagnetic Induction. A magnetic field is generated by the instrument in the flow tube. The fluid flowing through this magnetic field generates a voltage that is proportional to the flow velocity. This voltage is measured by the electronics and a corresponding output provided. Universal power supply accepts any voltage from 90 to 265 V AC. Bi-directional flow measurement measures the flow in both forward and reverse directions.Built-in totaliser provides a separate totalized volume value for flow in each direction. Remote monitoring is easy monitoring of the process even in hard to reach places. Conforms to International Standards - designed to meet global requirements and available with international approvals. For details contact: Toshniwal Hyvac Pvt Ltd 267 Kilpauk Garden Road Chennai 600 010 Tel: 044-26448558, 26448983 Fax: 91-044-26441820 E-mail: sales@toshniwal.net or Circle Readers’ Service Card 20
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CEW Products Valve Manifold
Rapid Mixer Granulator Cipriani Harrison supplies valve clusters (manifold) mounted on the SS frame. There are number of advantages in the prefabricated manifold.
Uniform and better quality of welding and surface finish; valve clusters (manifold) can be pretested before dispatch; cost-effective solution and lower star t-up time for system/plant. For details contact: Cipriani Harrison Valves Pvt Ltd 1901, GIDC, Phase IV Vallabh Vidyanagar Vitthal Udyognagar Gujarat 388 121 Tel: 02692-235082, 235182 Fax: 91-02692-236385 E-mail: info@harrisonengineers.com or Circle Readers’ Service Card 21
This type of granulator is used extensively in pharma industries. The machines have a SS mixing bowl containing a threebladed main impeller, which revolves in the horizontal plane, and a three-bladed auxiliary chopper (breaker blade) which revolves either in the vertical or the horizontal plane. For details contact: Kunal Machines 104 Kothari Indl Estate Next to Asian Paints LBS Marg, Bhandup (W) Mumbai 400 078 Tel: 022-61271111, 67251949 E-mail: kunalmachines@gmail.com or Circle Readers’ Service Card 22
Process Analyzer The 202X Process Analyzer family comes in three basic configurations, covering several market needs. The 2026 Titrolyzer is suitable for titrimetric, ion selective or pH measurements. The 2029 Process Photometer performs photometric absorption measurements in the visible light range. A 7” full-colour touchscreen shows trend graphs and allows easy access to your data. These process analyzers are especially suitable for analysis in the chemical, petrochemical, semiconductor, food and beverage, potable water, and environmental branches. Metrohm Process Analytics can offer process analyzers which are configured for each specific application challenge. Sample dilution, extra reagents, or even another sample stream can be added with the addition of peristaltic pumps in the modular wet part. Strict separation of wet part and electronics ensures safe operation in harsh environments. The electronics part is housed within non-corrosive polyester-coated stainless steel. With an Ingress Protection rating 66, the analyzer is guaranteed to be dust and water-tight. Metrohm Process Analytics provides virtually any sample preconditioning system, such as cooling or heating, pressure reduction, degassing, filtration and more. Information including results, remote control and status info, can be communicated through discrete I/O (ie, analog outputs digital in/outputs), MODbus TCP/IP (Ethernet), or RTU (RS485) communication. Remote control is possible through VNC (Ethernet). Results can also export to USB. For details contact: Metrohm India Ltd 205/206, Sector III Bldg 5 Millenium Business Park Mahape, Navi Mumbai 400 710 Tel: 022-27781003, 27781026, 27781027 Fax: 91-022-27781028 E-mail: joy@metrohm.in or Circle Readers’ Service Card 23
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Products CEW Robotic Palletizer
