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CHRONICLING PROCESS INDUSTRY INNOVATIONS SINCE 1966

CHEMICAL ENGINEERING WORLD FEBRUARY 2019

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CEW

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

EDITORIAL

Editor Deputy Editor Editorial Advisory Board Contributing Editors

Maulik Jasubhai Shah Hemant K. Shetty Hemant K. Shetty

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

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VOL. 54 | ISSUE NO. 02 | FEBRUARY 2019 | MUMBAI | ` 150

NEWS Industry News

FEATURES Pollution Control Techniques in Refinery and Downstream Petrochemical Plants Ajay Popat, President – Technology, Corporate Marketing and Corporate Diversification, Ion Exchange (India) Limited Strategies to Reap Operational Benefits from Smart Manufacturing or Industrial IoT Valentijn de Leeuw, Vice President, ARC Advisory Group Chemical Characterisation in the Safe Handling of Acids and Caustics Richard W. Prugh, Principal Process Safety, Specialist Chilworth Technology and Jitendra Kumar, Senior Process Safety, Specialist Chilworth Technology

MARKETING INITIATIVES Smart Factories and Lean Manufacturing

Insulate Without Giving Up Valuable Space with Thin Film Insulation Coatings

Chemical Mixing

PRODUCTS

EVENTS

PROJECT UPDATE

BOOK SHELF

AD INDEX

Disclaimer: The Editorial/Content team at Jasubhai Media Pvt Ltd has not contributed to writing or editing “Marketing Initiative.” Readers would do well to treat it as an advertisement. Printed and published by Mr Hemant K. Shetty on behalf of Jasubhai Media Pvt. Ltd., 26, Maker Chamber VI, Nariman Point, Mumbai 400 021 and printed at The Great Art Printers, 25, S A Brelvi Road, Fort, Mumbai 400 001 and published from 3rd Floor, Taj Building, 210, Dr. D N Road, Fort, Mumbai 400 001. Editor: Ms. Mittravinda Ranjan, 3rd Floor, Taj Building, 210, Dr. D N Road, Fort, Mumbai 400 001.

Chemical Engineering World

CEW Industry News Evonik More Than Doubles Venture Capital to Accelerate Innovation Evonik has launched its second venture capital fund with a volume of

€ 150 million, more than doubling the amount under management to € 250

million. The new fund will help secure access to disruptive technologies and innovative business models as well as supporting Evonik’s digital transformation and enabling early identification of potential technology acquisition targets. “Investments in and partnerships with start-up companies generate strategic value and growth opportunities”, said Dr Harald Schwager, Evonik’s deputy chairman of the executive board, who is responsible for innovation. “Our venture capital arm is a vital link to tomorrow’s technologies and way of doing business.” The head of Evonik Venture Capital GmbH is Dr. Bernhard Mohr. “The

extension of the fund volume to € 250 million manifests our ambition to establish Evonik Venture Capital as one of the global leading investors in the specialty chemicals space”, said Mohr. As well as providing capital, Evonik offers start-ups access to the resources of one of the world’s leading specialty chemicals companies. Since its inception in 2012, Evonik has realized 25 investments. The venture capital unit has a global reach with offices in Germany, U.S.A. and China. The investment focus is on business and innovation fields such as Health & Care, Animal Nutrition, Smart Materials and Specialty Additives, which Evonik has already identified as growth drivers. The portfolio, which is made up of both direct and fund investments, includes companies such as Israeli digital-printing specialist Velox and the biotechnology startup Numaferm, based in Dusseldorf. The portfolio company Structured Polymers, a U.S.-based business active in 3D-printing technology, was acquired by Evonik in early 2019.

Bentley’s Connected Data Environment Improves Collaboration on Thames Tideway Project The London sewerage system was designed in the Victorian era to serve a population of 4 million people. There are now more than 8 million people in London, and this growth has put significant strain on the system, causing it to spill millions of tonnes of sewage into the tidal section of the River Thames each year. This happens about 50 times during a year. The Thames Tideway Project will reduce these occurrences to about four a year. The project has been divided into three contracts, East, Central, and West with a total value exceeding GBP 4 billion. There are many challenges facing a project of this scale, from marine construction works in the River Thames, creating a new profile to the river walls, to solving design issues where large gas mains are present in proximity to the existing rivers walls. Therefore, it is critical that such services are protected during construction works. AECOM, part of a joint venture consisting of Ferrovial Agroman and Laing O’Rourke (‘Flo’), is the main designer on the Central Contract to the Main Works Contractor. AECOM undertook to host the Central Contract on behalf of Flo using Bentley Systems’ Connected Data Environment based on ProjectWise for its ability to manage engineering data and its scalability from small to large projects. Using workflows, defined document coding, and managed workspaces, AECOM has delivered a controlled and secure CDE to manage this highly complex project. ProjectWise, as the hub of the 10 • February 2019

CDE and leveraging the established project standards, provides a central repository for all project data produced by each stakeholder involved on this contract. This ensures that they are working to a common standard, including temporary and permanent works. MicroStation and OpenBuildings Designer act as the deliverables format for drawings and models, as defined by the main client. AECOM adopted these applications because of their compatibility with each other and with ProjectWise. AECOM also used Bentley Rebar, Navigator, Pointools, Descartes, gINT, Bentley Facilities Manager, and ContextCapture. Using these interoperable applications ensured limited risk and avoided the need for additional processes. AECOM has already realized numerous benefits and savings through the adoption of a digital twin and a CDE. iModels were produced from the Design Master Model on a weekly and monthly basis and available for all stakeholders to see the development of each site as it progressed. The project team used the iModels to carry out multi-discipline clash checks that were sent to the design and modeling teams to resolve. The project team also used iModels during the internal design review process. Using the project digital twin and CDE also resulted in “non-engineering” savings, including increased IT security and reliability, better access and editing control, improved automatic PDF generation, and reduced travel costs for project members by enabling real-time access anywhere, at any time.

Solenis and BASF Complete Merger of Paper and Water Chemicals Businesses Following the approval of all relevant authorities, BASF and Solenis have completed the previously announced merger of BASF’s wet-end Paper and Water Chemicals business with Solenis. With pro forma sales of approximately U.S. $3 billion, the combined company will operate under the Solenis brand and is positioned to provide expanded chemical offerings and cost-effective solutions for customers in pulp, paper, oil and gas, chemical processing, mining, biorefining, power, municipal and other industrial markets. BASF will own 49 per cent of the combined company and 51 per cent is collectively owned by Solenis management and funds managed by Clayton, Dubilier & Rice (CD&R). The new Solenis has approximately 5,200 employees, with increased sales, service and production capabilities across the globe. The merger includes the Paper and Water assets of BASF’s Performance Chemicals unit, including production sites in Bradford and Grimsby, UK; Suffolk, Virginia, USA; Altamira, Mexico; Ankleshwar, India; and Kwinana, Australia and related assets including intellectual property. BASF’s paper coating chemical business is not part of the transaction. “Combining our strong heritages creates the leading customer-focused, global solutions provider for the paper and water industries. Customers from these industries will benefit from our joint strengths, resulting in an unparalleled and complementary range of products and services, stateof-the-art innovations and know-how,” said John Panichella, president and CEO, Solenis. “Joining forces with Solenis is the right step for BASF’s Paper and Water Chemicals business to maintain sustainable growth. Together, we will provide the broadest scope of products and services to meet the specialty chemical needs of the global paper and water industry,” added Anup Kothari, president of BASF’s Performance Chemicals division. "Bringing together these two highly successful and complementary businesses creates an even stronger global enterprise with enhanced prospects for long-term growth and value creation," said David Scheible, chairman of Solenis and operating advisor to CD&R. Chemical Engineering World

CEW Industry News MoU for Coal Mining & Clean Coal Technologies

Haribhai Parathibhai Chaudhary, Hon'ble Minister of State for Coal and Mines and Grzegorz Tobiszowski, Secretary of State, Ministry of Energy, Republic of Poland. Additional Secretary, Ministry of Coal, Suresh Kumar have signed the MoU to foster relations in the field of coal mining and clean coal technologies. Two countries have already established Joint Coal Working Group to promote trade and investment in the coal sector and enhance the understanding of coal related energy issues, particularly clean coal technologies. The working committee will also promote the exchange of information on policies, programmes and technologies with special emphasis on coal exploration and exploitation, research and development, technical cooperation and capacity building. The joint working group created under the MoU would work very closely to achieve the goals in a time-bound manner.

thyssenkrupp commissions fertilizer plant for PVFCCo in Vietnam thyssenkrupp Industrial Solutions (India) has successfully commissioned in 2018 the process plant of the new fertilizer plant for the production of 250,000 tonnes of NPK fertilizer per year for Petrovietnam Fertilizer & Chemicals Corporation (PVFCCo) in Vietnam. NPK fertilizer is a multinutrient fertilizer comprised of the three primary nutrients required for healthy plant growth: nitrogen, phosphorus, and potassium. The new plant is located in the Phu My Town, 70 km away from Ho Chi Minh City. P D Samudra, CEO and Managing Director of thyssenkrupp Industrial Solutions (India) says: “Our experience in DI-Ammonium Phosphate (DAP) and NPK plants spans almost two decades and includes grassroots and expansion projects for a number of fertilizer majors in India and abroad. All of these have been built using the state-of-the-art Pipe Reactor technology of Incro. The PVFCCo project was an excellent example for the collaboration between various offices of thyssenkrupp Industrial Solutions worldwide We are especially honored to have been selected for this project which involved different entities of thyssenkrupp worldwide.” Work on the project began in 2015, when the Vietnamese fertilizer major entrusted thyssenkrupp with building the plant on a lumpsum turnkey basis after an international bidding process. The project was executed along with consortium partner Petrovietnam Technical Services Corporation (PTSC), which is based in Vietnam. PTSC was mainly responsible for construction, local transportation and safety-related measures at the project site. thyssenkrupp builds on a solid track record in building DAP-NPK plants. In recent times, the company has successfully commissioned a number of 12 • February 2019

plants in India and abroad. The NPK plant uses the Pipe Reactor technology from Incro, Spain, and phosphoric acid, liquid ammonia, sulfuric acid and different phosphatic fertilizers as feedstock to achieve the desired grade of NPK. Petrovietnam Fertilizer & Chemicals Corporation is a joint stock company manufacturing urea and other key fertilizers and chemicals. The company supplies different grades of fertilizers to support the country's agricultural needs and increase farm productivity.

Kirloskar Brothers Limited launches three new revolutionary products with universal applicability Kirloskar Brothers Limited (KBL) reiterated its capabilities as the country’s leading provider of innovative pumping solutions by launching three products in less than a month. The company has precisely launched three products, including two pumps and a water filtration product to be used with pumps. The KU6 - oil-filled 6” borewell submersible pump series will be available in three variants and is designed to ensure higher-efficiency at a lower cost as it consumes less power. These pumps are suited for meeting gardening and farming requirements in farmhouses & bungalows, domestic and industrial water supply, sprinkler & drip systems in farms, firefighting systems, etc. Speaking on the occasion, Ashish Tripathi, AVP, Retail Business, KBL, expressed: “These lowmaintenance pumps facilitate longer life of the motor by ensuring lower friction loss. The power-saving KU6 pumps can efficiently work even in low voltage, which makes them ideal for continuous working applications.” K-Kleen 25, on the other hand, is a unique chlorination technology designed exclusively for improving the quality of water delivered through the pump. The K-Kleen 25 kit, which can be mounted on any Mini range of pumps, comes equipped with an in-built inline chlorinator and cartridge that facilitate the filtering of water flowing through the pump on which it is mounted. Elaborating further on the features of this unique water-cleansing technology, Tripathi stated, “The reliable and effective water-cleaning technology kit is safe and easily portable. It is ideal for water pumps installed in residential buildings, public places like railway stations, bus-stands, schools and colleges, offices, schools and colleges, gram panchayat, etc.” Besides, the company also launched the Kirloskar Vertical Multi-stage (KVM) pump, developed predominantly for use in RO plants. In the RO plants, the KVM pump will be used for pumping water at high pressure across the membranes to facilitate delivery of potable and safe drinking water. Speaking on the occasion, Suman Chakraborty, AVP, Small Pump Business, KBL, expressed, “We truly believe that this highly-efficient pump wonder will act as the heart of a RO plant and, for such a critical application, the built quality of the pump is paramount. And it gives us immense pride and satisfaction to inform that the sturdy KVM pump has been built to stand the test of time, thus ensuring the customer of its long-lasting reliable operation.” The powerful KVM pump is compact and light-weight, thus enabling space-saving and its ease of integration in the plant. The special-purpose pump is available in various sizes depending on its concerned application in the RO plant. Though the pump is primarily developed for RO plants, it can also be used for pressure boosting, firefighting, industrial washing and air conditioning applications. Chemical Engineering World

CEW Industry News Braskem and Haldor Topsoe start up demo unit for developing renewable MEG Braskem and Haldor Topsoe have announced, that they have reached mechanical completion of the MOSAIK process step of their demonstration plant that will produce bio-based MEG from sugars. The demonstration plant, located in Lyngby, Denmark, is an important step to upscale the MOSAIK solution and begin production at an industrial scale, which is planned to commence in 2023. The plant demonstrates all key design features of the technology and can produce more than 100 tons per year of glycolaldehyde, which is converted into MEG in the next process step. Construction and pre-commissioning of the MOSAIK process step have been completed as planned and on schedule. The next activities in this part of the demonstration plant will be start-up and operation with the aim to achieve key technical targets and confirm economic feasibility of the process. Operation will begin March 1. In parallel with operating the first process step, the partners will complete the construction of the next process step, the downstream conversion to MEG. Mechanical completion is expected before the end of 2019. “Haldor Topsoe is a world leader within catalytic solutions, and we are determined to maintain that position also in the renewables arena. So we are extremely pleased to be able to begin the next phase of the validation of the MOSAIK solution for bio-based MEG together with Braskem. Our goal is to show that innovative catalytic technologies can make chemicals from biomass a commercially attractive option,” says Kim Knudsen, Executive Vice President at Haldor Topsoe. As a leading producer of thermoplastic resins in the Americas, Braskem wants to expand its portfolio of renewable products to offer new solutions that complement its bio-based polyethylene marketed with the I’m green seal. “The process for developing renewable MEG in partnership with Haldor Topsoe represents a major advance in competitiveness for Green PET. The partnership strengthens the leading role we play and adds value to our I’m green portfolio, which already features Green Polyethylene and Green EVA, both made from sugarcane. It also will further corroborate our vision of using biopolymers as a way to capture carbon, which helps to reduce greenhouse gas emissions,” said Gustavo Sergi, Director of Renewable Chemicals at Braskem. Topsoe delivers a packaged solution for this project with Braskem, including process design, engineering, catalyst, and technology.

Agilent Inaugurates Third Center of Excellence in India Agilent Technologies has opened the new facility in Mumbai, India, dedicated to developing integrated, end-to-end workflow solutions for supporting diversified end markets - including pharma, biopharma, and food testing. The Agilent CoE in Mumbai is a state-of-the-art laboratory established with the purpose of meeting the increasing demand for next generation lean laboratories, delivering higher productivity, more efficiency, and providing higher-quality data. This new CoE will also enable a strong, local touch point for Agilent customers in the region to interact with well-qualified subject matter experts, representing Agilent’s entire portfolio range. The facility is equipped with Agilent’s new products, software, and chemistries providing a wide range of application support to life science and applied markets. Agilent has strong focus on skills development activities, this CoE will offer customers comprehensive training and hands-on experience of instruments, lab informatics, good laboratory practices, and advanced analytical workflows. Agilent continues to strengthen its portfolio through R&D investments and M&As, 14 • February 2019

incorporating new capabilities and highly differentiated products. The western region of India has strong potential and is an area of focus for Agilent. This CoE investment is strategically intended to build a conducive environment where R&D expertise can be applied and developed. Furthermore, the scientific community will have the opportunity for collaboration to potentially achieve extra-ordinary scientific outcomes. The new laboratory will also support a platform for customer training on new applications, as well as solutions development. “This new CoE at Mumbai is creatively-designed with the latest technology offerings, integrated software, and related services to ensure we can deliver trusted answers to our customers,” said Bharat Bhardwaj, country manager for Agilent India. The Agilent CoE at Mumbai is the third CoE lab in India, adding to two already established in Manesar and Bangaluru respectively. “Agilent India’s core strength lies in its ‘Applications Solutions Organization’ which includes more than 35 technical experts across India, and a dedicated team based out of Mumbai, for catering to our customers requirements in the western region of India,” added Bhardwaj. The Mumbai CoE will enable Agilent to collaborate with customers, as well as academic, regulatory bodies, and industry partners, to create holistic, yet highly-specialized workflows—from sample preparation, to smart and fast results reporting. The aim of this CoE is to optimize laboratory processes and introduce transformative ways to advance analytical research and boosting productivity. The smart lab is equipped with digital technology to enable virtual sessions and interactions.