Cycloidal Gearboxes
The robotic palletizer is a sophisticated and costlier version. It works on 6 axes and controlled by servo motors for perfect accuracy and high speed of the operations. Speed of this palletizer is in the range of 18 to 22 bags/minute. The same can be offered for sophisticated automatic and high speed bagging lines. For details contact: Jasubhai Engg Pvt Ltd 64/a, GIDC Indl Estate Phase 1, Vatwa Ahmedabad Gujarat 382 445 Tel: 079-49003636, 49003737 Fax: 91-079-25831825 E-mail: mhd-sales@jasubhai.com
Eppinger develops and manufactures cycloidal gearboxes to round-off the product portfolio. In drive technology, especially in the field of tool machinery, automation and robotics, these compact designed high transmission precision gearboxes are used especially to meet the highest demands for stiffness, performance and efficiency. In addition to the constantly extended standard range, these cycloidal precision gearboxes can be adapted to customer requirements upon request. For details contact: EGT Eppinger Getriebe Technologie GmbH Breitwiesenweg 2-8 73770 Denkendorf, Germany Tel: +49 711 934934-626 Fax: +49 711 934934-22623 E-mail: info-egt@eppinger-gears.com
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Flat Dry Disconnect Coupler and Adaptor OPW Engineered Systems offers it’s new Kamvalok flat dry disconnect coupler and adaptor. Engineered with all the same industry-leading features and benefits as traditional OPW Kamvaloks, the major technological advancement in the Kamvalok Flat is the incorporation of flattened connection points, including patent-pending smooth, flat-face poppets. This design effectively eliminates all cavities where liquid can pool and subsequently spill upon disconnection, reducing up to 85% of fluid loss at disconnect. OPW Kamvalok dry disconnect couplers are ideal in liquid-transfer applications involving a variety of chemicals such as petroleum products, solvents, paint, lacquers, inks, adhesives, fatty acids, pharma, soaps, detergents, agrochemicals, caustics and many acids, to name a few. They feature easy-to-close stainless-steel Autolok locking arms and an industry-standard stainless-steel locking handle, which secures both the opened and closed positions to prevent accidental release or uncoupling. The Autolok locking arms also provide added protection with an automatic locking mechanism that is signaled by an audible, positive click, whereas uncoupling requires only an easy tug on the lock release. In addition, Kamvaloks feature vibration-resistant Twin-Kam arms The OPW Kamvalok Flat is available in aluminum and stainless steel, and offered in 1.5-, 2-, and 3-inch sizes. A variety of temperature ranges are also available. For details contact: Dover India Pvt Ltd – PSG 40 Poonamallee By-pass Sanneerkuppam, Chennai 600 056 Tel: 044-26271020, 26271023 E-mail: sales.psgindia@psgdover.com or Circle Readers’ Service Card 26
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CEW Products Double Cone Blender
Moisture Analyser Balances
GMP compliant, contact parts manufactured in SS. The double cone ensures good rolling and cross-mixing. A-shaped frames provide stability of structure. Main drive provided with variable frequency drive to control blender RPM. Start-stop arrangement ensures that the blender always stops in an upright position. Internal baffles ensure good blending and break lumps. Guard rails are provided with limit switch for safety. PLC/HMI-based control panel models available.
Citizen’s new MB Series moisture analyser with HALOGEN heating is mainly designed on the basis of time saving factor for universal use in chemical, pharma, oil and petroleum industries also in material testing and environmental laboratories, and in sewage treatment plants.MB Series is compact in shape and big in performance. It performs all the major functions of routing moisture analysis.