Industrial Cybersecurity Solution against USB Device Attacks Honeywell has announced the latest release of Secure Media Exchange (SMX), a cybersecurity solution to protect industrial operators against new and emerging Universal Serial Bus (USB) threats. SMX now includes patent pending capabilities to protect against a broad range of malicious USB device attacks, which disrupt operations through misuse of legitimate USB functions or unauthorized device actions. These advanced protections complement additional SMX enhancements to malware detection, utilizing machine learning and artificial intelligence (AI) to improve detection by up to 40 per cent above traditional anti-virus solutions according to a Honeywell study. Together, these updates to the SMX platform deliver comprehensive, enterprise-wide USB protection, visibility and control to meet the demanding physical requirements of industrial environments. “Malicious USB attacks are increasingly sinister in their ability to emulate, exploit and manipulate USB devices, often causing damage and operational outages,” said Sam Wilson, global product marketing manager, Honeywell Industrial Cybersecurity. “Honeywell is the first to deliver a powerful industrial cybersecurity solution to protect against malicious USB device attacks, which represent the majority of USB threat types and advanced malware. And as USB usage increases and devices proliferate, human verification of device actions will continue to play an important role.” SMX protection includes Honeywell’s innovative Trusted Response User Substantiation Technology (TRUST), which introduces a human validation and authentication step to ensure that USB devices are what they claim to be. TRUST helps prevent unwanted or suspicious devices from introducing new threats into the industrial control environment. In the case of USB storage devices, additional layers of advanced malware detection technology are used to further protect against malware, including machine learning and AI to improve detection of increasingly complex malware, including zero days and evasive malware. Chemical Engineering World

CEW Industry News Thermax inaugurates its state-of-the-art manufacturing facility at Sri City, Andhra Pradesh

Thermax Limited, the leading energy and environment solutions provider today, inaugurated its new manufacturing facility in Sri City, Andhra Pradesh. The company’s latest state-of-the-art production unit, deploying high levels of digitisation, will manufacture a wide range of vapour absorption machines comprising chillers, heat pumps and heaters in its first phase. Constructed on a 40-acre plot in the Domestic Tariff Zone at Sri City with an investment of ` 166 crore (23 Mn USD) in Phase I, the unit has a capacity to produce 400 machines per year. “We have come up with a world-class facility that is aligned to our vision of ‘Smart Thermax’ and a significant step in diversifying our operations to leverage the infrastructural advantages of strategic locations such as Sri City. We have invested in digitisation and automation to facilitate zero-defect processes that will ensure superior quality products to our customers”, said M S Unnikrishnan, MD & CEO, Thermax. Located around 75 km from Chennai, Sri City is emerging as a preferred business destination that provides seamless connectivity by road, air and seaports. “While this new plant will help us serve our existing and potential customers in the southern region better; it will also be an important manufacturing hub for Thermax’s global operations that will augment our export capabilities. With the increasing demand for green and energy efficient solutions globally, we see our vapour absorption products manufactured in this plant as an ideal fit towards sustainability”, said Meher Pudumjee, Chairperson, Thermax. All manufacturing processes are designed to create a safe and healthy working environment, and comply with the stringent green building norms. This is the ninth manufacturing plant of Thermax in India, out of the fifteen hubs spread across India, China, Germany, Denmark, Indonesia and Poland.

Birla Carbon Egypt wins the 'Pioneer Business for Sustainable Development 2018' award At the UN Sustainable Development Goals and Business Opportunities for the Private Sector conference, held recently in Cairo, Egypt, Birla Carbon was named the 'Pioneer Business for Sustainable Development 2018'. This accolade was conferred upon Birla Carbon in recognition of its efforts in the field of sustainable development and social responsibility. Sharing his thoughts on the award, Dr Santrupt B Misra, Chief Executive Officer, Birla Carbon, said, “As a leader in the carbon black industry, it is our constant focus, through innovation, to develop solutions that are sustainable not only for the business but for the environment in which we operate. This award is a recognition of our commitment to continue to be the pioneers of sustainable development in the carbon black industry, by living our purpose - ‘Share the Strength’.” John Davidson, President, Europe and Africa region, Birla Carbon said, "Birla Carbon has always endeavored to be the most respected, sustainable and dynamic global carbon black business. This award shows that we are not only on the right path but are also seen as a leader in this aspect.” He further added, “It will be our responsibility to maintain this position and continue to work towards a sustainable tomorrow." 18 • February 2019

The conference was co-hosted by five business member organizations from Egypt, Jordan, Morocco, Tunisia and Denmark. It was the first regional Sustainable Development Goals (SDG) conference specifically for the private sector. Its aim was to get all relevant stakeholders to raise their awareness on the SDGs. The Federation of Egyptian Industries/ Environmental Compliance Office and Sustainable Development awarded 12 best member company cases out of 192 participants in the competition, representing concrete Sustainable Development Goals projects. The UN Sustainable Development Goals address the main global challenges societies face across the globe towards 2030. The business community plays a central role in reaching the 17 goals. To fully benefit from this market potential, businesses must innovate, develop new technologies and services, and create new business models sustainable for climate, environment and human beings as well as for society and businesses is a clear message.

Two 2nd Generation Ethanol Plants to be Set up in UP ShivOm Dayal Energies (P) Ltd, is setting up two biofuel projects worth ` 800 Crore. The two biofuel plants will be set up in the districts of Saharanpur and Bijnor. The UP government approved the two secondgeneration ethanol plants which will incur an investment of INR 400 crore each. The State government will also offer the company with facilities including stamp duty waiver, capital subsidy as well as SGST rebate. Each of the sanctioned biofuel facility is expected to utilise about 200 tonnes of agro-waste per day for the production of 50,000 litres of second-generation ethanol. The plants will be set up under technical collaboration with the Institute of Nuclear Energy Research (INER), Taiwan. The facilities will be utilizing agro-waste including rice straw, wheat straw and bagasse as raw materials to produce second-generation ethanol. The benefits of the project include additional income for farmers, reduction in stubble burning, socio-economic upliftment of farmers, saving on foreign currency and lowering bills of crude. The two plants are also expected to reduce carbon footprint and increase employment generation. “The sanctioning of the mega-plants also strengthens our core mission of becoming the largest cellulosic ethanol producer in India and offer support to rural development and agricultural sectors. Going forward we will strive to contribute towards our Honourable Prime Minister’s vision of 10% ethanol blending in petrol by the year 2022,’’ said . Bainu Anand Ahuja, Director, ShivOm Dayal Energies.

EPC Engineering & Technologies GmbH provides technology for PET plant modification Flexibility in plant operation thanks to variPIPE: this is what U.S.-based company Unifi Manufacturing, Inc, one of world’s leading innovators in manufacturing synthetic and recycled performance fibers, counts on. Once again, Unifi commissioned EPC Engineering & Technologies GmbH with pipeline design and equipment supply. Within Unifi’s PET plant, the polymer distribution on two lines is being modified in order to ensure a more flexible plant operation. The basic and detailed design of the melt pipelines was carried out by EPC Engineering & Technologies GmbH using the company's own variPIPE calculation software. This software was specially developed for the simulation and design of high-pressure pipes for highly viscous liquids. The software was used to calculate the optimum pipe design for the spinning process, ensuring the best possible product quality, maximum flexibility and very good economic efficiency. The design phase of the project is now complete and the plant is currently under construction. Chemical Engineering World

CEW Features Technical Article

Pollution Control Techniques in Refinery and Downstream Petrochemical Plants Pollution is a universal problem that intensifies with each passing day due to growing population and pollution of surface & ground water sources. Indiscriminate industrial development and exploitation of limited water sources are compelling every industry to seriously address this problem. Besides this, availability of water has become a serious issue. Therefore, industries are considering various options to reduce their water usage and to recycle water to the extent possible along with adopting manufacturing technologies that require less water, produce minimum waste water as well as other solid & liquid waste. Increasing cost of water and stringent regulations have helped make water recycle a viable option. This article deliberates on the topics of recycle, zero liquid discharge and solid waste management and explores their various technologies.

revention is better than cure. This also applies to pollution. Prevention or minimisation of pollution at source is the best control method. Hence, before going into the methods of effluent treatment, we should look at the possibilities of preventing or minimising effluent generation. Pollution prevention is defined as the use of materials, processes or practices that reduce or eliminate the generation of pollutants or wastes at the source. Also known as reduction at source, pollution prevention includes practices that reduce the use of hazardous and non-hazardous materials, energy, water or other natural resources. Pollution prevention in the manufacturing industry can be achieved by changing production processes to reduce or eliminate the generation of waste at the source. As it applies to industry, the environmental management hierarchy stipulates that when possible: • Pollution should be reduced at the source • Pollution products that cannot be reduced should be recycled in an environmentally safe manner • Disposal into the environment should

Raw Water

Water Treatment Plant

be used only as a last resort and should be conducted in an environmentally safe manner Recycle of Waste Water and Study of its Application in Various Industries Waste water recycle should take shape at the drawing board stage in contrast to the conventional treatment approach of designing the raw water and waste water treatment plants (end of pipe solutions) separately. This will enable planning for water recycle at the design stage itself. The benefits are many. Firstly, because water is recycled, raw water consumption reduces. The designer can therefore plan for a raw water treatment plant of lower capacity and cost. Secondly, the effluent treatment plant’s capacity is also reduced as we are treating the effluent which is not being recycled and hence the quantity of waste disposed is less, leading to further cost reduction. Investment is certainly required for product recovery, water recycle plants and advanced technologies to handle even higher concentrations of contaminants.

Treated Water

Process

Effluent

However, the life cycle and return on investment is quite attractive. Pollution is not just abated but prevented; pollutants are separated not destroyed; energy is saved and the total cost of water and waste water treatment is reduced. Hence, we can use this experience of on/ offsite recycle and integrated solutions for water and waste water treatment in large industries to achieve the goal of ‘Total Water Management’ at the design stage. We need to only apply these approaches in a complex industry in multiple ways. Guidelines for Selection of Recycle Scheme 1. Study the manufacturing process thoroughly and identify areas where reduction of water consumption is possible. 2. Identify the process where reduction of pollution load is possible by changing raw material or adopting cleaner manufacturing process. 3. Proper analysis of various streams especially targeting the contaminants which are process specific.

Effluent Treatment Plant

Discharge

Figure 1: Conventional Treatment 20 • February 2019

Chemical Engineering World

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CEW Features Reduction at Source

Product Recovery Recovered Product

Raw Water

Water Treatment Plant Recycled Water

Water Reuse

Treated Water

Process

Effluent

Zero Liquid Discharge Plant

No Liquid Discharge

Product Recovery Plant Partially Recovered Effluent

Waste Minimisation

Figure 2: Modern Integrated Solution

4. Identify streams that can be segregated and treated economically. For example, in electroplating, the rinsed water can be segregated and treated for recovery of plating metal. This not only reduces the overall cost of recycle but also facilitates the recovery of valuable products from the waste water stream. 5. Identify effluents which are relatively clean and can be treated with simple processes so that they can be recycled internally without letting the water out into an effluent treatment plant. 6. Identify the quality of water required at various manufacturing stages. For instance, steam generation may require high quality water and washing or cooling water make up may not require high quality water. It is always economical to design a recycle system to produce water suitable for lower end usage. 7. Select a technology that is easy to implement, operate, maintain & service. 8. Look for the availability of spare parts that may be needed in the future. 9. Reliability of performance in the long run is extremely important. 10. Low in operating cost. 11. Good service network of the plant supplier. 22 â&#x20AC;˘ February 2019

Recycle Technologies Any waste water recycling plant requires four stages of treatment as follows: 1. Effluent treatment 2. Tertiary treatment 3. Advanced tertiary treatment 4. Zero liquid discharge Effluent Treatment For a good effluent recycle system, a good effluent treatment is a pre-requisite. Unless we remove the easily removable pollutants with cost-effective methods, it would be difficult to recycle the effluents economically. Usually effluent treatment plants (ETPs) are designed to meet statutory requirements for disposal. When recycling is considered, the ETP should also be designed considering overall requirements of treatment. For example, in India, disposal standards do not require complete removal of nutrients and dissolved salts. But, when we are installing a downstream reverse osmosis system, it is better to remove nutrients and dissolved salts in the biological system of the ETP. This will help reduce fouling of the reverse osmosis system. There are different technologies available for effluent treatment to remove different pollutants. Table 1 lists some generic technologies applied in effluent treatment.

Tertiary Treatment Treatment beyond disposal norms for reusing effluents for low end usages is called tertiary treatment. It acts as pretreatment to advanced treatment for complete recycle of effluents. Table 2 enlists some generic technologies applied in tertiary treatment. Advanced Tertiary Treatment Further treatment of secondary treated effluents is required for conforming to the requirements of high end usages (boiler feed, process, etc.) of treated water. Table 3 enlists some of the technologies available to remove various pollutants in advanced treatment: There are various other technologies which are contaminant and end use specific such as fluoride removal. Zero Liquid Discharge Treatment (Evaporation and recovery of waste water containing highly soluble salts) The highly concentrated reject from the process is further treated in multi effect evaporator (MEE) system generally after reducing dissolved salts by RO processes and the advanced tertiary treatment. Chemical Engineering World

CEW Features Table 1 Effluent Treatment Technologies (Primary and Secondary) Pollutant

Treatment Technology

Floating matter

Manual bar screens, mechanically cleaned screens, drum screens, etc.

Grit

Manual grit chambers, aerated grit chambers, deaerator, etc.

Oil & grease

Oil & grease traps, API oil separators, TPI oil separators, dissolved air floatation (DAF) systems, tubular ultra filtration, etc.

Acidity/alkalinity

Neutralisation using acid/alkali dosing

Suspended solids

Clarifiers, clariflocculators, high rate solid contact clarifiers (HRSCC), lamella clarifiers, tube settlers, DAF, ultra high rate clarifiers, pulsating clarifiers, etc.

BOD/COD/NH 4/TKN/TP/Phenol/CN/SCN

Biological systems such as activated sludge process, trickling filters, sequential batch reactors (SBRs), membrane bio-reactors (MBRs), etc.

Heavy metals

Precipitation using solid contact clarifiers, ion exchange processes, membrane systems for metal recovery, etc.

Toxic substances

Different treatment technologies are adopted based on the nature and concentration of toxic substances. For example, phenols can be removed with biological systems at low concentrations whereas chemical oxidation may be required for higher concentrations.

Recalcitrant compounds/COD

Photo-chemical oxidation is used to remove or break recalcitrant and complex organics such as phenols, benzene, pesticides, etc.

Table 2 Tertiary Treatment Technologies Pollutant

Treatment Technology

Turbidity

Gravity sand filters, pressure sand filters, dual media filters, multi media filters, continuous sand filters, auto valve-less filters, etc.

Bacteria

Chlorine dioxide, chlorination, ozonation, ultraviolet sterilisation, mixed oxidant systems, etc.

Colour

Oxidation, precipitation, adsorption, nanofiltration, etc.

Residual chlorine Activated carbon filtration, dosing of reducing agents, ultraviolet treatment, etc. Table 3 Advanced Tertiary Treatment Pollutant

Treatment Technology

Hardness

Chemical precipitation, ion exchange softeners, nanofiltration, etc.

Silica

Chemical precipitation, ion exchange processes, reverse osmosis, etc.

Turbidity, SDI

Sand or multimedia filtration, ultra filtration, microfiltration, etc.

Dissolved solids

Reverse osmosis systems, ion exchange processes, electrodialysis, etc.

The MEE process uses either mechanical or thermal vapour compression using forced circulation evaporators, falling film evaporators or in combination. Thus, evaporation is increasingly considered for the treatment of refinery and downstream petrochemical waste water to recover 24 â&#x20AC;˘ February 2019

more than 95% of water, or as a part of the zero liquid discharge (ZLD) process. Water Management in Refinery - Case Studies 1. Reliance Industries Limited Reliance Industries Limited (RIL) has

enhanced the capacity of the Jamnagar Refinery to 12,00,000 barrels per stream per day (1200 K BPSD) with the commissioning of the Jamnagar Export Refinery Project (JERP) in Gujarat. Waste water treatment is carried out in a dedicated state-of-the-art completely automated and PLC â&#x20AC;&#x201C; operated effluent treatment plant supplied by Ion Exchange. The effluent treatment area is designed to contain and treat all internal process/utility waste water and storm/fire water, with the objective of zero discharge from the new refinery complex. The treated water is recycled back as cooling tower make-up and partially used as process water after reverse osmosis treatment to the high total dissolved solids treatment train or guard tanks, as required. Effluents are segregated into four identical waste water streams designed for a treatment capacity of 500 m 3/h each and maximisation of reuse. The scope of treatment also includes three by-product streams generated during the treatment of refinery waste water (skimmed or slop oils, oily sludge and biological sludge). Skimmed oil Chemical Engineering World

CEW Features

Effluent Treatment Plant at Reliance Industries Ltd., Jamnagar, Gujarat

is chemical and heat treated, with recovered oils transferred back to the refinery for reprocessing. Each of the above streams employs identical equipment for treating effluents, namely:

project, a new effluent treatment plant (ETP-III) treats effluents generated from the refinery project to meet the MINAS standard. With a view to conserving water, a new zero discharge plant (ZDP) was designed and constructed by Ion Exchange. This plant treats the treated water from ETP-III to enable use of the treated water as make - up to the demineralisation plant. The capacity of the ZDP is 200 m 3/h. The plant was commissioned in 2005 and is operated and maintained by Ion Exchange. 3. Indian Synthetic Rubber Limited Another such example of ZLD is for Indian Synthetic Rubber Limited (ISRL). Three streams containing 3000 m 3/d process effluent along with

requirements from buyers in case of exporters, etc. ZLD also gives enormous importance to sludge management (which is not discussed in this paper and which needs separate attention). Apart from these reasons, industries now identify recycle and ZLD as their social responsibility for environmental friendly manufacturing of goods. Many technologies are now available for managing industrial waste water and other waste. It is of utmost importance to involve environment management specialists right from the planning stage of the project so that the best optimum solutions can be developed. Priority should always be given to source reduction and product recovery rather than end of pipe waste water treatment

• Free oil removal facilities including pre-deoiler and API separators with continuous oil skimming and sludge removal facilities • Dissolved air Flotation (DAF) unit • Two stage biological treatment • Clarification • Dual media filtration • Activated carbon adsorption • Disinfection – with chlorine and chlorine dioxide The effluent treatment plant is treating 100 per cent effluent generated by the refinery since its commissioning in December 2008 and consistently produces treated effluent (pH 6 - 8.5, sulphide < 0.5 ppm, COD < 50 ppm, oil and grease < 5 ppm, phenol < 0.35 ppm) meeting guaranteed parameters for reuse for various applications mentioned earlier. 2. Chennai Petroleum Corporation Limited The ZLD plant for the expansion at Chennai Petroleum Corporation Limited (CPCL) uses advanced membrane processes to reuse water for its process requirement. CPCL, during its expansion, increased the crude refining capacity at Manali by 3 million metric tonnes per annum. As part of this 3 MMTA expansion 26 • February 2019

ISRL- Downsteam Petrochemical

360 m 3/d cooling tower blow down and 240 m 3/d DM plant effluent are being treated through primary, secondary, tertiary and advanced tertiary treatments. The final reject (from RO) is being treated in thermal MEE, thereby achieving the objective of > 95 per cent water recovery and ZLD.

and expensive methods of ZLD. Right technologies should be adopted for recovery and recycle of water from waste water. Final effluents which cannot be recycled should be treated and disposed of in an environmental friendly way.