For details contact: Kunal Machines 104 Kothari Indl Estate, Next to Asian Paints LBS Marg, Bhandup (W) Mumbai 400 078 Tel: 022-61271111, 67251949 E-mail: kunalmachines@gmail.com
For details contact: Citizen Scale (I) Pvt Ltd Citizen House, Unit No: E-2 Plot No: 11, WICEL Opp: SEEPZ Gate No: 1 Andheri (E), Mumbai 400 093 Tel: 022-42437700 Fax; 91-022-42437800 E-mail: sales@citizenscales.com
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Platinum Cured Silicone Hose Reinforced with SS 316 Helical Wire Imavac is platinum cured silicone hose reinforced with SS 316L helical wire. It has better transparency to visualize flow and kink resistance. Imavac is designed for material transfer application under high vacuum in pharma industries. The product is more superior compared to Imafit in high pressure and high vacuum rating applications. It is also used for anti-static application. Imavac conforms to US FDA 21 CFR 117.2600 Food Grade Standard, USP Class VI, and ISO 10993-1. It is certified by ROHS and TSE/BSE Certification (free of animal derived material), free of restricted heavy metals. It is free of Phthalate/Bisphenol/Volatile Plasticizer. It has US FDA DMF accreditation #26201. Complete validation package available upon request. Imavac has high burst pressure resistance compared to Imafit. It is designed for high vacuum rating applications. It has anti-static properties to dissipate static electrical charge makes it suitable for highly volatile flammable fluid transfer. It imparts no taste and odour. It is lot traceable. Its temperature range is -80 OC to 180 OC. It is available with SS-316 L Tri-Clover end. It is sterilizable by Autoclave, Ethylene Oxide Gas & Gamma Radiation. For details contact: Ami Polymer Pvt Ltd 319 Mahesh Indl Estate, Opp: Silver Park Mira-Bhayander Road, Mira Road (E) Thane, Maharashtra 401 104 Tel: 022-28555107, 28555631, 28555914 E-mail: mktg@amipolymer.com or Circle Readers’ Service Card 29
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Products CEW Gravity Feed Metal Detector
Check Weigher
Gravity feed metal detector metaltrap SS30-GF is an eddy current based digital metal detection system designed for pharma, chemical and food industry for detecting metal contamination in powder and granules. The rejection mechanism used is pneumatically operated Diverter type as it is full proof and allow product containing large lumps to be checked without problem of blockage. For details contact: Technofour Electronics Pvt Ltd Gat No: 3 (PT). 5 (PT), 243 (PT), Kasurdi (Kheba) Khed Shivapur-Saswad Road Post: Khed Shivapur, Tal: Bhor Dist: Pune, Maharashtra 412 205 Tel: 02113-305200, 305246 Fax: 91-02113-305250 E-mail: pcssales@tepl.co.in / teplinbox@gmail.com or Circle Readers’ Service Card 30
Check weigher CW120001 system provides 100 per cent online weighing, ensuring compliance with international standards of pharma, food, chemical and cosmetic industries. Check weigher CW 1299 also improves production line profitability through significant reduction in product give-away. The entire system is made from SS and designed for easy removal for cleaning purposes. For details contact: Technofour Electronics Pvt Ltd Gat No: 3 (PT), 5 (PT), 243 (PT), Kasurdi (Kheba) Khed Shivapur Saswad Road Post: Khed Shivapur, Tal: Bhor, Dist: Pune Maharashtra 412 205 Tel: 02113-305200, 305246 Fax: 91-2113-305250 E-mail: pcssales@tepl.co.in / teplinbox@gmail.com or Circle Readers’ Service Card 31
Smooth-Surface Motors The new permanent-magnet synchronous motors without cooling fins achieve level IE4 / super premium efficiency. This can greatly benefit the food, beverage and pharma industries, and other hygienically demanding applications. The efficient smooth-surface motors are suitable for use in dry areas as well as in applications requiring frequent cleaning. As they generate very little excess heat, they need no fans and therefore do not contribute to the spreading of germs. The IE4 or Super Premium Efficiency synchronous motors operate significantly more efficiently than induction motors, specifically in the partial load range. This results in substantially lower cost for energy consumption and lower TCO. The motors furthermore feature a particularly high power density and a very long product life. Frequency inverters can be mounted directly onto the motor or near the motor for perfect flexibility. Three motor sizes (80, 90 and 100) with power ratings from 0.75 to 2.2 kW are available. They complement the existing smooth-surface induction motor range, which already covers outputs from 0.37 to 1.1 kW. The motors can be supplied with a brake. For washdown-enabled invertercontrolled drive systems with an IP66/IP69K protection rating, NORD can draw on four different suitable gearbox series. Wash-down drive configurations all feature die-cast aluminum housings with smooth surfaces, designed so that cleaning fluids and foams easily run off. For extra corrosion protection, they can be fitted with the nsd tupH Sealed Surface Conversion System, which is approved for food and drink applications in accordance with FDA Title 21 CFR 175.300. For details contact: NORD Drivesystems Pvt Ltd 282/2, 283/2, Village Mann Tal. Mulshi, Adj. Hinjewadi MIDC II Pune, Maharashtra 411 057 E-mail: Muthusekkar@nord.com / marketing.in@nord.com or Circle Readers’ Service Card 29 32
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AIA Industrial Expo
33 rd Annual World Petrochemical Conference (WPC2018)
Date : 09-11 Jan 2018 Venue : D.A.Anandpura Sports And Cultural Centre, Ankleshwar, India Event : AIA Industrial Expo is a 3 day event being held from 9th January to the 11th January 2018 at the D.A.Anandpura Sports Complex in Ankleshwar, India. This event showcases products like Agro Chemicals, Fertilizers, Pesticides, Dyes, Pigments & Dyes Intermediates,Fine & Specialty Chemicals, Chemical Plants & Machinery, Foundry Machinery, Chemicals and Gear & Gear Boxes and many more etc. in the Chemicals & Dyes, Plants & Machinery industries.