Conclusion Waste water recycle and ZLD is mandatory for many industries because of water scarcity, legislation, rising water costs, unreliable water supplies, environmental

Ajay Popat President – Technology, Corporate Marketing and Corporate Diversification Ion Exchange (India) Limited

Author’s Details

Chemical Engineering World

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CEW Features Guest Column

Strategies to Reap Operational Benefits from Smart Manufacturing or Industrial IoT Globally, the transformation of the manufacturing sector has begun. The emergence of the Industrial Internet of Things (IIoT), Industrie 4.0, Smart Manufacturing, and other new approaches and initiatives have the potential to uproot traditional ways of doing business. In a connected and collaborative environment the entire manufacturing and supply chain ecosystem becomes agile, flexible and performs better. The impact of these new technologies is being felt across all industries, including the downstream chemical industry.

s Smart Manufacturing Or Industrial IoT a Smart Strategy? Before the shale oil and gas boom in the US, and in Europe after the financial crisis of 2008, the industry GDP was declining. The European Union started issuing manufacturing competitiveness reports to guide policy makers to stimulate the economy. The studies found that manufacturing contributes over-proportionally to exports, a way of bringing liquidity to the region, and increases the resilience to crises and capacity to recover after them. Benchmarking with countries such as Germany with a higher than average industry GDP demonstrated that the average level of industry GDP could be increased. Finally, the fact that innovation in manufacturing is proven to stimulate manufacturing growth made the EU innovation program Horizon 2020 receive a focus on manufacturing. Both the program for the discrete and the process industries are set up as private-public partnerships to increase ownership by industry, and multiply the public investment. Europe’s strategy

Figure 1. Industrie 4.0, a government initiative. Source Presentation by Dr. Achatz, ThyssenKrupp, Orlando 2015

28 • February 2019

inspired the member countries to set up their own programs in line with national needs, the most well-known being Germany’s Industrie 4.0; however the UK’s Catapult program and France’s Industrie du Futur are also likely to create economic impact. For the so-called innovation-driven economies as the World Economic Forum calls them, initiatives that impact product value are the most effective to boost growth; however, cost-related improvements in the domain of process and productivity innovation are also useful. All initiatives mentioned aim to affect these economic factors. Some initiatives, mostly government initiated, such as Horizon 2020 or Industrie 4.0, but also Smart Manufacturing Leadership Coalition (SMLC) are concerned with environmental footprint; and the European initiatives also have social sustainability goals, such as well-being at work, jobs, quality of life, etc. We do then conclude that these initiatives are a smart strategy for growth and societal well-being. Other major initiatives New information technologies have been applied to optimise individual unit processes in factories, but Smart Manufacturing (SM) systems that integrate manufacturing intelligence in real-time across an entire production operation are rare in large companies, and virtually non-existent in small and medium size organisations. The SMLC was founded as an industry initiative in the US to overcome the costs and risks associated

with commercialisation of Smart Manufacturing (SM) systems, primarily oriented towards the process industries. A few years later, the Industrial Internet Consortium was founded to accelerate the development, adoption and widespread use of interconnected machines and devices and intelligent analytics. Also China and India started their initiatives. Vocabulary To create clarity we make the following distinction between smart manufacturing and Industrial IoT: Smart Manufacturing is more encompassing and includes all methodologies, processes and technologies that substantially improves the outcome of manufacturing, be it in the form of product value, quantity or quality, or in the form of productivity or reduced environmental footprint. There are two main sources of improvement: advanced manufacturing that involves improvements in fundamentals, such as physics, or chemistry, such as photonics, or chemical nanostructures – engineering science, such as modular production technology and intensification, additive manufacturing or advanced forming. The second group is related to IT, communication or automation related technologies, among which we find internet enabled applications, often referred to as Industrial IoT. For example, advanced or model-based process control, often applied in refining and petrochemicals, could be applied to a larger degree in smaller chemical processes. Industrial Data Analytics have a great potential for the industry. Chemical Engineering World

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CEW Features A supply chain operating network such as Elemica could perfectly play its role in such a scenario to make the link between supplier and manufacturer to find the raw material that could arrive earliest at the production site, when the supplier has IoT connectivity with its logistics network. The latter could then directly coordinate via Industrial IoT connectivity with the manufacturer to reserve a docking station and create an unloading appointment.

Figure. 2 Industrial IoT; Strategy Report by Greg Gorbach, ARC Advisory Group

Figure. 3 A snapshot of supply chain management; Smart Manufacturing Leadership Coalition

Application Examples Current manufacturing processes and technologies can be augmented with smart manufacturing or Industrial IoT, and create incremental value quickly. In Europe, ThyssenKrupp is one of the integrated companies that consistently implements Industrie 4.0 across domains and operations. The company was able to increase the throughput of a plant producing intermediate products (transforming steel slabs into rolled steel), by applying pull manufacturing and coordinating manufacturing and logistics with real-time information. While pull manufacturing is not new, it a great opportunity for many industry sectors to apply it. Fortunately Industrie 4.0 creates momentum to do this. In specialty and performance chemicals as well as life sciences, the NAMUR organisation is well known for their vision and standards, mostly in automation and IT for manufacturing. In supply chain coordination, the contribution by Dr Poetter from Bayer Technology Services in 2013, anticipated the use of wireless and/ or internet connectivity to faster order raw materials to variable production orders. 30 • February 2019

In the near future, modular production technology - miniature chemicals plants in a container - will make supply chains much more agile than today’s. But to plan and optimise them, they become also more complex. Manufacturing capacity can then be very fast and flexibly scaled up and down, and production units can be shipped to sites close to raw material production or consumers. Early examples today are on-site production of liquefied air and dangerous gases as feedstock for downstream production. As a result of these developments, ARC Advisory Group expects that supply chains will become far more agile, dynamic and complex over the coming years. Not only will the number of permutations of possible routings become orders of larger magnitude, also the tighter supply chain network integration will cause important supply and demand volatility that should be damped with high quality supply chain coordination and professional operation of supply chain operation networks (SCON). New developments in discovery, predictive and prescriptive analytics applied to supply chain network regulation and optimisation are very promising to assist the operators. As these can operate in-memory and in the cloud, they take out ‘latency’ of previousgeneration applications and can compensate for supply chain volatility. Industrial data analytics, in combination with the internet is particularly powerful. When data scientists add their complex event processing techniques and statistical methods to process structured (eg, timeseries) data and unstructured data such as operator logs, to the modelling techniques based fundamental and engineering science, great results can be obtained in the domains of production, quality, energy or assets. Production analytics at Dow or Sabic UK have proven to create several millions of dollars

in operating efficiency. Other companies use quality analytics to monitor maintenance needs of quality testing techniques, or to determine the useful life span of rotating equipment before maintenance, resulting in improved uptime, increased first-quality production and major cost reductions. Engineering humans into the system Industrial IoT, supply chain optimisation and analytics can help the operators best, when they allow them to focus on problem solving by providing easily interpretable analyses within context and free them from repetitive tasks. Then the operator can work at his best, and assess, delegate, interpret, judge and decide with consciousness and skill. As each decision involves emotional processing in the brain, for example when it concerns ethics, we will continue to need operators as part of our systems. Recommendations ARC recommends users to take time for planning the future and set radical improvement targets in product, process and supply chain performance, as Industrial IoT solutions have shown to be able to provide those. These goals should be aligned with the users’ strategies, and a roadmap should include quick wins - as incremental solutions are available today - as well as a long term plan. Since the smart manufacturing landscape changes quickly these roadmaps must be updated regularly.

Author’s Details Valentijn de Leeuw Vice President ARC Advisory Group E:VdeLeeuw@ARCweb.com Chemical Engineering World

CEW Features Technical Article

Chemical Characterisation in the Safe Handling of Acids and Caustics Employers must be aware of workplace hazards facing their employees and take appropriate action to minimise or eliminate exposure to these hazards. This paper discusses the hazards and the precautions that can prevent serious health risks to workers due to exposure to corrosives. Corrosive chemicals are essential to many work processes; however, they can enter the body through ingestion, inhalation, or contact with the skin and eyes.

mployee exposure to corrosives must be evaluated to determine the need for engineering and administrative controls as well as the need for personal protective equipment. The results from injuries can be severe and even fatal. Mists produced by liquids can result in lung damage if inhaled, serious burns or irritation can be the result of accidental contact to the skin or eyes, and lung and skin cancer have been linked to chromic acid. Additional threats to employees are posed by the ease with which many corrosive chemicals ignite, explode or react with incompatible substances. Acids and caustics have two common key properties; they are all corrosive and are extremely common in industry. Taking the time to ensure that acids and caustics are managed appropriately is critical to process safety. They can damage human tissue, and attack many other materials as well. They can react with metals, producing hydrogen gas which is highly flammable. Many acids and some caustics may have toxic properties, and they may release corrosive vapours at room temperature when in a concentrated form, such as nitric acid and hydrochloric acid. Some chemicals turn corrosive when they come into contact with water or humidity; for example, 1, 2-dichloroethane attacks iron and some other metals in the presence of moisture at high temperatures. Corrosive substances widely used in industry can be grouped into general classes, such as those that are listed below, in order to facilitate training and organising process safety information:

32 • February 2019

• • • •

Acids and acidic anhydrides Alkalis (bases/caustics) Halogens and halogen salts Organic halides, organic acid halides, esters, and salts • Miscellaneous corrosive substances (substances that are widely used but do not fall into the above-mentioned classes) Due to potentially hazardous properties, it is extremely important to fully characterise all process stream raw materials, intermediates, by-products, products, and residuals/wastes that are corrosive or have the potential to generate corrosives. The characterisation should be used to develop prevention and control strategies in the programs such as mechanical integrity, management of change, process safety, hazard communication, personal protective equipment, industrial hygiene, engineering controls, uncontrolled emissions, permitting, and emergency response planning. Characterisation, Use, and Handing of Acids & Caustics The common term `corrosive substances’ originated in the United Nations Committee of Experts on the Transport of Dangerous Goods. In 1956, these were defined as: `These are substances which, by chemical action, will cause severe damage when in contact with living tissue or, in case of leakage, will materially damage or even destroy other goods or the means of transport; they may also cause other hazards’. Corrosive material may be in the form of: Gas (chlorine, nitrogen oxides, and ammonia); Liquid (sulphuric acid, and hypochlorite

solutions); or Solid (sodium hydroxide, and aluminium chloride). Groups of substances with corrosive properties include: • Acids and Anhydrides such as Acetic Acid and Acetic Anhydride; Phosphoric Acid and Phosphorous Trioxide; Sulphuric Acid and Sulphur Trioxide. • Alkalis (bases/caustics such as Sodium Hydroxide; Aqua Ammonia; Organic Amines such as Ethanolamine • Halogens and Acid Halides such as Chlorine gas; Iron (Ferric) Chloride; Chlorite solutions; Acetyl Iodide • Other Compounds such as Mercury; Ammonium Polysulfide; Hydrazine; Peroxides The US Department of Transportation (DOT) regulations consider a corrosive material to be a liquid or solid that causes visible destruction or irreversible alterations in human skin tissue at the site of contact or in the case of leakage from its packaging, a liquid that has a severe corrosion rate on steel. The DOT further develops this definition by offering the following: A liquid is considered to have a severe corrosion rate if its corrosion rate exceeds 1/4 inch per year on SAE 1020 low-carbon steel at a test temperature of 130 0°F. The pH scale is used to compare the level of acidity or alkalinity of various acids and bases and their diluted solutions. The pH value is related to the amount of hydrogen ions present in the solution. The pH of a neutral solution or substance is 7. Acids have a pH of that is less than 7, and Chemical Engineering World

Features CEW Substance

Concentration in Water

Effect on Concrete

Acetic Acid

Up to 10%

Negligible

Acetic Acid

10% and Above

Corrosive; Rate depends on Concentration

Acetic Anhydride

Concentrated

Slow decomposition

Ammonium Hydroxide

All Concentrations

None

Arsenic Acid

All Concentrations

None

Barium Hydroxide

All Concentrations

None

Boric Acid

All Concentrations

Negligible

Calcium Hydroxide

All Concentrations

None

Carbon Disulfide

Up to 99.8%

None

Formic acid

Up to 10%

Negligible

Formic acid

10% and Above

Slow decomposition

Hydrogen chloride

Up to 37% [Saturation]

Corrosive; Rate depends on Concentration

Hydrogen fluoride

All Concentrations

Corrosive; Rate depends on Concentration

Nitric acid

All Concentrations

Corrosive; Rate depends on Concentration

Oxalic acid

Up to 9% [Saturation]

Negligible

Perchloric acid

All Concentrations

Corrosive; Rate depends on Concentration

Potassium hydroxide

Up to 5%

Negligible

Potassium hydroxide

5% to 53% [Saturation]

Corrosive

Sodium hydroxide

Up to 1%

Negligible

Sodium hydroxide

1% to 52% [Saturation]

Corrosive

Sulphuric acid

All Concentrations

Corrosive; Rate depends on Concentration

Tartaric Acid

Up to 17% [Saturation]

None

Table 1: Effects of Some Corrosive Liquids on Concrete

bases have a pH that is greater than 7. The pH scale is logarithmic, and for every whole number increase or decrease, the pH changes 10-fold. For example, the alkalinity of wet cement is 30 million times higher than the pH of skin; a pH of 13, as compared to 5.5 for human skin. Strong acids may have a pH that is less than 1.0, and strong alkaline solutions can have pH values above 14. The health effects of acids and caustics resemble those caused by heat. Effects of direct contact vary from irritation causing inflammation, to a corrosive effect causing ulceration, and, in severe cases, chemical burns. Occupational hazards due to contact with corrosives mostly affect skin, eyes and the respiratory tract. The tissues most susceptible to rapid, severe, and often irreversible damage are those of the eyes. The effect depends on the properties of the substance, on its concentration, and the time of contact with acid or caustic. Even a dilute solution may cause irritation Chemical Engineering World

Controlling the Hazards of Acids and Caustics Engineering and administrative controls can be used to reduce employee exposure to corrosive liquids, and mists or dusts in the air and – in particular – to lessen the hazard of direct contact of corrosive materials with the eyes, lungs, and skin.

Administrative controls include: Operating procedures and training to reduce unplanned or uncontrolled releases associated with the handling, transporting, processing, and storing of corrosive liquids; Safety procedures – including lock-out and confined-space entry – to reduce employees’ exposure duration to liquids, mists, and vapours; and Hazard Analysis to identify unrecognised sources of exposure to corrosive liquids. .

Engineering controls include: Eliminating the use of a corrosive liquid, or replacing it with a liquid that is less corrosive; Containment of acids and caustics, in equipment that is constructed from materials that can resist corrosion, or where a corrosion allowance is provided for a known corrosion rate; Limitation of process temperatures to minimise corrosion rates; and Local exhaust ventilation (hoods, or process enclosures) to limit personnel exposures to corrosive vapours.

The characteristics of corrosive materials are both general and specific. Effective process safety management includes both the toxic and physical hazards associated with process chemicals. Information on the properties of a given substance should be obtained before handling. The use of testing and screening tools such as corrosivity and compatibility tables (Tables 1 to 4), safety data sheets, and/or chemical safety cards can be helpful in evaluating chemicals prior to purchase and process changes. Proper hazard assessment is key

with prolonged or repeated contact, for example with skin.

February 2019 • 33

CEW Features Plastics

Max. Temp. ( oC)

Typical Uses

PVDF (polyvinylidene fluoride)

Storage tanks and pipes for sulphuric acid, nitric acid, hydrogen chloride, hydrogen fluoride Vaporisers Drying tower for chlorine Scrubbers and pipes for sulphuric acid, phosphoric acid, hydrogen chloride, hydrogen fluoride 100 Dilution tank for sulphuric acid

FEP (fluorinated ethylene propylene; tetrafluoro ethylene)

95 120 90 90 100

LPE (linear high density polyethylene)

90 85 70 70

Electrolytic bath Pipes Equipment for sulphuric acid regeneration Tanks containing chlorine Pipes for chlorine

Room Laboratory bottles temperature

PP (polypropylene)

80 80 70 70 70 60

Pipes for sulphuric acid, hydrogen chloride, hydrogen fluoride Entrainment separator for sulphuric acid, phosphoric acid, hydrogen fluoride Storage tanks for sulphuric acid, hydrogen chloride Gas pipes for sulphuric acid, sulphur dioxide, sulphur trioxide Scrubbers of sulphuric acid, phosphoric acid Blowers, fans

PVC (polyvinyl chloride, rigid)

50 50 50 30 40

Surface treatment baths and pipes Entrainment separator for sulphuric acid, chromic acid Pipes for sodium chlorate Storage tanks for hydrogen chloride Blowers, fans

Table 2: Uses of Plastics for Corrosive Liquids

to process safety, which includes support â&#x20AC;&#x201C; upstream and downstream â&#x20AC;&#x201C; processes, materials, and activities. It is important to ensure that receiving, warehousing, and logistics employees are able to stage and properly store chemicals upon arrival. In addition, a hazard evaluation checklist can be used in the change-control process to identify potential hazards within operations where these chemicals may be processed and/or generated. The Manufacture, Storage and Import of Hazardous Chemicals (MSIHC) Rules require specific preventive actions that the employers need to implement. The occupier is responsible to ensure safe operation and adequate engineering and administrative control to provide safe operating facility to its employees and neighbouring population. The Process Safety Management (PSM) provides good guidance for gauging process safety awareness. Chilworth offers PSM gap analysis, training, process 34 â&#x20AC;˘ February 2019

hazard reviews and audits to assist clients in proactively managing process hazards on a global basis, including India. Storage of Corrosive Raw Materials and Corrosive Wastes Taking the time to ensure that acids and caustics are managed appropriately is critical to process safety. Also, it is important to characterise process-stream raw materials, intermediates, products, byproducts, and wastes or residuals that are corrosive or can react with moisture or air to generate corrosives. All containers need to be properly labelled so that the contents can be readily identified. Pay close attention to expiration dates, making sure that unstable acids and caustics are disposed of on or before the expiration date. Additional factors that should be taken into consideration when storing acids and

caustics include: First and foremost is to make sure that acid and caustics are not stored together. If there were to be a spill, chemical reactions could occur if they are stored in the same storage area. Second, make sure you check the MSDS of the acid or caustic to determine concentrations and any other storage conditions which must be maintained such as temperature or low moisture, etc. Anticipating acidic and caustic constituents in residual waste streams is also very important. Aerosols of solid or liquid corrosive substances are air pollutants, and so are corrosive gases, and they may require control measures subject to permitting. Changes in the level of acidity and alkalinity affect the flora and fauna in soil and water. For example, acidity of pH 4 can be lethal to crickets and frogs. Some alkalis such as ammonia also have an acute toxic effect on fish. Soil may be classified as contaminated due to acidity when at a Chemical Engineering World

Features CEW Substance

Incompatible With:

Acetic Acid

Chromic acid, nitric acid, hydroxyl compounds, ethylene glycol, perchloric acid, peroxides, permanganates

Ammonia (Anhydrous)

Mercury, chlorine, bromine, iodine, calcium hypochlorite, hydrofluoric acid (anhydrous)

Bromine; Chlorine

Ammonia, acetylene, butadiene, butane, methane, petroleum gases, hydrogen, sodium carbide, benzene, finely divided metals, turpentine

Chromic Acid

Acetic acid, naphthalene, camphor, glycerol, alcohols, flammables

Fluorine

A wide range of substances and construction materials

Nitric Acid

Acetic acid, aniline, chromic acid, cyanides, sulfides, flammable solids, liquids or gases, copper, brass, heavy metals

Sodium Hydroxide; Potassium Hydroxide

Aluminum, zinc, or galvanised metals: produce flammable gases: hydrogen and dichloroacetylene.

Sodium Nitrite

Ammonium nitrate and other ammonium salts

Sulphuric Acid

Potassium chlorate, potassium perchlorate, potassium permanganate and similar compounds of sodium, magnesium and lithium

Table 3: Uses of Plastics for Corrosive Liquids

pH value of 4 to 5 and heavily contaminated when the pH is 2 to 4. When soil has a pH value of 9 to10, it is contaminated due to alkalinity and, at a pH value10 to 12, it may be classified as heavily contaminated. Neutralisation does not always remove the hazards to the environment, as the salts produced in this reaction may also be harmful. Checklist for the Handling of Corrosive Materials The following aspects can be incorporated into a preliminary hazard review or checklist and should be considered when planning or organising the use, storage and handling of corrosives at your facility: 1. The physical and chemical properties of materials, from ingredients to wastes. 2. The level of acidity or alkalinity of acids and bases and their diluted solutions, as expressed by the pH value. 3. The occupational exposure limits required to control and prevent adverse effects of acids and bases on health. 4. Incompatible materials and conditions such as illustrated in the Example Tables in Figures 1 to 4. 5. Materials of construction for storage tanks, to resist internal and external corrosion. 6. The potential mixing points, such as process vessels, mixers, pumps, and other equipment. 7. The need for isolation of piping that contains incompatible materials. Chemical Engineering World

8. The need for procedures such as lockout, vessel entry, and line-breaking. 9. Consideration of alternative materials of construction, piping configurations, equipment design, and accessibility for maintenance, inspection, and testing. 10.Minimising the hazard to workers and to the surroundings, using distance or barricades. 11.Gas and vapour sensors or monitors, with alarms. 12.Dikes, trenches, sumps, or reservoirs to collect spillage of hazardous liquids. 13.Ventilation to limit the extent of gas and vapour releases. 14.Emergency planning, training, and drills. 15.Spill-response teams and equipment, including sampling and monitoring, and personnel control. 16.Personal protective equipment, particularly for members of the spillresponse teams. 17.Hazard markings for all tanks and containers, including appropriate dating. 18.Compliance with national, international, and local regulations, codes and standards. 19.Internal and external inspections and/ or tests, with permanent record of findings. 20.A file for each process vessel that contains – or could contain – corrosive material, to include equipment drawings, materials of construction,

welder’s certificates, heat treatment, vessel supports and/or foundations, maintenance procedures, inspection and test schedules, and changes made since fabrication and installation. References 1. National Institute for Occupational Safety and Health, “Pocket Guide to Chemical Hazards”. 2. Jernkontoret [Stockholm], “Corrosion Tables” (1979). 3. Dillon, C. P., “Materials Selection for the Chemical Process Industries”, McGrawHill, Inc., (1992). 4. North Carolina Department of Labor Education, Training and Technical Assistance Bureau, “Industry Guide #30” (September, 2011)

Author’s Details Richard W. Prugh Principal Process Safety Specialist Chilworth Technology E: safety-usa@chilworthglobal.com Jitendra Kumar Senior Process Safety Specialist Chilworth Technology E: jitendra.kumar@dekra.com February 2019 • 35

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Smart Factories and Lean Manufacturing

he thing about revolutions is that even though they might seem impossible in the beginning, afterwards it becomes difficult to imagine our lives how they used to be before. From steam and power to mass production, the industrial revolutions have shaped the dynamics of our societies for the last part of the 20 th Century. This shaping of change continues in the form of Industry 4.0, also referred to as the Fourth Industrial Revolution, manufacturing’s next act, or smart factory concept. This current trend of automation and data exchange in manufacturing technologies has many names yet it all boils down to same essential dynamics. It is the new, smarter way of manufacturing that includes cyberphysical systems, the Internet of things and cloud computing that is revolutionizing the manufacturing industry as we speak. Industry 4.0 creates "smart factories" to optimize manufacturing in an innovative way, enabling monitoring of physical processes, creating a virtual copy of the physical world and allowing more informed and timely decision-making. The author of this article discusses what smarter factories are and how they are shaping change for the manufacturing industry.

responded to the survey are expecting to dramatically increase their overall level of digitization. While just 33 per cent rate their company as advanced today, that number jumps to over 70 per cent when talking about 2020. It is worth to mention that Industry 4.0 and Fourth Industrial Revolution are not necessary synonyms. The earlier refers strictly to the changes taking place in the manufacturing industry, whilst Fourth Industrial Revolution discusses in a wider scope a systemic transformation of the society. With this in mind, this article discusses Industry 4.0 in a more narrow scope, focusing on the effects on manufacturing. Smart Factory The above mentioned merging of the virtual and physical worlds through ICT technology, cyber-physical systems and improved data management in the form of big data and cloud, have enabled the birth of the “Smart Factory” concept. Processes in a smart factory are driven by cyber-physical connections, enabling real-time decision

making and a feedback loop between the planning and what is actually happening on the manufacturing floor. Automation is one of the defining characteristics for smart factories, and it drives significant real-time quality, time, resource, and cost advantages in comparison with classic production systems. Some of the key benefits of smart factories include: • Mass customization: Smart Factories enable increased flexibility in production. Automation and transmission of data enables different products being produced in one facility. • Leaner and more agile processes: Inventory, materials availability and resources are linked to sensor technology that automatically recognizes fluctuations in manufacturing demand and therefore improves the overall supply chain efficiency. • Safety enhancement in dangerous working environments: Safety risks at traditionally risk-prone environments

Industry 4.0 vs 4th Industrial Revolution According to McKinsey(1), Industry 4.0 can be defined as the next phase in the digitization of the manufacturing sector, that is inspired by four modern changes in the industry: the recent rise in data volumes, computational power and connectivity; the emergence of analytics and businessintelligence capabilities; new forms of human-machine interaction such as touch interfaces and augmented reality systems; and improvements in transferring digital instructions to the physical world, such as advanced robotics and 3D printing. Similarly, according to the 2016 Global Industry 4.0 Survey by PwC (2), Industry 4.0 refers to a profound digital transformation that is underway for the leading industrial and manufacturing companies across the globe. The 2000+ companies that 36 • February 2019

Figure 1: Processes in a smart factory are driven by cyber-physical connections, enabling real-time decision making and a feedback loop between the planning and the manufacturing floor.

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Figure 2: Smart Factory Concept enables modeling the physical world and creating a virtual copy of the shop floor to automate the fabrication process.

such as offshore rigs and chemical facilities are lowered by providing augmented reality and simulation solutions. • Improved quality: Sensor data can be used to determine errors during manufacturing phase to proactively identify mistakes. Although the benefits of a Smart Factory concept are becoming more widely recognized, many manufacturers are still delaying the decision to invest in digitalization. The key concerns hindering the go-ahead are data security and high cost of initial implementation. The close networking and the exchange of internal and external data holds a certain potential risk, which requires a better data protection and backup systems to be implemented. In addition, data usage and processing capabilities must be developed as the effectivity of data driven processes is the key element for business success for Smart Factories. In the near future separation of the system landscapes – ERP, CRM, MES and PLM – won’t be necessary, which will offer a tremendous increase in data processing potential. Chemical Engineering World

The cost of initial implementation can be considerable, as the cyber-physical production environment often requires changes both on the IT environment and the physical production site. However, the long-term benefits will quickly overcome the cost of implementation, as downtime can be cut up to 50 per cent with the help of smarter facility solutions, according to the Digital Transformation of European Industry and Enterprises report (4). First step towards a Smart Factory Together with their counterparts in other industries, manufacturers and fabricators are also looking for ways to enable smarter production and fabrication activities in order to move towards the Smart Factory concept. The first step towards a Smart Factory can be taken by enabling access to critical information in real-time throughout the production process, creating a cyberphysical feedback loop between production and planning, and by removing manual verification steps that are error prone. We are talking about modeling the physical world and creating a virtual copy of the shop floor to automate the fabrication process. An example of a solution that enables this

in a zero-footprint environment is Intergraph Smart Production (SPx). Smart Production features a unique bottom-up approach to control the complete production process within yards and fabricators, integrating with design, schedule, material management and the machines on the shop floor. Smart Production includes an intelligent interface that gives suggestions and recommendations on how the object creation could be executed as efficient as possible, based on the feedback from the cyber-physical systems. Once an object is released to production, Smart Production monitors all the physical processes and the stages it goes through. If the interface is connected to the physical machines, Smart Production can capture all the data directly from the machine without manual intervention and/or provides feedback to the operator. This enables more informed and timely decision making, as the operator can track whether or not a part meets the quality standards at any given time during the production. If the parts are not up to the February 2019 • 37

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Marketing Initiatives predefined quality standards, corrective actions can be automated to reroute the part for correction or to remake the part completely. A key element in this process is the use of continuous and real-time measurement technology to ensure that the parts are up to the predefined quality standards. For these measurements, Smart Production utilizes the measurement technology from other Hexagon companies, including Leica Geosystem’s laser trackers. This type of integrated and intelligent approach creates a centralized and integrated production management system that enables multiple benefits: • Change Management: Manage all production process changes consistently throughout with a data-centric approach. • Control Production: Access real-time feedback from shop floor machines and workstations to provide valuable insights on work progress at any given time. • Improve Material Utilization: By integrating inventory, actual usage, and remnant management into the process, significant material optimization can be achieved. • Easy Production Scheduling: Just-intime production scheduling is supported throughout the complete process, including assembly and sub-assembly stages using the part fabrication scheduling into accounts within the fabrication facilities. • Reduction of Storage: Based on the principles of lean manufacturing, it can be ensured that only the parts that are needed at a certain moment are being worked upon. The just-in-time delivery of the parts lessens the space needed for intermediate storage whilst decreasing the time needed for materials handling as required parts are easy to find. • Timely Delivery: Control of the complete process in a predictive manner, which improves the delivery schedules. This 38 • February 2019

results in more timely invoicing, enhancing the cash flow and customer satisfaction. Future The current handover of information from engineering to the fabricators is often paper-based and in an Excel spreadsheet format since people are often hesistant to provide a digital copy of the data. Therefore, still today, many fabricators and shipyards are using paper-based methods for quality control, tracking and fabricating activities, making the leap towards a truly digital environment challenging. Furthermore, it is not merely enough to collect data through sensors as this data also needs to be interpretable and actionable. However, when a digital production process such as the one enabled within Smart Production powered by NESTIX (SPx), is in place, manufacturing processes can be fully aligned with construction phases. This way the fabricator can positively impact CAPEX of large construction projects by ensuring a delivery of items at the exact right time and exactly right location. Higher precision and full integration within the complete supply chain will be a game changer for the companies who are adopting a Smart Factory concept in the future. The traditional ways of manufacturing and fabricating will be marginalized as demands for staying onbudget and on-schedule are increasing.

The current trend of automation and data exchange in manufacturing technologies enables new, smarter ways of manufacturing and those that embrace this concept will see improvements in quality, better utilization of time as well as resources and thus cost advantages in comparison with the more traditional production systems. Intelligent software solutions, such as Intergraph Smart Production (SPx), can help companies to take the first steps towards implementing the Smart Factory concept to improve efficiency, productivity and safety.

References 1) Manufacturing’s Next Act by Cornelius Baur and Dominik Wee© McKinsey & Company. 2) Industry 4.0: Building the Digital Enterprise© PwC. 3) Smart Factory© Germany Trade & Invest https://industrie4.0.gtai.de/ INDUSTRIE40/Navigation/EN/Topics/ Industrie-40/smart-factory.html 4) Digital Transformation of European Industry and Enterprises. A Report of the Strategic Policy Forum on Digital Entrepreneurship. Strategic Policy Forum© European Parliament.

Conclusion The key focus points of Industry 4.0 or the Smart Factory concept include full utilization of the required data, having real time information available and being able to continuously capture data during the manufacturing process. This enables timely and informed decision-making, allowing optimal usage of time, resources and capabilities onsite. The connectivity (Internet of Things) and the use of continuous measurement technologies will not only improve the quality but also help manufacturers to discover new ways to enhance efficiency by analyzing the collected data.