Date: 19th – 23rd March, 2018 Venue: The Hilton Americas-Houston, Texas, USA Event: The World Petrochemical Conference (WPC) is the premier gathering for the petrochemical industry, bringing together more than 1,000 senior chemical industry decision-makers from more than 40 countries for networking, unparalleled insight and critical analysis from IHS Markit, your trusted partner in decision-making.
For details contact: Ankleshwar Industries Association Mr. Raghunandan (M) +91-98250 42135 Email: info@ankleshwarexpo.com Website: www.ankleshwarexpo.com
Sales Manager, Events
For details contact: Lynn Urban 1 877 413 5187 (US only) +1 303 397 2801 (outside US)
Waste Technology India Expo
Asia Petrochemical Industry Conference (APIC) 2018
Dates : 18-20 January 2018 Venue : Bombay Convention & Exhibition Centre, Mumbai Event : Waste Technology India Expo is a 3 day event in Mumbai. The waste management and recycling exhibition will have solutions for managing and recycling of different kinds of waste, both solid and liquid, generated in industries, cities, homes, etc, to ensure clean surroundings. This event showcases product from air and water management, environment and waste management industries.
Date: 9 th – 10th May, 2018 Venue: Kuala Lumpur Convention Centre, Kuala Lumpur, Malaysia Event: APIC 2018 is the prime networking place for Asia’s Petrochemical industry players. Gain strategic insights and bright ideas from well established players in the field that are well positioned to address the industry’s diverse needs and business requirements. Be a delegate to find out more.
For details contact: Virtual Info System Pvt Ltd 231 Mastermind-1, Royal Palms Mayur Nagar, Aarey Milk Colony Goregaon (E), Mumbai
For details contact: Nadiyana +603 - 2171 3578 Email: nadiyana@icep.com.my
7 th International Conference on Chemical and Process Engineering (ICCPE 2018) 2018 GlobalChem Conference & Exhibition Dates : February 28 - March 2, 2018 Venue : OMNI Shoreham Hotel, 2500 Calvert Street, Washington, USA Event : For over 30 years, GlobalChem has been the chemical industry’s premier policy and regulatory conference of its kind. Each year, this annual gathering of industry professionals offers a valuable opportunity to review key developments in the global chemicals management arena while looking ahead to some of the most pressing issues the industry faces. For details contact: American Chemistry Council (202) 249 6121 Email: online@americanchemistry.com Website: http://www.globalchem.org/ 86 • December 2017
Date : 23rd - 25th May 2018 Venue : Chulalongkorn University, Bangkok, Thailand Event :The primary goal of the ICCPE 2018 is to promote research and developmental activities in Chemical and Process Engineering. Another goal is to promote scientific information interchange between researchers, developers, engineers, students, and practitioners working in Bangkok and abroad. The conference will be held every year to make it an ideal platform for people to share views and experiences in Chemical and Process Engineering and related areas. For details contact: Natureevents +1 (202) 626-2522 E-mail: c.paulsen@us.nature.com Chemical Engineering World
Project Update CEW New Contracts/Expansions/Revamps The following list is a brief insight into the latest new projects by various companies in India.