For details contact:

Erika Ahvenainen Senior Communications Specialist Hexagon PPM E-mail: Erika.ahvenainen@hexagon.com Marcel Veldhuizen Vice President Fabrication Solutions Hexagon PPM E-mail: Marcel.veldhuizen@hexagon.com Chemical Engineering World

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Insulate Without Giving Up Valuable Space with Thin Film Insulation Coatings

f you own refrigerated trucks or trailers, you know that every inch of space counts. Insulating these to reduce heat loss with something thick means you lose valuable cargo space. The same is true for buildings with solid walls that need to be insulated for energy efficiency and to reduce energy costs. Insulating a 4,000 SF metal building to reduce heating/cooling costs with a foam or fiberglass insulation could take up approximately 6 to 12 inches (15 to 30 centimeters) of your space along each exterior wall, potentially reducing the usable area of your building by over 3 per cent. Another tight area where thick insulation is just not possible is onboard ships, where space is at a premium. Insulating hot pipes and equipment with a thick covering means the headway or walkway space is even more severely limited. These are all examples of where thin film thermal insulation coatings (TIC) provide the best solution…a combination of excellent thermal insulation in a thin film coating that takes up very little space, just microns rather than inches. Insulation Does not Have to Be Thick to Work Well! The mechanism behind a leading innovative product, Synavax patented thermal insulation coatings, is the unique material used that reduces heat conduction in a very thin layer. Thousands of these heat transfer reducing particles are in each thin layer of their coatings, doing the work of a thicker insulation at just fractions of the thickness. These thermal insulation coatings come in two main systems, one is a smooth finish 1-part clear film insulation coating and the other is a textured finish 2-part grey or white thermal insulation coating

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with additional abrasion and chemical resistance. The 1-part clear coatings are applied at just 100 microns (0.0039 inches) per coat and dry to just 19 microns; about the same thickness as a coat of paint. A typical application is between 3 to 6 coats. So, even at 6 coats, you have taken up just 0.0044” of space in dry film thickness. The 2-part heavy-duty industrial coating, Heat Shield EPX-H 2O is a little thicker at 254 microns (0.01”) per coat, but still very thin when compared to inches of older insulating materials. A typical 6 coat application of the coating on a pipe or oven would be just 0.06” (less than one tenth of an inch!) Any area can benefit from a thinner insulation, but here are a few where it is particularly useful: • Solid block walls

Case Study – South Africa Paper Mill Surface: Steam Pipe Product: Heat Shield EPX-H 2O (2-part coating) Number of Coats: 6 Total applied thickness: 1.5 mm (0.25 mm per coat) Cure time after application: 24 hours Uncoated Temperature: 138 oC (280.4 oF) EPX-H 2O Insulated Temperature: 50 oC (122 oF) Temperature Reduction: -88 oC (-158.4 oF) Goals achieved: Reduce surface temperature to a safe touch level for personnel safety and save energy. Case Study – Container Vessel Surface: Tubular system and tanks of the HFO system Product: Heat Shield High Heat (1-part coating) Number of Coats: 6

• Metal buildings

Total dry film thickness: 200 microns

• Cathedral ceilings

Fuel Costs % Reduction: 30 per cent

• Ships

Diesel Fuel Use for Reduction: Saved 360 liters per 24 hours

• Pleasure boat cabins • Transport vehicles and trailers to

Payback Achieved: Within 95 days of sailing

• Equipment in tight areas (like textile process drying cans)

Goals achieved: Lower fuel costs, prevent corrosion, insulate in highly moist area and area with little space.

• Shipping containers building space

converted

• Ovens or dyeing machines that open/ close often So, how well do thin film insulation coatings work? They not only are comparable to rockwool, fiberglass and other types of insulation, they are also resistant to moisture infiltration, so they do not degrade as quickly, plus protect surfaces from corrosion and corrosion under insulation (CUI). Here are two examples that illustrate their insulating and energy saving abilities.

Clearing Up Thermal Insulation Coating Misconceptions These patented thermal insulation coatings disrupt conventional thinking about how to insulate. No longer do facilities have to suffer from corrosion under insulation (CUI) or use insulation that harbours dirt, dust and mould. Thermal insulation coatings offer a whole new way to insulate in a thin film layer and also have multiple other benefits, such as corrosion-prevention, mould/mildewresistance, UV resistance and more. February 2019 • 39

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Marketing Initiatives thin film coatings. These coatings have been tested by multiple independent laboratories and have demonstrated a decrease in heat transfer of 34.8 per cent at a 3-coat application (ISO 8990:1999) and an increase in thermal resistance of 40 per cent at 6 coats (UKAS Guarded Hot Plate). This unique and patented technology is able to significantly reduce heat transfer in a thin film coating layer. Misconception 2: Insulation Just Does not Last Very Long While a short lifespan is often the case with fiberglass, mineral wool and other older insulation technologies, you do not have to resign yourself to a short insulation lifespan when you use thin film thermal insulation coatings. Figure 1: Thin film industrial insulation coating being sprayed in a tight area of an oven exterior.

But with any new technology there can be certain misconceptions from those that are not familiar with it. Despite the multiple added benefits from using thin film TICs rather than older fibrous insulation, some facilities still drag their feet about upgrading to this newer material because they do not quite understand it.

made for thicker insulations and do not properly measure the thermal resistance of thin film thermal insulation coatings. Other insulation testing standards are designed for any type of thermal barrier, including

Because these coatings are highly moisture repellent and resistant to infiltration by dust, dirt, mould and other contaminants, they have a long lifespan (5-20 years or more, depending upon application) and just as importantly,

Here are few misconceptions about TICs cleared up: Misconception 1: Insulation Has to Be Thick and Have an R-value The whole reason for insulation is to reduce heat transfer. If you have a steam pipe, you insulate it to reduce heat loss from the pipe, thus saving energy. You also might insulate it to reduce the temperature, so it will not burn people. For buildings, insulation is used to reduce heat gain in the summer and heat loss in the winter. But nowhere do the laws of thermal dynamics state that you have to have a thick material to reduce heat transfer. Synavax coatings do not have an R-value because the R-value testing methods were 40 â&#x20AC;˘ February 2019

Figure 2: An oven door insulated with a thermal insulation coating can easily open and close.

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Figure 3: Clear thin film building insulation coating is easily painted onto the walls to increase energy efficiency.

they maintain their maximum insulating performance throughout their lifespan. 3rd party salt spray testing performed to a British Petroleum test standard that subjected the coating to artificial sea water spray during a 100-day test. The thermal performance of the TIC remained intact while it was being drenched with water! Misconception 3: Insulation Coatings are Hard to Apply Some people unfamiliar with thermal insulation coatings may jump to the conclusion that they will be harder to apply than fiberglass/rockwool and cladding. But the opposite is true. These insulation coatings do not need any exterior covering, so no struggling with aluminium sheeting and trying to screw it on to fit pipes, valves and elbows. Synavax coatings can be applied while equipment is in operation and surface Chemical Engineering World

Figure 4: Thermal insulation coatings can be used in tight areas, like these dyeing tubes, were thicker insulation cannot

temperature is as high as 204 oC (400 oF). They are also easily sprayed over all exterior surfaces. No special equipment is needed, just a standard paint sprayer or texture sprayer. It is very easy for maintenance crews to apply themselves and the manufacturer provides complimentary online video training. Conclusion Insulating pipes, tanks, equipment and buildings with thinner insulation opens up many benefits, including more freedom of design. For example, if you only need a few millimeters of insulation on your piping that means more pipes can be located within the same space.

They are the future of insulation and hold much promise for sustainability in multiple sectors, including manufacturing, buildings, transportation, and oil and gas. Once you get past some of the common misconceptions, making the case to your organization for TICs will provide a reward in energy savings, safety and asset protection for many years to come.

Factory and building layouts can be optimized for peak efficiency because less space needs to be factored into the plan for insulation. Space savings is a benefit for multiple industries, and it is a great reason to begin upgrading to thermal insulation coatings.

Francesca Crolley Vice President - Training & Specifications Synavax, Inc E-mail: contact@synavax.com February 2019 â&#x20AC;˘ 41

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Chemical Mixing

owder mixing is a critical process in chemical product manufacturing, ie, micro-nutrients, pesticide, herbicide, coating chemical, metal powder, thermostat regin, etc, because the desired final product is purely dependent on the mixing of products and its attributes.

Hence, the experts always suggest using proper equipment for an optimum mixing. Toshniwal upon analyzing the Indian demand offers technological-based paddle mixer Norwegian technologicalbased twin shaft fluidized zone mixer and the Canadian single shaft Phlauer mixer products.

most popular, ideal machine to guarantee the perfect mix, high throughput and economic operations. It is very versatile and ideal for adding shear. The horizontal mixer can support bags with ingredients, the operators does not light the bags. Hence, Toshniwal offers PTS product. a) Powder Transfer System Toshniwal introduced vacuum conveying system and offers solution for the transfer of powder, granules and flakey ingredients with expertise in vacuum technology of more than three-decades.

a) Twin Shaft Paddle Mixer Toshniwal’s twin shaft paddle mixer of Norwegian technology is a horizontal batch mixer for homogeneous mixing of powders, granules, extruded products, micro-ingredients, liquids, with exactly the same result. The mixer has two counter rotating shafts with welded paddles.

The innovative powder transfer system can be used to transfer from almost every receptacle or machine and be charged into any type of receiver. The system allows powder to be charged directly into closed-hopper/ vessels, etc, including those under vacuum or pressure in a totally safe way preventing the dust formation, the system can be retrofitted / integrated in to the existing production line.

b) Single Shaft Paddle Mixer This horizontal single shaft batch mixer of A&J Mixing Technology, Canada is the

Automation The concept of these mixer further automated by providing

• • • • • • •

Dumping station Feeding conveyer Collection arrangement Bagging Sensors Vibrator Flow meters, etc.

Application and Advantages Toshniwal offers the mixer which is capable in precision mixing and also handling different characteristics and food ingredients, ie, fat, oil, flavour, thickness, etc, to get ultimate end-product in high degree quality levels. The mixing equipment has proven application such as: •

Crop-care nutrition

•

Detergent powder

•

Powder metallurgy

Conclusion The proven Toshniwal mixer with integrated PTS concept is very broad, with help of automation can obtain unit that adjust perfectly to the requirements of the most demanding customers.

For details contact: Toshniwal 267 Kilpauk Garden Road Chennai 600 010 Tel: 044-26448983, 26448558 Fax: 044-26441820 E-mail: sales@toshniwal.net, Website: www.toshniwalindia.com 42 • February 2019

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Products CEW Sludge Dewatering Machine The micro sludge dewatering machine is unique. It offers dewatering at a very low energy consumption and top of it solid yield in dewatered sludge is also high. The machine operates at a very low sound level with negligible vibration. It is the industry’s dream machine. Easy to operate and simple to maintain the machine has a unique concept of thickening and pressing in single cylinder. That is why micro sludge dewatering machine can work at a very low concentration of slurry. With this feature, it can operate without any thickener. It can take slurry directly from the treatment process such as sludge sump/clarifiers/oxidation ditches and can give dewatered sludge. This is up to 22 per cent of solids. The slurry is pumped to the inlet chamber where we regulate the flow (excess flow is returned to sump). The metered slurry flows to the flocculation tank where poly-electrolyte solution is added. Slow speed agitator is provided in flocculation tank for mixing and formation of flocks. Then it flows to the compaction cylinder, where in the first section, thickening takes place. Further compaction comes into play in the compaction zone. Filtrate is discharged from the gap between the rings under gravity. The pitch of screw and gap between the ring decrease towards the sludge discharge at the end of the cylinder. The pressure plate at the discharge end increases the internal pressure of cage, thus resulting in formation of the dehydrated cake. For details contact: Micro Transmission Systems C-23, Sector 85, Phase 2 Dist: G B Nagar, Noida, Uttar Pradesh 201 305 E-mail: info@microtransmissionsystems.com or Circle Readers’ Service Card 01

Shredders Alfa Therm twin shaft series shredders are designed to operate at slower speeds, utilizing high torque and the tearing, crushing and shearing actions between counter-rotating, opposing blades. This results in minimal power consumption and reduced noise when compared with other types of shredders, whilst still achieving high throughput rates and maintenance costs. These machines are particularly suited to the size reduction of bulky materials. Machines are supplied complete with electrical control panel and are guarded to prevent access to moving parts thereby ensuring safe operation. Their double shaft shredders are robust and rugged machines with a throughput of up to 10 tonnes/hr. Key features of these shredders include less material preparation, safe to operate, very low vibration, lower dust and noise thus offering a safer work environment, lower risk of projectiles from the cutting chamber, longer life to the cutters and entire equipment, higher online reliability and lower power requirements. Alfa Therm single shaft shredder is used in recycling operation for the production of valuable secondary raw materials. Alfa Therm SS Series shredders are single shaft shredders which are powerful, versatile and can be used for shredding of all kinds of input materials and wellsuited for different industries. The single shaft shredder reduces all cutable material to a particle size. For details contact: Alfa Therm Ltd 6 Community Centre Mayapuri Indl Area, Phase 1 New Delhi 110 064 Tel: 011-28115222, 28116333 E-mail: alfatherm@vsnl.com / shredders@alfatherm.in Circle Readers’ Service Card 24 or orCircle Readers’ Service Card 0200

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CEW Products Servo Motors

IR Photo-Electric Detectors/Sensors

The second generation of the type AKM2G synchronous servo motor for example delivers up to 30 per cent higher power density with its optimized stator winding technology. Kollmorgen has succeeded in making a noticeable reduction in winding losses which is a further improvement to the already very good current speed-to-torque ratio of the existing AKM servo motors. Another plus point of the new servo motor generation: The smoother cogging behaviour noticeably increases the control accuracy.

A photo-electric detector system comprises basically a light beam transmitter working in conjunction with a receiver, sensitive to the transmitted light. The object is detected by its effect of breaking or changing the intensity of the light beam. The light source used in the system is generated by a lightemitting diode (LED) in the transmitter and is modulated at a particular frequency and ensure an extremely long service life. They are available in through beam; reflective and diffuse types.

For details contact: Kollmorgen India 1001 Sigma House, Hiranandani Business Park Powai, Mumbai 400 076 Tel: 022-42270300 E-mail: snehal.ambre@kollmorgen.com

or Circle Readers’ Service Card 03

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

Load Cell Minebea Intec offers an innovative enhancement to its successful load cell PR 6201. The load cell Inteco provides customers from various industries with a significantly extended range of possibilities – from simple fill quantity control to high-precision weighing of even the heaviest silos and containers. In developing the new load cell Inteco, Minebea Intec has made the most of the opportunity for optimisation. The analogue output signal of 2 mV/V sets a standard on the market and ensures flexibility when selecting weighing electronics. Higher load levels of up to 75 t are also now available. This allows even the heaviest silos and containers to be weighed safely and ensures a more economic weighing solution. The expanded accuracy classes and the increased precision are documented by C6 approval. A new type of SS makes the load cell Inteco even more resistant to corrosion than its predecessor, the PR 6201, and also prolongs the service life in challenging environments, such as the chemical industry. Upgrading the load cell to a digital solution gives users a clear advantage. For example, fitted with the converter Connexx, the Inteco can be installed easily without the need for a cable junction box. Fast signalling times ensure reliable, precise dosing processes and optimal transparency. Weight values can also be generated individually – per load cell – meaning that defective load cells can easily be identified and replaced. The standard interface CANopen ensures straightforward commissioning and calibration via PC. It is also possible to use cables up to 200 m in length. For details contact: Minebea Intec GmbH Meiendorfer Str 205 A D-22145 Hamburg, Germany Tel: +49.40.67960.917 E-mail: Inken.Martens@minebea-intec.com or Circle Readers’ Service Card 05

44 • February 2019

Chemical Engineering World

Products CEW Smooth Surface Motors NORD DRIVESYSTEMS offers a wide range of smooth surface motors for industries and applications with high hygiene standards. The new size 71 smooth body motors are available in three power classes: 0.12 kW, 0.18 kW and 0.25 kW. IE3 efficiency level guarantees resource-saving operation. Thanks to their aluminium housing (protection class IP66), the motors are protected against corrosion. Additional protection is provided by the optionally available, innovative nsd tupH surface treatment. NORD smooth body motors are fanless and therefore contribute to the non-proliferation of germs during production. The modular design provides wide application flexibility due to numerous equipment options. Variants with condensation outlets (sealed), encapsulated terminal box, standstill heating, temperature sensor, temperature monitor and/or protection class IP69K expand, among other things, the possible uses. The motors are available in various versions. They are suitable for the entire NORD range, preferably for use with NORD aluminium smooth surface drives (NORDBLOC.1 helical gear units, NORDBLOC.1 bevel gear units, SMI worm gears). NORD smooth surface motors are specifically designed for easy cleaning and have even and regular surface transitions wherever possible. Thus, cleaning liquids and foam can wash off easily. Due to their washdown design, they are especially suitable for the application in the food and beverage industry. For details contact: Getriebebau NORD GmbH & Co KG Getriebebau-Nord-Straße 1 22941 Bargteheide/Hamburg Germany Tel: +49 45 32 / 2 89 -0, Fax: +49 45 32 / 2 89 -22 53 E-mail: pl.muthusekkar@nord.com / Joerg.Niermann@nord.com or Circle Readers’ Service Card 06

Fully Integrated Cameras at SPS IPC Drives B&R’s entry into the machine vision market is led by two camera variants: Smart Sensor and Smart Camera. Since the hardware is fully integrated in the automation system, the cameras can be synchronized to machine functions with microsecond precision. The Smart Sensor is designed to implement single machine vision functionality, such as QR code reading or position detection. Unlike many other devices in its class, there is no need to install dedicated hardware for each function. Instead, the user simply configures the desired Smart Sensor function in the Automation Studio development environment. OEMs only have to stock a single camera type and are nevertheless able to support a wide range of applications. In cases where more than one functionality is required, it is easy to switch to the more powerful Smart Camera. The existing application software, parameters and models can continue to be used. Whichever camera type is selected, installation could hardly be easier: Simply hook the camera up to the machine network, and it automatically obtains all the settings it needs from the controller. Smart Sensor and Smart Camera can each be equipped with one of three image sensors, ranging from 1.3 to 5 megapixels. All three sensors are characterized by their large pixel size, high light sensitivity and low noise. This guarantees optimum image quality – even in high-speed applications. Lighting can be implemented in the form of integrated LEDs or external barlights and backlights. Housing variants are available with either an integrated lens or a standard C mount. The integrated lenses have electronic focus adjustment and are available in focal lengths from 4.6 to 25 mm. All B&R lenses are specially optimized for the image sensors used to achieve maximum sharpness and optimal imaging performance. The camera only needs a single cable. The camera is integrated into the machine network via an M12 hybrid connector which also supplies the necessary 24 V DC power. A second hybrid connection enables easy daisy-chain cabling with additional cameras or B&R lighting elements. For details contact: B&R Industrial Automation Pvt Ltd 8 Tara Heights, Mumbai-Pune Road Wakdewadi, Pune, Maharashtra 411 003 Tel: 020-41478999 , Fax: 91-020-41478998 E-mail: pooja.patil@br-automation.com Circle Readers’ Service Card 24 or orCircle Readers’ Service Card 0700