CHEMICALS Coal India is planning a `10,000-crore joint venture along with GAIL India, Rashtriya Chemicals & Fertilizers (RCF) and The Fertilizer Corporation of India (FCIL) to set up a urea and ammonium nitrate chemicals complex that will run on gasified coal. Coal India has appointed Projects and Development India (PDIL) to conduct a feasibility study on the project. The plan is to use around 6 million tonnes of coal from coalfields at Talcher in Odisha and manufacture about 3 lakh tonnes of urea annually and around 300-400 tonnes of ammonium nitrate per day. Ammonium nitrate is the principal ingredient for making explosives used as blasting material at coal mines. The country is facing a crunch in the supply of ammonium nitrate and explosive suppliers often jack up prices, resulting in higher input costs for the company. Songwon Industrial Co Ltd 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. AkzoNobel and Atul Ltd have agreed to jointly set up a manufacturing plant for monochloroacetic acid (MCA) at Atul’s facility in Gujarat. Each partner will hold a 50 per cent stake in the venture. The partnership will build on Atul’s status as a leading global supplier of the herbicide 2,4D (which uses MCA as a key raw material), and AkzoNobel’s leading global position in MCA market, with plants in the Netherlands, China, Japan and the US. The investment is subject to regulatory approvals and signing of final agreements. The partnership will use chlorine and hydrogen manufactured by Atul to produce the monochloroacetic acid, taking advantage of both Atul’s existing infrastructure and the leading eco-friendly hydrogenation technology supplied by AkzoNobel. From an initial annual capacity of 32 kilo-tonnes (KT) at start-up, the plant has been designed for future expansion to 60 KT. The plant will produce enough MCA to meet the captive requirement of Atul; AkzoNobel will market the rest of it, primarily in India. Monochloroacetic acid is an essential building block in the chemical industry and is used in a wide variety of chemicals. Camlin Fine Sciences Ltd, which offers shelf-life solutions (anti-oxidants and intermediates), performance chemicals and aroma chemicals, has received environmental clearance from the State Level Environment Impact Assessment Authority of Gujarat for setting up a manufacturing facility for hydroquinone (HQ) and catechol and their down-stream products at Dahej SEZ. The Dahej plant will expand capacities and provide CFS with a base to manufacture hydroquinone and catechol in India. The plant will also help Camlin Fine Sciences to add capacity for manufacturing of vanillin, for which catechol is a key raw material. Chemical Engineering World
The company expects to commission the Dahej plant in FY18. The plant will have capacity to produce 9,000 metric tonne per annum (MTPA) and 6,000 MTPA of HQ and catechol, respectively. SRF is planning to invest ` 3,500 crore over the next four years, 70 per cent of which would go into its fast-growing chemicals business, to cater to rising global demand. SRF, which exports 90 per cent of its chemicals and counts Syngenta, BASFBSE 0.08 per cent, BayerBSE -0.04 per cent CropScience and other global biggies as its clients, has over the years steered its focus away from technical textiles to chemicals, where it has witnessed a rapid revenue growth and fat operating margin. LyondellBasell, one of the world’s largest plastics, chemical and refining companies, completed the previously announced acquisition of the polypropylene (PP) compounding assets of Zylog Plastalloys Pvt Ltd. The company entered into a definitive agreement to acquire Zylog’s PP compounding assets in November 2015. LyondellBasell has supplied the Indian market through imports and tolling arrangements since 2009. In October 2015, LyondellBasell acquired SJS Plastiblends Pvt Ltd’s PP compounding business which is located in Aurangabad, Maharashtra. With the acquisition of Zylog’s manufacturing operations in Sinnar, Maharashtra, and Chennai, Tamil Nadu, LyondellBasell is now the third largest producer of PP compounds in India with an annual capacity of 44,000 metric tonnes. In addition to the already existing product lines offered at these sites, LyondellBasell will produce its Hostacom glass fibre-reinforced, mineral filled and unfilled coloured grades as well as Hifax high impact thermoplastic olefins. These compounds are used to manufacture automotive parts, home appliances and other products. Bodal Chemicals of Ahmedabad has received environmental clearance (EC) from the Ministry of Environment, Forests & Climate Change