Chemical Engineering World

February 2019 • 45

CEW Products Granulation Line The M 100 high-shear mixer for manufacturing wet granules was developed by Romaco Innojet especially for the new IGL 100 granulation line. In combination with the VENTILUS V 100 LE dryer, this technology is ideal for achieving compact granules, which are mainly processed during the production of pharma solids. Innojet now also offers an end-to-end line concept for manufacturing and subsequently drying wet granules. The first version of the Innojet IGL 100 is designed to handle batches of up to 100 litres. In the medium term, the new IGL Series will be capable of processing batches as large as 800 litres. The line concept ships with central process control and can be cleaned using an integrated WIP (wash in place) system. The transfer from the mixer to the dryer is gravimetric. The very short transfer section manages without an external air supply and meets the high requirements for the containment. The wet granules are then dried extremely gently and uniformly in the VENTILUS V 100 LE. The process air for this purpose is introduced by means of the ORBITER booster. Thanks to Romaco Innojet’s patented air flow bed technology, the movement of the product can be precisely controlled, so that the drying process is not only gentle but also very efficient. For details contact: Romaco Group Am Heegwald 11, 76227 Karlsruhe Germany Tel: +49 (0)721 4804 0 Fax: +49 (0)721 4804 225 E-mail: susanne.silva@romaco.com or Circle Readers’ Service Card 08

Bevel Gear Units with 50 Nm The new SK 9x0072.1 Series has a power range from 0.12 to 1.1 kW and covers speed ratios from 3.03 to 47.67 : 1. The two-stage helical bevel gear units are characterised by high efficiencies, compact design, top reliability and long working life. The high-strength aluminium housing guarantees high rigidity and max durability with low weight. Additionally, the modular design provides wide application flexibility due to numerous application and mounting options. There are two models available: SK 920072.1 and SK 930072.1. The open housing of SK 920072.1 is lightweight but nevertheless solid due to its construction. This variant is available with a universal foot flange version. With its closed housing, the SK 930072.1 is particularly suited for applications with stringent requirements for hygiene and cleanliness. Additional protection is provided by the optionally available nsd tupH surface treatment. The standard version is equipped with a B14 flange. All versions are available with solid or hollow shafts. The motor can be mounted directly without a coupling or adapter (IEC or NEMA). Accessories including torque arms, flanges, covers and fastening elements from the UNIVERSAL Series may also be used for this gear unit. The new, compact and flexible NORDBLOC 1 bevel gear units are particularly suited for intralogistics and packaging technology, and thanks to their washdown design may also be advantageous for the food and beverage industry. The LogiDrive combines these new NORDBLOC.1 gear units with an energy-efficient IE4 synchronous motor and the NORDAC LINK field distributor for an optimally matched drive system. These standardised geared motor variants are highly efficient, and thanks to Plug & Play technology they are extremely maintenance-friendly and benefit from a considerable reduction of spare part stocks, which also results in the reduction of versions. For details contact: Getriebebau NORD GmbH & Co KG Getriebebau-Nord-Straße 1 22941 Bargteheide/Hamburg Germany Tel: +49 45 32 / 2 89 -0 Fax: +49 45 32 / 2 89 -22 53 Circle Readers’ Service Card 24 or orCircle Readers’ Service Card 0900

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Chemical Engineering World

Products CEW Single-sided Rotary Press The KTP 590X is an extremely versatile single-sided rotary press which can be used to manufacture both mono-layer and bi-layer tablet formats. It can be switched between mono-layer and bi-layer mode without any modifications to the compression roller set-up. Bi-layer tablets can be compressed at any time on the version with three compression rollers. The tablet press is equipped for this purpose with two standard fill shoe modules, which distribute the powder uniformly in the die. Thanks to the optimised paddle design, even poorly flowing or sticky powders can be processed efficiently and compressed homogeneously. With its three separate compression stations, the Kilian KTP 590X is equally suited for manufacturing effervescent tablets. The powder is tamped initially to prevent the formation of air pockets and capping. Then it is pre-compressed and finally converted into finished tablets in the main compression unit. The dwell time is significantly longer owing to the use of Kilian 28/41 tooling, meaning harder tablets can be made, even at high operating speeds. The Romaco Kilian KTP 590X single-sided rotary press boasts a max output of up to 510,000 tablets per hour, even in bi-layer mode. Low process temperatures, efficient cleaning and changeover and a mature hygiene concept – the KTP 590X single-sided rotary press too, conforms to the design principles of Romaco Kilian’s successful KTP Series. For details contact: Romaco Group Am Heegwald 11, 76227 Karlsruhe Germany Tel: +49 (0)721 4804 0 Fax: +49 (0)721 4804 225 E-mail: susanne.silva@romaco.com or Circle Readers’ Service Card 10

Motors Drive systems count as the main consumers of energy in industry and consume up to 70 per cent of the total energy required. NORD DRIVESYSTEMS manufactures energy-saving three-phase motors of classes IE1, IE2, IE3 and IE4. As they offer considerably higher efficiencies than conventional motors, considerable energy savings can be achieved, and operating costs can be reduced. NORD motors offer high performance at low energy consumption. They are robust, efficient and reliable and can be combined with all NORD gear units. In addition, they offer a high power density, high torques and a high overload capacity of up to 300 per cent. Due to their compact design, they also can be easily integrated into confined spaces. NORD motors come with many options and in numerous versions. Due to its hygienic, easily washable surface, the wash-down version, as a smooth motor, is ideally suited for use in the food and beverage industry. NORD smooth motors generate less heat and have a longer operating life than previous normal motors. The IE3/IE4 motors have a significantly extended operating range, which means that no safety reserves or lower safety reserves need to be taken into account for the design of the drive unit. The robust aluminium motor housing has Protection Class IP 69K and can also be pressure cleaned. As an option, the innovative nsd tupH surface treatment is available. The IE4 synchronous motors are particularly economical. The use of permanent magnets in the rotor makes these motors extremely efficient. Thanks to this technology, this high efficiency remains unchanged, even during partial load operation and at low speeds – ideal for fluctuating loads due to different products or batch sizes. NORD IE4 motors are used throughout the world, particularly in intralogistics (eg, in post distribution centres and airports) as well as in pumps. The NORD product range comprises synchronous motors with powers from 0.75 to 5.5 kW, and asynchronous motors with powers from 0.12 to 55 kW. ATEX versions are also available. For details contact: Getriebebau NORD GmbH & Co KG Getriebebau-Nord-Straße 1 22941 Bargteheide/Hamburg Germany Tel: +49 45 32 / 2 89 -0 Fax: +49 45 32 / 2 89 -22 53 E-mail: Joerg.Niermann@nord.com / pl.muthusekkar@nord.com Circle Readers’ Service Card 24 or orCircle Readers’ Service Card 1100

Chemical Engineering World

February 2019 • 47

CEW Products Planetary Gearboxes

Diesel Generator Safety Solution

The servo gearbox PT completes the whole range of their servo gearboxes that consist of high-end planetary gearboxes, right angle gearboxes, hypoid gearboxes, cycloid gearboxes as well as various combinations thereof. All common servo motors can be easily installed with all sizes of their gearboxes. Their PT servo planetary gearboxes guarantee high stiffness and reliable transmission through their unique design. All ring gears, planet gears and sun pinions are case-hardened and ground. This provides for an outstanding transmission quality and allows for precise positioning tasks.

The generator safety unit, GSU905Dx is a complete digital console for generators to safeguard and monitor key parameters. GSU ensures extended lifetime of the DG and reduces downtime and maintenance costs and alerts in case of fuel pilferage. GSU allows safe starting of the engine through console or through a remote start output. GSU protects the system by shutting down the moment it detects violation of safety. GSU is easy to install and use in the field. It provides optional communication port to interface for external system to read key parameters/events.

For details contact: EGT Eppinger Getriebe Technologie GmbH Breitwiesenweg 2-8, 73770 Denkendorf Germany Tel: +49 711 934934-626, Fax: +49 711 934934-627 E-mail: info-egt@eppinger-gears.com

For details contact: SUN Indl Automation & Solutions Plot No: 95, Developed Electronic Indl Estate Perungudi, Chennai 600 096 Tel: 044-30788900 E-mail: sias@vsnl.com

or Circle Readers’ Service Card 12

or Circle Readers’ Service Card 13

Industrial Gear Unit MAXXDRIVETM industrial gear units by NORD DRIVESYSTEMS are characterised by high power density, quiet operation and top reliability. Large rolling bearings ensure extremely high axial and radial load capacities and a long service life. The technological heavyweight drives also offer a modular, flexible design as well as varied mounting options. This makes the robust helical and bevel gear units in one-piece UNICASE housings ideal for a great number of heavy duty applications. On the basis of the industrial gear units, NORD plans complete drive systems for heavy duty operation with motors and drive electronics, for tasks including conveyor technology, pumps and agitators. NORD now extended the successful series of industrial gear units: Two new sizes, 5 and 6, extend the previous range with rated torques of 15 kNm and 20 kNm. Offering a total of 11 sizes, the drive specialist now covers a torque range from 15 to 250 kNm. All options of the previous range are available for the new types as well. In addition, NORD has supplemented sizes 5 to 11 (rated torques from 15 to 80 kNm) of its modular series with extruder flanges. Users benefit from generously dimensioned thrust bearings which easily absorb process forces and ensure a long service life. The extruder flange option can be customised to the customer’s shaft and optimally matched to the customer’s demands with several bearing variants. Offering many options for input and output shafts, mounting, seals and monitoring (temperature, vibration, etc), NORD’s extensive range of industrial gear units provide a high level of flexibility for designing demanding applications. NORD is the industrial gear unit manufacturer with the world’s largest industrial gear units in UNICASE housing. For details contact: Getriebebau NORD GmbH & Co KG Getriebebau-Nord-Straße 1 22941 Bargteheide/Hamburg Germany Tel: +49 45 32 / 2 89 -0 Fax: +49 45 32 / 2 89 -22 53 E-mail: Joerg.Niermann@nord.com / pl.muthusekkar@nord.com or Circle Readers’ Service Card 14

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Products CEW TwinCAT IoT Communicator The TwinCAT IoT Communicator makes it easy for PLCs to communicate with mobile devices by connecting the TwinCAT controller directly and securely to a messaging service through TLS encryption. For smartphone and tablet users, the associated IoT Communicator App ensures that process data can be represented on all mobile devices in a clear overview. Alarms are sent to the device as push messages. The TwinCAT 3 IoT Communicator exchanges data using a publish/subscribe mechanism. Since no special firewall settings are needed, integration into an existing IT network is easy. Information is exchanged via a message broker that uses the standardised MQTT protocol and acts as a central messaging service in a cloud or local network. A high level of communication security is guaranteed by proven TLS encryption (up to Version 1.2). Transmitted process data can be displayed on mobile devices using the IoT Communicator App, which is available for both Android and iOS operating systems. The IoT Communicator App also incorporates an integrated QR code scanner to facilitate entry of access data for communication between the broker and individual users. The TwinCAT IoT Communicator simplifies the transmission of push messages. It offers a number of advantages over conventional e-mail and SMS messages by visualizing live data, variables and status values. This makes the IoT Communicator an ideal addition to the related TwinCAT IoT and TwinCAT Analytics software products. For details contact: BECKHOFF Automation Pvt Ltd Suite 4, Level 6, Muttha Towers, Don Bosco Marg Yerwada, Pune, Maharashtra 411 006 Tel: 020-40004802 Fax: 91-020-40004999 E-mail: a.phatak@beckhoff.com or Circle Readers’ Service Card 15

Edge Controller A single device to acquire data, evaluate it and send it to the cloud is possible with B&R’s Edge Controller. The powerful industrial PC can even be used for big data analysis and machine learning, while at the same time serving as a full-fledged industrial controller. B&R’s Edge Controller is based on the robust Automation PC 910, whose high-performance variant is equipped with an Intel XEON processor able to handle resource-intensive tasks like machine learning. The Edge Controller runs a hardened operating system – a commercial Linux variant with guaranteed long-term support. Cloud transmission occurs via MQTT. B&R Hypervisor makes it possible to simultaneously run a real-time operating system on the Edge Controller. That turns the edge device into a full-fledged industrial controller with cycle times in the sub-millisecond range. An unlimited number of I/O modules or controllers can be connected via the POWERLINK Industrial Ethernet protocol, OPC UA or other fieldbus systems. With the Edge Controller, this will soon also be possible with OPC UA TSN. For details contact: B&R Industrial Automation Pvt Ltd 8 Tara Heights, Mumbai-Pune Road Wakdewadi, Pune Maharashtra 411 003 Tel: 020-41478999 Fax: 91-020-41478998 E-mail: pooja.patil@br-automation.com Circle Readers’ Service Card 24 or orCircle Readers’ Service Card 1600

Chemical Engineering World

February 2019 • 49

CEW Products HYDROSYS (Liquid Ring Vacuum Pump)

Roots Pumping Systems

With vast experience coupled to the countless installations in the field, Toshniwal offers many types of turnkey packages to meet the customer’s needs.

Counted among the prominent manufacturers, suppliers and exporters of a wide range of roots pumping systems, Toshniwal provides solution to your vacuum application.

Pump system Type HYDROSYS include liquid ring vacuum pump, cyclone type air-liquid separator and heat exchanger, and associated accessories all mounted on a fabricated frame.

It replaces multi-stage water/liquid ring pumps, steam jet ejectors with compact vacuum packages. Available in a spectrum of specifications, these systems are used in distillation process, food processing, drying of powder and solids, and transformer evacuation. The volume flow is from 180 to 97,000 m3/hr. There is savings in energy resulting from low motor rating. Booster and rotary may be started at the same time.There is built-in bypass value to protect from overloads.

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

For details contact: Toshniwal Instruments (Madras) Pvt Ltd 267 Kilpauk Garden Road Chennai 600 010 Tel: 044-26445626, 26448983 E-mail: sales@toshwnial.net or Circle Readers’ Service Card 18

Process Oxygen Analyzer Barben Analytical offers OXYvisor, its second-generation process oxygen analyzer, which optically measures oxygen in either the gas or liquid phase. In the gas phase, the analyzer measures from trace (0.5 ppmv) to % level oxygen, and in the liquid phase, it measures dissolved oxygen from 1 ppb to ppm. The OXYvisor can be used for continuous oxygen measurement for a wide range of industrial process and laboratory applications. It detects oxygen in flare gas, nitrogen headers, and hydrocarbon and other process streams. It is commonly used to detect oxygen to prevent the corrosion of capital equipment and to ensure product quality. Typical applications include vapour recovery systems, annealing furnaces, produced water, enhanced oil recovery waterfloods, tank blanketing systems, and upstream to midstream natural gas processes. The analyzer uses a proven optical luminescence technique that offers high accuracy, dependability and low maintenance. Its optical technology contains no membranes, which are susceptible to fouling, or electrolyte, which can poison or fail. The unique, industrialized optical oxygen sensing technology is based on proven quenched luminescence measurement principles. The OXYvisor provides supervisory-type monitoring capabilities with advanced diagnostic, auto calibration and remote validation capabilities. This functionality allows users to take significant process actions on alarm conditions at remote locations with high confidence, while significantly reducing maintenance and calibration needs. OXYvisor can be used in conjunction with Barben’s BOSx Series, FiberSense, FlexSense and SafeTap sensors. It has been tested and approved for direct use in Zone 2, Group IIC and Class I, Div 2 Groups A, B, C, D hazardous areas. It is NEC- and CEC-certified for North America and has ATEX and IEC global certifications. For details contact: Barben Analytical 5200 Convair Drive Carson City, NV 89706, U.S.A. Tel: +1 775-883-2500 Fax: +1 775-883-6388 E-mail: sales.barbeb@ametek.com or Circle Readers’ Service Card 19

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Chemical Engineering World

Products CEW Powder Transfer System Toshniwal has exper tise in manufacturing vacuum pump of more than three-decades for varied application. The vacuum conveying technology is a proven method of moving dry bulk solids and powders in a range of applications. It is widely used in food, pharma, chemical and industrial environments. Frequently noted benefits of vacuum conveying systems include cleanliness due to the closed conveying lines, reliability, low noise, simple operation, gentle material transfer with dilute to dense phase conveying, easy low-cost maintenance, lower operating cost and safety. The most common vacuum conveying systems use a batch process. The transfer line is sealed, a vacuum pump is activated, and the process material (powder or granules) is conveyed to a receiving vessel. When the batch is complete, vacuum is released and the material is dropped or transferred from the receiving vessel to the desired destination. The system is again sealed, and vacuum is reintroduced to get the product flowing again. The selection of the vacuum pump is one of the most impor tant element of the system design. The vacuum pump needs to be able to quickly evacuate air from the line, pull and maintain enough vacuum to induce product movement, and provide a volume of air that is sufficient to transfer all the material needed in a given time. For details contact: Toshniwal 267 Kilpauk Garden Road Chennai 600 010 Tel: 044-26448983, 26448558 E-mail: sales@toshniwal.net or Circle Readers’ Service Card 20

Model-Based Systems Engineering Maplesoft offers MapleMBSE, the software that enables companies to employ a Model-Based Systems Engineering (MBSE) approach to their design projects without requiring every engineer on the project to be an expert in complex MBSE tools. The latest release, MapleMBSE 2019.0, further improves the workflow by making it even easier to create and modify many of the structures used to define and analyze the design. Using an Excel-based interface, MapleMBSE provides a streamlined interface for each task in your MBSE project, such as defining requirements, impact analysis, trade-off studies, and failure mode effects analysis. These streamlined interfaces make these tasks significantly easier to perform, and reduce the time and errors that typically come with using a standard MBSE tool. The new release includes enhanced support for the Systems Modeling Language (SysML) used by many MBSE tools, including MapleMBSE. Increased support is available for a variety of constructs that are used to define requirements, architecture, behaviour, and relationships, including activity diagrams, state machines, and parametric diagrams. By making it easier to create and modify these underlying SysML constructs, the new release further reduces the time and effort required to define the requirements and the relationships between them, analyze the impact of changes, and improve the design. Other improvements in this release enhance the integration of MapleMBSE with model management systems, including faster model access through Teamwork Cloud. By connecting MapleMBSE to Teamwork Cloud, customers can seamlessly access models created in a number of different tools, including MagicDraw, and Cameo Systems Modeler. MapleMBSE can also be integrated directly with other SysML-based tools, such as IBM Rational Rhapsody. For details contact: Maplesoft 615 Kumpf Drive, Waterloo, ON N2V 1K8, Canada Circle Readers’ Service Card 24 or orCircle Readers’ Service Card 2100

Chemical Engineering World

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CEW Products External Gear Pump

Internal Gear Pump The self-priming external gear pump ZPA is particularly suitable for uncritical media without fillers, which are compatible to the used standard materials, and is an ideal solution for bottling and filling. A combination to multiple flow pumps is possible as the combination with high-pressure radial piston pumps.