for the expansion of dyes and dyes intermediates manufacturing facility located at Vadodara, Gujarat. The company is expanding its dyes and intermediates manufacturing capacity from 2,200 metric tonne per month (MTPM) to 6,000 MTPM, and set up a co-generation power plant (5-MW) in Gujarat. Bodal Chemicals, one of the leading manufacturers of dyes and dyes intermediates in the country, has the capacity to manufacture over 25 varieties of dye intermediates and around 150 variants in dyestuff which are mainly used as raw material in textile, leather, paper and other dye consuming industries. Out of the total production, the company exports about 40 per cent to more than 35 countries across the world. Perstorp of Swedish a specialty chemicals firm is planning to set up a manufacturing facility for pentaerythritol (penta) in Maharashtra. To evaluate the opportunity to invest in a new world scale production plant for penta in India, the company has signed an MoU with Maharashtra Industrial Development Corporation (MIDC). Pentaerythritol, a white crystalline polyhydric alcohol containing four primary hydroxyl groups, is used as building blocks in alkyd resins for coatings, radiation curing monomers, polyurethanes, rosin esters, synthetic lubricants and explosives. Perstorp currently manufactures producing penta in three different production plants in Germany, the US and Sweden. The related December 2017 • 87
CEW Project Update market for coatings in India is growing fast in the country. Building a world scale production plant will be yet another important part of Perstorp’s ambitious plan to strengthen the position in the Asian market. In July 2015, Perstorp acquired the penta business from Koei Chemical Co Ltd, a Japanese chemicals producer. IOL Chemicals & Pharmaceuticals Ltd (IOLCP), a producer of active pharmaceutical ingredients (APIs), has increased the production capacity of ibuprofen to 6,200 tonnes per annum (TPA) at Barnala plant in Punjab. Expansion follows a de-bottlenecking project undertaken by the company at an estimated cost of `24 crores. IOL Chemicals already exports ibuprofen, a non-steroidal anti-inflammatory drug (NSAID) used as painkiller, to regulated and emerging markets, ie, Europe, Latin America, Middle East, etc. With the recent approval from US FDA, the company is expanding its ibuprofen business in the US as well. Being the only integrated ibuprofen player globally, IOL Chemicals aims to build and sustain the growth of its APIs business in coming years by exploring the higher value regulated markets. MINING NTPC Ltd the state-owned power generator hopes its captive coal production will reach 100 million tonne (MT) 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. KIOCL will revive iron ore mining after a decade in Karnataka, after the State granted the company a lease of over 474 hectares at Devadaru hills in Ballari. KIOCL had suspended mining in the eco-sensitive Western Ghats following a Supreme Court directive in 2006. The company has already prepared an action plan and initiated the process for obtaining the necessary statutory clearances. Once approvals are given, it would invest `1,500 crore in a pellet plant and also a unit to enrich iron ore from the mines. After suspension of mining, KIOCL had shifted to operating 3.5 million tonne per annum pellet plant in Mangaluru. Last year, it produced 1.46 million tonnes, utilising half its capacity, as against almost nil production in the previous year. Under the Make-In-India programme, International agencies have already implemented pilot projects by bringing high grade iron ore from South America, Iran and other parts of the world and utilising KIOCL’s facility, have taken away pellets facilitating better utilisation of its plant capacity and profitability utilising its manpower.The company’s blast furnace Unit having a capacity of 216,000 tonnes of pig iron which was put under suspension since 2009 has been taken for repair and the Unit is ready for operation for producing foundry grade pig iron adding towards its profitability in the coming financial year. The firm earned a profit of`47.93 crore in FY17 as against a loss of ` 80.15 crore the previous year. Revenues grew 353 per cent to ` 929.36 crore from `205.57 crore in the previous fiscal. JSW Energy, part of the Sajjan Jindal-led JSW Group, is believed to be in the race for buying out the thermal power assets of Monnet Power and Jindal India Thermal Power Ltd (JITPL) in Odisha. Monnet Power’s 1,050-MW coal-based power plant near Angul was in advanced stage of commissioning. Monnet Power’s parent company, Monnet Ispat & Energy had won the Mandakini coal block in Odisha in competitive bidding, it surrendered the block later on grounds of economic unviability. Monnet Power had accumulated debt in excess of `5,000 crore. Though 88 • December 2017
lenders had earlier denied a haircut in JSW Energy’s prospective deal to acquire majority equity in Monnet Power, the Sajjan Jindal-owned firm is still believed to be in the hunt for the asset. Besides Monnet Power, JSW Energy is also eyeing takeover of BC Jindal controlled JITPL’s 1,200-MW coal-based plant at Derang near Angul. The first unit (600-MW) of the 1,200-MW plant had begun commercial operations and started power supplies to the Odisha grid. But, coal paucity and absence of firm linkages had caused disruptions in the operations of the power plant. This project has been completed at a cost of `7537 crore which includes a debt component of `5,900 crore. JITPL has power purchase agreements (PPAs) with Odisha’s Gridco Ltd, Kerala State Electricity Board and Tata Power Trading Corporation. Apart from JSW Energy, JITPL also had competing offers from Adani Power and Singapore’s SembCorp.. NLC India (formerly Neyveli Lignite Corporation) which is in the hunt for buying out power assets is understood to have shown interest in the 700-MW Odisha plant of Hyderabad-based Ind-Barath Power Infra Ltd (IBPIL). The power plant located at Sahajbahal, near Jharsuguda, has commenced commercial operations. Though the exact size of the potential deal is not known, the valuation could be anywhere in the range of ` 5000-5,500 crore. In August last year, NLC India had floated an Expression of Interest (EoI) from companies owning coal and lignite-based power projects, for a possible acquisition. NLC India’s installed thermal power capacity is 3, 240-MW. It runs a 10-MW solar power unit and wind power assets with a capacity totalling 37.5-MW. Western Coalfields, state-run Coal India arm, has received the environment clearance for its `263 crore expansion project in Nagpur district, Maharashtra.The proposal is to enhance the production capacity of the Gokul open cast mine to 1.875-million tonnes per annum (MTPA) from the existing 1-MTPA. The mine, located in 767.17-hectare, has a mineable reserve of 14.50-million tonnes. Among the conditions specified, the company has been asked to get ‘Consent to Operate’ Certificate from the State Pollution Control Board for the existing production capacity of 1-MTPA and also the ‘Consent to Establish’ for the proposed capacity of 1.875-MTPA prior to enhancing the production capacity. With regard to transportation of coal, the company has been asked to carry out by covered trucks and take mitigative measures to control dust and other fugitive emissions all along the roads by providing sufficient number of water sprinklers. The company has been informed to adopt controlled blasting techniques to control ground vibration and flying rocks. It has also been told to implement a progressive afforestation plan covering an area of 376.04-hectare at the end of mining. Of the total quarry area of 231.73-hectare (on floor) and 291.21-hectare (on surface), the backfilled quarry area of 115.39-hectare should be reclaimed with plantation and there will be no void left at the end of the mining operations. The land after mining should be restored for agriculture purpose. OIL & GAS Bharat Petroleum Corporation Ltd (BPCL), India’s second biggest state-run refiner, plans to spend about `13,000 crore on expanding its Numaligarh refinery in Assam by 2017-18.The company plans to expand the Numaligarh refinery to 9 million tonnes from the current 3 million tonnes. Chemical Engineering World
Book Shelf CEW Pollution Control in Chemical and Allied Industries: With Focus on Air and Water Pollution Authors : Hanley N Price : ` 1,678.00 (Paperback) Pages : 664 pages Publisher : CBS Publishers and Distributors Pvt LTD About the Book : The intent of this reference textbook is to describe environmentally preferable or ‘green’ approaches to the design and development of chemical processes and products. The entire text is divided into 4 section covering 31 chapters. All the sections present the material in a cogent and lucid style to meet the student’s expectations from basic textbook. Diagrams and tables supplement the text. This reference textbook is an essential reading for all students and teachers of engineering, environment and life sciences. The researchers and consultants in environmental field with special emphasis on chemical industries, chemists and industrialists will also find it highly useful and informative.