Thanks to internal gear wheels, the gear pump ZPI allows an especially low-noise conveying of the fluid which not only reduces the noise emission but also the costs for noiseabsorbing measures. Furthermore, the high volumetric efficiency of the ZPI internal gear pump has a positive effect on the energy balance due to the improvement of the overall efficiency.

It finds application in filling, bottling and filtration, heating circuits, cooling circuits, lubrication and oil hydraulics.

It finds application in low-noise hydraulic drives, coolant pumps for machine tools, overdrive pumps for hydraulic presses in combination with Beinlich Radial Piston pumps.

For details contact: Bedaflow Systems Pvt Ltd W-7, Sector-11 Noida, Uttar Pradesh 201 301 E-mail: info@bedaflow.com

For details contact: Bedaflow Systems Pvt Ltd W-7, Sector-11 Noida, Uttar Pradesh 201 301 E-mail: info@bedaflow.com or Circle Readers’ Service Card 22

or Circle Readers’ Service Card 23

Efficient Motors for the Processing Industry Drive systems count as the main consumers of energy in industry and consume up to 70 per cent of the total energy required. NORD DRIVESYSTEMS manufactures energy-saving three-phase motors of classes IE1, IE2, IE3, and IE4. As they offer considerably higher efficiencies than conventional motors, considerable energy savings can be achieved, and operating costs can be reduced. NORD motors offer high performance at low energy consumption. They are robust, efficient and reliable and can be combined with all NORD gear units. In addition, they offer a high power density, high torques and a high overload capacity of up to 300 per cent. Due to their compact design, they also can be easily integrated into confined spaces. NORD motors come with many options and in numerous versions. Due to its hygienic, easily washable surface, the wash-down version, as a smooth motor, is ideally suited for use in the food and beverage industry. NORD smooth motors generate less heat and have a longer operating life than previous normal motors. The IE3/IE4 motors have a significantly extended operating range, which means that no safety reserves or lower safety reserves need to be taken into account for the design of the drive unit. The robust aluminium motor housing has protection class IP 69K and can also be pressure cleaned. As an option, the innovative nsd tupH surface treatment is available. The IE4 synchronous motors are particularly economical. The use of permanent magnets in the rotor makes these motors extremely efficient. Thanks to this technology, this high efficiency remains unchanged, even during partial load operation and at low speeds – ideal for fluctuating loads due to different products or batch sizes. NORD IE4 motors are used throughout the world, particularly in intralogistics (eg, in post distribution centres and airports) as well as in pumps. The NORD product range comprises synchronous motors with powers from 0.75 to 5.5 kW, and asynchronous motors with powers from 0.12 to 55 kW. ATEX versions are also available. For details contact: Getriebebau NORD GmbH & Co KG Getriebebau-Nord-Straße 1 22941 Bargteheide/Hamburg Germany Tel: +49 45 32 / 2 89 -0 Fax: +49 45 32 / 2 89 -22 53 E-mail: pl.muthusekkar@nord.com / Joerg.Niermann@nord.com or Circle Readers’ Service Card 24

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Products CEW Mobile Dust Extractors Whatever material, dust, chips or fumes you would like to remove or transport from or within the workplace, Dustcontrol UK Ltd the solutions, even in dangerous environments, such as ATEX zones. With such a wide range available Dustcontrol UK Ltd developed a diverse customer base, including clients from construction, heavy industry, aerospace and transport as well as the food industry, to name a few. Dustcontrol supplies industrial mobile dust extractors and air cleaners, on-tool suction casings, stand-alone separators and cleaning accessories. This helps companies worldwide achieve cleaner and more efficient production, in addition to improved product quality. All of our mobile vacuums and air cleaners are delivered as standard with Hepa H13 filtration and built to Application Class H for hazardous dusts and the most demanding environments. Their vacuums all feature cyclone-based separation and are fitted with pleated cartridge filters to provide high and consistent performance in the most energy-efficient way. Reverse pulse filter cleaning also means filters can be kept clean without the need for removing them in the workplace. All machines are designed to be as ergonomic as possible, so they are easy to handle, move around and transport, as well as being simple to maintain.Dustcontrol has over 45 years’ experience in developing high-efficiency dust extraction solutions including machines, capture hoods for hand-held power tools and fixed equipment and a wide range of cleaning accessories. For details contact: Dustcontrol UK Ltd 7 Beaufort Court Roebuck Way Knowlhill Milton Keynes MK5 8HL U.K. Tel: 01327 858001 Fax: 01327 858002 E-mail: sales@dustcontrol.co.uk or Circle Readers’ Service Card 25

Real-time Moisture Measurement AMETEK Process Instruments has broadened its AMEVision communication and display system capabilities to include the 3050 Series of moisture analyzers. Originally designed for WDG-V analyzers, the AMEVision system provides real-time moisture measurements and trend data while also detailing a variety of maintenance and troubleshooting information. Users can now continually monitor the measurement and diagnostic information for up to eight 3050 Series moisture analyzers. AMEVision enables the convenience of on-site calibration and communication with analyzers via Modbus RS485 and Ethernet LAN. The system augments or replaces the 3050 configurator software, providing all the same features and capabilities, including span verification and zero calibration. Additionally, AMEVision stores the last 10 successful calibrations and all alarms. The 3050 Series analyzer can be pre-configured at the factory to directly communicate with AMEVision, eliminating the need to set it up, which will ultimately save time in the field. Users can extract data and upload new configuration files directly to the unit via a USB port. AMETEK Process Instruments is the leader in online analytical instrumentation with the industry’s most extensive product line. The company offers analyzers based upon 11 differentiated technology platforms for use in a variety of markets including oil and gas, power, pharma manufacturing and semiconductor chip manufacturing. AMETEK Process Instruments is a unit of AMETEK, Inc., a leading global manufacturer of electronic instruments and electric motors. For details contact: AMETEK 1100 Cassatt Rd, Berywn Pennsylvania 19312 U.S.A. E-mail: greg.galiffa@ametek.com Circle Readers’ Service Card 24 or orCircle Readers’ Service Card 2600

Chemical Engineering World

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CEW Products DC Storm LPG Propane Powered Vacuum

Membrane Separation

Dustcontrol UK offers the firm’s new DC Storm LPG propane powered vacuum has a 15 KW motor with the capacity to manage dust extraction in conjunction with work involving large floor grinders, hammer drills, scarifier/shaver or cutting machines for surface preparation, as well as heavy-duty cleaning with long hoses. As with all of Dustcontrol’s mobile equipment, the Storm LPG is fitted with Hepa 13 filters and built to Application Class H as standard for a no compromise approach. The company has over 45 years of experience in developing dust extraction solutions and centralised vacuum systems to fit client requirements in the construction industry. They are experts in capturing dust at its source - both where and when it is created.

Use of membrane separation technology for water and wastewater purification has gained worldwide acceptance due to several advantages over ion exchange resin technology. Paragon has experience in supply and operation of systems utilizing membrane technology for many industrial applications. Paragon offers complete range of systems for water and wastewater treatment using membrane separation technology. It is a nonchemical treatment the use of hazardous chemicals for regeneration is not required. Output capacity of the system does not change with the change in water TDS. Plant can operate continuously without any break for regeneration.

For details contact: Dustcontrol UK Ltd 7 Beaufort Court, Roebuck Way Knowlhill Milton Keynes MK5 8HL U.K. Tel: 01327 858001, Fax: 01327 858002 E-mail: sales@dustcontrol.co.uk or Circle Readers’ Service Card 27

For details contact: Paragon Water Technologies Pvt Ltd 501-502 Vikram Tower, 4th Floor Sapna Sangita Main Road Indore, Madhya Pradesh 452 001 Tel: 0731-4082074 Telefax: 91-0731-4091508 E-mail: mail@paragonwatertech.com or Circle Readers’ Service Card 28

Fluon ETFE Powder Coating & Lining Fluon ETFE is a thermoplastic fluoropolymer, a copolymer of tetrafluoroethylene and ethylene, developed by Asahi Glass Co Ltd. Fluon ETFE is widely used in various industrial applications for its outstanding processability in addition to excellent chemical resistance and electrical properties associated with fluoropolymers generally, such as PTFE, PFA and FEP. Various anti-corrosion equipment are made by Fluon ETFE powder by various moulding methods such as electrostatic powder coating, rotolining, fluid bed, etc. Seamless coating is easily available in each process. Fluon ETFE is stable against most chemicals, including acids, alkalies and solvents, across a wide temperature and at various pressures. ETFE has the benefit of outstanding processability enabling various shapes and sizes, and thick coatings of over 1-mm to be achieved. The IL primer Series increase Fluon ETFE adhesive properties, thus increasing the potential applications of Fluon ETFE. Powder grades of ETFE are electrostatically charged then sprayed on to the substrate and subsequently baked in an oven. Powder grades of ETFE are placed inside a double-axial rotating container and subjected to a heating and cooling cycle. Standalone tanks may also be coated using an appropriate release agent. The substrate is heated and dipped into a container of fluidized powder. FM Global provides an approval standard for fume exhaust ducts (Class 4922) regarding controlling the spread of a fire. Fluon ETFE has excellent inflammability and is widely adopted as the material of choice for FM duct material. Fluon ETFE has excellent anti-stick properties and significantly reduced odour transfer index compared to other polymer materials. For details contact: Asahi Glass Co Ltd Shin-Marunouchi Bldg 1-5-1 Marunouchi Chiyoda-ku Tokyo 100-8405, Japan Tel: +81-3-3218-5875 Fax: +81-3-3281-7856 or Circle Readers’ Service Card 29

54 • February 2019

Chemical Engineering World

CEW

NATIONAL

INTERNATIONAL Chemspec India

European Coatings Show

Dates: 16-17 April 2019 Venue: Mumbai Exhibition Centre, Mumbai Event: Chemspec India aims to represent diverse sectors of

Dates: 19-21 March 2019 Venue: NurnbergMesse GmbH, Nuremberg, Germany Event: This event showcases products that include coating raw

For details contact: Chemical Weekly 602-B Godrej Coliseum Off Sion Trombay Road B/h Everard Nagar, Sion (E) Mumbai

For details contact: NurnbergMesse GmbH Messezentrum 90471 Nurnberg Nuremberg, Germany

the chemical industry such as organic and fine chemicals, active pharma ingredients, drug intermediates, dyes and pigments, agrochemicals, contract and toll manufacturing, coatings, cosmetic chemicals / ingredients, pigments and solvents, and much more.

materials, binders, solvents, pigments, fillers, additives, printing ink raw materials, adhesive raw materials, polymer dispersions, intermediates for construction chemicals, raw materials, additives and admixtures, laboratory and production equipment, testing and measuring equipment, plant and machinery, spray systems, drying and curing plant, environmental protection and safety at work, etc, in the chemicals and dyes industry.

Expo Paint &Coatings

Dates: 10-12 July 2019 Venue: Pragati Maidan, New Delhi Event: This event provides a platform to the needs of every facade of

the coating industry right from raw materials, formulation, application, technology, finishing, quality assurance, recycling and disposal. The exhibition will feature a wide range of products, raw materials, application systems, machines, tools, current trends, development and innovations shaping the future of coating industry. This expo will bring together leading local and international manufacturers, formulators, buyers, industry professionals, consultants, enthusiasts and prospective entrants from the paint and coatings, surface finishing and allied industry presenting unrivaled opportunities to network, exchange best practices, do business, unveil new products and source cutting-edge product and technologies. For details contact: Toredo Fairs India Pvt Ltd 16/1, 1st Floor, 2nd Cross Mission Rd Srinivasa Colony Bengaluru Karnataka 560 027 Pharma Tech Expo

Dates: 20-22 August 2019 Venue: Gujarat University Convention and Exhibition Centre (GUCEC), Ahmedabad

Event: PharmaTech Expo 2018 & LabTech Expo 2018 is an

International Exhibition on pharma machinery, lab, analytical, pharma formulations, nutraceutical and packaging equipment. This will give oppor tunities to suppliers, manufacturers, industrialists, entrepreneurs, buyers and consultants to assemble at this common platform. The focus will be on the Pharmaceutical Formulations, Nutraceuticals, APIâ&#x20AC;&#x2122;s, Cosmetic and Ayurveda sector. For details contact: PharmaTechnologyIndex.com Pvt Ltd 701-702 Corporate House Nr Dinesh Hall, Income Tax Ashram Rd Ahmedabad, Gujarat Chemical Engineering World

ACHEMA

Dates: 14-18 June 2021 Venue: Frankfurt Fair, Frankfurt, Germany Event: This five day event showcases products like engineering products, abrasives, chemicals and compounds, chemical machineries, equipment, manufacturing technologies, chemical engineering compounds, laboratory compounds and other similar range of products and services. For details contact: Messe Frankfurt Exhibition GmbH Ludwig-Erhard-Anlage 1 Frankfurt, Germany

International Exhibition of Chemical Industry and Science

Dates: 16-19 September 2019 Venue: Expocentre, Moscow, Russia Event: This event will display products like raw materials for the chemical and petrochemical industry, and inorganic chemistry, refining and petrochemicals, fuels, lubricants, organic synthesis, small volume chemicals, chemical fibers and yarns, composite materials, fiberglass, household chemicals, perfumes and cosmetics, reagents, catalysts, film photographic, magnetic media, design of chemical plants, warehouses, terminals, personal protective equipment, tools fire and explosion, chemical production management, transportation of chemicals and petrochemicals, logistics solutions, containers and packaging, chemical technology, research and more For details contact: Expocentre Krasnopresnenskaya nab 14 Moscow, Russia, 123100 February 2019 â&#x20AC;˘ 55

CEW

Project Update New Contracts/Expansions/Revamps

The following list is a brief insight into the latest new projects by various companies in India.