Corrosion and Materials Selection: A Guide for the Chemical and Petroleum Industries Authors : Alireza Bahadori Price : USD 227.67 Pages : 576 (Hardcover) Publisher : Wiley About the Book: The petroleum and chemical industries contain a wide variety of corrosive environments, many of which are unique to these industries. Oil and gas production operations consume a tremendous amount of iron and steel pipe, tubing, pumps, valves, and sucker rods. Metallic corrosion is costly. However, the cost of corrosion is not just financial. Beyond the huge direct outlay of funds to repair or replace corroded structures are the indirect costs – natural resources, potential hazards, and lost opportunity. Wasting natural resources is a direct contradiction to the growing need for sustainable development. By selecting the correct material and applying proper corrosion protection methods, these costs can be reduced, or even eliminated. This book provides a minimum design requirement for consideration when designing systems in order to prevent or control corrosion damage safely and economically.
Chemical Process Equipment: Selection and Design Authors : James R Couper, W Roy Penney, James R Fair, Stanley M Walas Price : USD 47.25 Page : 755 (Hardcover) Publisher: Butterworth-Heinemann About the Book: Chemical Process Equipment is a guide to the selection and design of a wide range of chemical process equipment. Emphasis is placed on specific information concerning the process design and performance of equipment. To this end, attention is given to examples of successful applications, and a generous number of line sketches showing the functioning of equipment is included with many graphs and tables giving their actual performance. For coherence, brief reviews of perininent theory, including numerical examples to illustrate the more involved procedures, are provided in key chapters. Chemical Engineering World
Handbook of Petrochemicals Production Processes (Mechanical Engineering) Author/s : Robert A. Meyers Price : USD 169.551 Pages : 744 (Hardcover) Publisher :McGraw-Hill Education About the Book: Although described as a handbook, this work is more an encyclopedic description of 53 industrial process technologies for producing 18 different petrochemicals. Each process is described in a separate chapter by a different author or authors from one of 18 different companies from North America, Europe, or Japan. The descriptions are mostly brief (averaging 13 pages) and include the following information: general process description, process chemistry, process perspective, process description, product specifications, wastes and emissions, and process economics. The amount of detail varies, but the most common elements are the chemistry and flow diagram of each process, with other details being mostly of a qualitative or descriptive nature. The reader should be aware that there are many other large companies that have patented processes for a number of the chemicals included (notably absent is ICI, one of the largest, so the compilation should be considered representative rather than extensive. This excellent introduction and summary of typical plant operations is recommended as a valuable reference for any technical library that includes industrial chemistry and/or chemical engineering.
December 2017 • 89
CEW Ad Index Sr. No.
Client’s Name
Page No
Sr. No.
Inside Cover I
19
Mist Ressonance Engg. Pvt. Ltd
Client’s Name
Page No
1
Atomic Vacuum Company (Exports)
47
2
Bedaflow Systems Pvt Ltd
51
20
Nirmal Industrial Controls Pvt Ltd
3
Bonfiglioli Transmission (Pvt) Ltd
29
21
Plastindia
27
4
Busch Vacuum India Pvt Ltd
43
22
Rasaii Flow Lines Pvt Ltd
53
5
Cole-Parmer India
41
23
Ravel Hiteks Pvt Ltd
67
6
De Dietrich Process Systems India Pvt. Ltd.
23
24
Ross Process Equipment Pvt Ltd
11
7
Desmi India LLP
15
25
SEW
17
8
Fluoro Tech Engineering Works
69
26
SSP Pvt Ltd
9
GEA Process Engineering (India) Pvt Ltd
5
27
Sulzer India Pvt Ltd
55
10
GET Water Solutions Pvt Ltd
59
28
Suraj Ltd
69
11
Grundfos Pumps India Pvt Ltd
18 & 19
29
Tecnimont Pvt Ltd
45
12
Hi-Fab Engineers
67
30
Three Ten Initiative Technologies LLP
65
13
Hi-tech Applicator
3
31
Thyssenkrupp Industrial Solutions (India) Private Limited 39
14
Horizon Polymer Engineering Pvt Ltd
6&7
32
Uni Klinger Ltd
57
15
ImageGrafix Engineering Services Pvt. Ltd
75,77,79,81
33
UNP Polyvalves (India) Pvt Ltd
21
16
Ion Exchange
33
34
Vac Enterprises India
65
17
KSB Pumps Ltd
31
35
Vega India Level & Pressure Measurement Pvt Ltd
35
18
Lubrizol Advanced Materials India Pvt Ltd
9
36
Chemtech World Expo 2018
61
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