CHEMICALS Shalimar Paints lays down the foundation of its Nashik manufacturing plant with a planned monthly capacity of 2,180-kilo-litres. Set to commence operations by April 2019 with a planned production capacity of 2,180-kilolitres per month, Shalimar's state-of-the-art Nashik facility will increase the brand's overall production capacity by 65 per cent. It is also expected to stimulate the local economy by creating around 200+ employment opportunities for prospective jobseekers in the region. The newest Shalimar plant hints at the brand's aggressive push to capitalise on the growing market demand for its high-quality, high-performance paint and coating products, as well as to further consolidate its position as one of the fastest growing paints companies in the country. Shalimar has also pledged further investment into its Nashik plant and aims to establish it as a key component within its regional distribution network, as well as its pan-India supply chain. The paint industry has been growing at a rapid rate in India and measures between 1.5 to 2 times GDP growths. Rapid urbanization, better transparency and consumer evolvement has been leading the growth of the industry. Songwon Industrial Co Ltd a specialty chemicals company of South Korea has launched its new pilot plant in Panoli (Gujarat), thereby strengthening the organisation’s overall specialty chemicals development capability. Built on Songwon’s Indian site with all the necessary main unit operations, the new plant is equipped with the most up-to-date technologies and materials for producing a wide range of chemicals for a broad spectrum of applications - from one kilo up to several hundred kilo samples. To reinforce the organisation’s position in existing areas of business and enhance its ability to enter new areas, the new pilot plant will be supported by the Songwon’s strong local R&D team in Panoli, as well as its central technology innovation center located in Maeam, Korea. Insecticides (India) Ltd has announced a ` 200-crore expansion plan to increase its capacity in the next three years. In the first two years, it would spend about ` 100-crore, followed by an investment of ` 100-crore in 2020. The firm is planning to set up an Export Oriented Unit in Gujarat with an eye on increasing export component of the business. Exports contributed about ` 35-crore in the total turnover of `1,109-crore in 2017-18. The firm has a share of about 5 per cent in the ` 18,000-crore crop protection market in the country. MINING Coal India (CIL) is expected to put another 25-30 million tonnes (MT) of coal under the hammer in the ongoing quarter. This comes after e-auction volumes dipped following the decision to pump more coal into the coalstarved power sector through fuel-supply agreements (FSAs). The coal behemoth has been able to book 54-MT of coal through e-auction till December (first three quarters) as against 79-MT in the similar period of the last fiscal year, registering a 31.65 per cent dip. On the other hand, its offtake via the FSA route to power plants increased by over 12 per cent. As more coal gets routed via the FSA route, e-auction volume will be low. Production in January-March was expected to be substantial, which will leave Coal India with more to offer in auctions. It is expected that another 25-30 MT of coal will be offered this quarter on the auction platform. Coal consumers in the non-power sector have long been 56 • February 2019

complaining about scarcity because most of this fossil fuel is being routed to feed coal-starved thermal power plants. Coal India’s production, as well as offtake, was hit in December owing to industrial unrest in its key production zones in Jharkhand and Odisha and cyclones, which disrupted production and supply lines. Besides, the availability of rakes from the Railways also constrained the company from supplying coal. South Eastern Coalfields (SECL), its most important subsidiary, registered a 13.1 per cent fall in production in December at 12.52 MT while Mahanadi Coalfields, the second-largest subsidiary, registered a 3.2 per cent dip at 13.05 MT. These two subsidiaries account for more than 45 per cent of Coal India’s production. Sales were low at 52.77-MT, which is a 1.2 per cent fall compared to December 2017-18. However, in the next fiscal year, the e-auction volumes are expected to dip further. E-auctions directly add to Coal India’s bottom line because the prices are often higher by at least 60 per cent over the notified price. Thus, effectively while the miner spends the same amount of money to mine the coal which is either sold as linkage or put under the hammer, it earns 20 per cent higher in auctions. Prices in the e-auction, however, are expected to remain stagnant in the ` 2,400 a tonne level backed by muted global coal prices. According to S&P Global Platts, the price of FOB Kalimantan 4,200 kilo calorie per kilogram GAR (gross as received) — which is imported in huge volumes by both India and China — has declined almost 22 per cent since October 1, given the sagging demand in China and improving supply in Indonesia. NTPC Ltd hopes its captive coal production will reach 100 million tonne as soon as its five coal blocks commence operations, aided by faster regulatory clearances and the part-privatization model of Mine Development and Operator (MDO). The success of the plan would determine fuel security of the operations of India's largest power producer. Coal India aims to raise output from its troubled Rajmahal mine in Jharkhand to 60,000 tonnes a day by March 2019, having resolved land-acquisition related problems which had crimped production to 20,000 tonnes per day. Coal from the Rajmahal mine helps NTPC run close to 4,200-MW of power generation plants in eastern India, which supply power to Bihar, Jharkhand and West Bengal, and also to northern India including Delhi and Uttar Pradesh. NTPC’s generation capacities were faced with depleting coal stocks and lower power generation as supplies from Rajmahal dwindled. Reserves at Rajmahal within the land acquired by Coal India were almost exhausted and required expansion to keep production levels intact. However, land acquisition at two villages - Bansbiha and Taljhari - spanning 160 hectares, adjacent to the existing project turned out to be a lengthy process, as sorting out ownership issues resulted in inordinate delay. It led to drastic fall in supplies and stocks at the coalfield, as well as at two critical power plants in the region - at Farakka and Kahalgaon. At present, Coal India is using 15 goods trains to transport coal from the Rajmahal mine to power stations in the region. One goods train can load up to 3,500 tonnes of coal. Coal India is also sending five loaded goods trains from West Bengal’s Ranigunj coalfields to augment supplies at power stations. At present, the entire production from Rajmahal is getting delivered to power plants and there has been no stock buildup yet. CIL, ONGC to produce coal-bed methane from 10 new mines: support SAIL in one more. The Coal Ministry has identified 11 mines to produce

Chemical Engineering World

Project Update coal bed methane (CBM). Of these, 10 will be worked on jointly by ONGC and Coal India Ltd (CIL). The two entities will also work on one mine with SAIL. Initially, ONGC will harness the gas and then CIL will extract coal from them. In addition to the mines with CIL, the two (ONGC and CIL) will also help develop Steel Authority of India Ltd’s Parbatpur coal block (Jharkhand). Here too, ONGC will first harness the CBM. SAIL had surrendered the Sitanala and Parbatpur coal mines. In its representations while surrendering the Parbatpur mine, SAIL had said there was a reduction in the area available for coal mining due to overlapping of mining area. SAIL had engaged MECON to prepare a techno commercial viability report, which declared the project unviable. The SAIL board had then decided to return the Parbatpur mine to the Coal Ministry. JSW Energy, part of the Sajjan Jindal-led JSW Group, is believed to be in the race for buying out the thermal power assets of Monnet Power and Jindal India Thermal Power Ltd (JITPL) in Odisha. Monnet Power’s 1,050-MW coal-based power plant near Angul was in advanced stage of commissioning. Monnet Power’s parent company, Monnet Ispat & Energy had won the Mandakini coal block in Odisha in competitive bidding, it surrendered the block later on grounds of economic unviability. Monnet Power had accumulated debt in excess of ` 5,000-crore. Though lenders had earlier denied a haircut in JSW Energy’s prospective deal to acquire majority equity in Monnet Power, the Sajjan Jindal-owned firm is still believed to be in the hunt for the asset. Besides Monnet Power, JSW Energy is also eyeing takeover of BC Jindal controlled JITPL’s 1,200-MW coal-based plant at Derang near Angul. The first unit (600-MW) of the 1,200-MW plant had begun commercial operations and started power supplies to the Odisha grid. This project has been completed at a cost of ` 7,537-crore which includes a debt component of ` 5,900-crore. JITPL has power purchase agreements (PPAs) with Odisha’s Gridco Ltd, Kerala State Electricity Board and Tata Power Trading Corporation. Apart from JSW Energy, JITPL also had competing offers from Adani Power and Singapore’s SembCorp. The valuation of the prospective deal is not known. JSW Energy refused a comment on the status of its takeover plans of Monnet Power and JITPL. NLC India (formerly Neyveli Lignite Corporation) which is in the hunt for buying out power assets, is understood to have shown interest in the 700-MW Odisha plant of Hyderabad-based Ind-Barath Power Infra Ltd (IBPIL). The power plant located at Sahajbahal, near Jharsuguda, has commenced commercial operations. Though the exact size of the potential deal is not known, the valuation could be anywhere in the range of ` 5,000-5,500-crore. In August last year, NLC India had floated an Expression of Interest (EoI) from companies owning coal and lignite-based power projects, for a possible acquisition. NLC India’s installed thermal power capacity is 3,240-MW. It runs a 10-MW solar power unit and wind power assets with a capacity totalling 37.5-MW. Western Coalfields has received the environment clearance for its ` 263-crore expansion project in Nagpur district, Maharashtra. The proposal is to enhance the production capacity of the Gokul open-cast mine to 1.875-million tonnes per annum (MTPA) from the existing 1-MTPA. The mine, located in 767.17-hectare, has a mineable reserve of 14.50-million tonnes. The clearance to the project is subject to certain conditions. Total cost is estimated to be ` 263-crore. Among the conditions specified, the company has been asked to get 'Consent to Operate' certificate from the State Pollution Control Board for the existing production capacity of 1-MTPA and also the 'Consent to Establish' for the proposed capacity of 1.875-MTPA prior to enhancing the production capacity. With regard Chemical Engineering World

to transportation of coal, the company has been asked to carry out by covered trucks and take mitigative measures to control dust and other fugitive emissions all along the roads by providing sufficient numbers of water sprinklers. The company has been informed to adopt controlled blasting techniques to control ground vibration and flying rocks. It has also been told to implement a progressive afforestation plan covering an area of 376.04-hectare at the end of mining. Of the total quarry area of 231.73-hectare (on floor) and 291.21-hectare (on surface), the backfilled quarry area of 115.39-hectare should be reclaimed with plantation and there will be no void left at the end of the mining operations. The land after mining should be restored for agriculture purpose. OIL & GAS Chennai Petroleum Corpn Ltd (CPCL), Indian Oil Corpn's (IOC's) group company is planning to set up a greenfield refinery at Nagapattinam in Tamil Nadu, at a cost of ` 27,460 crore. The products, including motor spirit (MS) and high speed diesel (HSD), which will be produced from the refinery will help meet the latest BS-VI specification in the southern States. The new refinery will be part of the Govt of India's plan to set up a petroleum, chemicals and petrochemicals investment region (PCPIR) in this region. The boards of CPCL and IOC have accorded in-principle approval for the 9 million metric tonne per annum (MMTPA) refinery at CBR at an estimated investment of ` 27,460 crore, plus or minus 30 per cent.The investment includes ` 2,800 crore for setting up a polypropylene unit of around 500,000 metric tonne (TMT) per annum capacity. Detailed feasibility report (DFR) preparation is underway and is expected to be completed by April 2019. The refinery is expected to be operational by 2023-24. The products from the refinery will meet the latest BS-VI specifications. CPCL's new refinery complex will come up with the latest technology and it will include a polypropylene unit to maximise value addition from the complex. It will produce valuable products, including liquefied petroleum gas, petrol, diesel, aviation turbine fuel, polypropylene, etc, besides petrochemical feed stocks. The petrochemical complex will also feed stocks to downstream industries, including pharma, paint and lacquer, printing inks, adhesives, coatings, chemicals, automobile lubricants and PVC, among others. CPCL operates two refineries with a total capacity of 11.5 MMTPA (10.5 MMTPA at Chennai and 1 MMTPA near Nagapattinam) in Tamil Nadu. The company's crude throughput increased to 10,789 TMT in 2017-18, from 10,256 TMT in 2016-17. Its profit after tax stood at ` 913 crore in 2017-18, as compared to ` 1,030 crore in 2016-17. Reliance Industries Ltd has secured backing of the key expert appraisal committee (EAC) in the Ministry of Environment, Forest and Climate change to expand the capacity of its export-oriented refinery in the special economic zone (SEZ) at Jamnagar by 5.8 million tonnes (MT). The planned expansion will raise the installed capacity of the SEZ refinery to 41 MT from 35.2 MT and lift the overall capacity of the Jamnagar refinery complex to 74 MT. The additional terms include prior transfer of environment clearance issued on March 30, 2010 to Reliance Jamnagar Infrastructure Ltd to Reliance Industries Ltd (the entity that applied for the environment clearance). The Jamnagar refinery processed 69.8 MT of crude in FY18, exceeding its installed capacity of 68.2 MT. Higher refinery utilisation helped the company cater to growing demand for transportation fuels. Between April and December 2018, Reliance refined 52.3 MT of crude. Reliance Petroleum Ltd, a unit of Reliance Industries, built its first refinery at Jamnagar with an installed capacity of 18 MT which was later expanded to 27 MT. February 2019 • 57

CEW

Project Update The capacity of the Jamnagar refinery and petrochemical complex was further expanded by Reliance Industries to 59.7 MT during which the production was split between Reliance Petroleum (26.7 MT) as an only for exports refinery unit and Reliance Industries (33 MT) that sold most of its products in the local market. The capacity of the SEZ refinery was further expanded by Reliance Jamnagar Infrastructure Ltd to 35.2 MT from 26.7 MT. Great Eastern Energy Corpn (GEECL) and Essar Oil are upbeat about shale gas reserves in the CBM blocks of West Bengal, as GAIL looks for more buyers as it is poised to start business with city gas distribution. H Energy is looking for opportunities to supply imported gas from Malaysia to GAIL in a bid to get a price advantage over GAIL’s supplies from Dahej. While West Bengal finance and industry minister Amit Mitra hopes that the shale gas reserves in the state would attract ` 60,000 crore worth of investment in production, supplies and creating infrastructure, Y K Modi, executive chairman, GEECL, said that it has found proven reserves of 6.6 trillion cubic feet of shale gas in the CBM blocks of West Bengal, which would require ` 15,000 crore worth of investment for exploration. Mitra said Essar Oil has reported the same amount of reserves and it could change the state’s economic landscape by 2020. Modi said the Centre, through a notification in August 2018, has allowed exploration of shale gas in its CBM blocks. GEECL has drilled over 150 wells, which has CBM reserves of 2.6 trillion units. Essar for CBM has drilled around the same number of wells and is poised to increase CBM production to 2.3 million standard cubic metre per day from the present 1 mscm per day. Mitra said GAIL, which is steadily progressing with its construction of Haldia -Jagadishpur pipeline, is poised to start business in West Bengal with city gas distribution. S Bairagi, GAIL’s chief general manager-marketing, said out of its ` 15,000 crore investment for the 2,600 km Haldia-Jagadishpur pipeline, West Bengal would get an investment of ` 3,600 crore. The pipeline in Matrix Fertilizer, Durgapur, would reach by July this year, whereas the pipeline is expected to reach Haldia by December 2020. An official said GAIL, besides Matrix, has tied up with Bhusan Steel, Himadri Chemicals and other small players for sale of gas but it needs more buyers to utilise its pipeline capacity, which can carry 9 million metric cubic metres per day. For city gas distribution, the government has signed an agreement for supplies of 1.2 mmcd but GAIL was looking for a 2.5 mmcd market. However, GAIL’s present focus is to build infrastructure for gas distribution for which they have formed a JV with State-run Greater Calcutta Energy Supply Corpn and incorporated the JV on January 4, Mitra said. He said the zero date for starting construction work of the 448-km pipeline in and around Kolkata is April this year, and GAIL is committed to supply to 14 lakh consumers, including the transport sector by 2020. This would entail an investment of ` 5,000-6,000 crore. The economic life of the project is for twenty years. Bairagi said the company was creating a pipeline network in Kolkata, Howrah, Hooghly, North and South 24 Paraganas and Nadia districts with compressor pressure of 14,62,101 kg per day. For the city gas distribution, GAIL – apart from sourcing gas from Dahej – is looking at other sources. H Energy was building an LNG terminal at Kukrahati near Haldia on 47 acres, from where it was building a pipeline up to Khulna in Bangladesh. This would entail an investment of ` 1,500 crore for the terminal and another ` 2,200 crore for the pipeline, said Darshan Hiranandani, MD and CEO. He said the company would import LNG from Petronas Malaysia and is committed to supply 2 million tonne to Bangladesh and keep 1 million tonne to market domestically. GAIL 58 • February 2019

may be a potential buyer for the city gas distribution, Hiranandani said. Indian Oil Corpn, with the final clearance from the National Green Tribunal (NGT), is all set to re-start construction activities at its ` 2,200-crore LPG import terminal-cum-pipeline project at Puthuvypeen near Kochi. Necessary orders in this regard have been issued by the Kerala government and the work is expected to commence in January. The NGT judgment has made it amply clear that there is no environmental pollution in the Puthuvypeen project. IOCL has adopted global standards on safety measures and one-third of the cost is being spent on safety. The risk analysis study conducted by Projects & Development India Ltd has estimated the risk factor in a million chances per year. The Kochi terminal, with the pipelines connecting the bottling plant, will eliminate the movement of bulk LPG by road, citing the removal of LPG tanker lorry movement from Mangaluru to Tamil Nadu after the commissioning of Ennore terminal. The Kochi project consists of an import terminal, multi-user liquid terminal (MULT) jetty, Kochi-Salem pipeline and the bulk LPG terminal at Palakkad with a total investment of ` 2,200-crore. Of this, the ` 225-crore jetty is ready and the company has invested another ` 160-crore for construction activities. The physical progress of the work is only 40 per cent complete, which includes ground improvement, land development, etc. Kerala presently has an average waiting period of 15 days to receive a LPG refill. This could go up if the infrastructure expansion does not happen. Referring to LPG consumption in the State, it was 8.4 lakh tonnes in 2016-17, which would touch 13.2 lakh tonnes by 2022 and 22.7 lakh tonnes by 2028. India imports 50 per cent of its LPG requirements. With the boom in LPG requirement, imports are expected to go up. To meet the huge growth in volumes, infrastructure must be improved. LPG is imported through the major ports on the coast and there are 13 import terminals. Kochi is next on the list. The design of the terminal has been approved by regulatory agencies, which will inspect during the construction stage and prior to commissioning. CPC Corp of Taiwan is planning to invest $6.6 bn in petrochemical project in Paradip, Odisha. In this regard, delegation led by CPC president Shun-Chin Lee met the Indian Minister for Petroleum & Natural Gas to discuss the proposal. With an annual production capacity of 15 million tonnes, the Indian Oil Corpn’s (IOC), Paradip Refinery was selected to host the new project, which will utilise the refinery’s feedstock. It will have many downstream units for the production of a wide range of end-products and petrochemical intermediates. Indian Oil Corpn (IOC) plans to invest ` 20,000-crore in city gas distribution (CGD) projects in the next five to eight years. IOC, which owns a third of India’s oil refining capacity identifies compressed natural gas (CNG) replacing some of the petrol and diesel consumed in vehicles today and LPG replaced by piped cooking gas in households. The company plans to invest at least ` 20,000-crore for the CGD business in those projects won during the ninth round of bids. The investment will mainly include setting up of CNG dispensing stations as well as laying pipelines in cities to transport gas to households for cooking purposes and industries for commercial use. According to oil ministry figures, India needs to invest an estimated $100 billion in natural gas infrastructure by 2022, including setting up a gas grid across 228 cities, Chemical Engineering World

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

The End of Project Overruns Authors: Robert M Patty and Michael A Denton Price: $140.93 No of pages: 498 pages (Paperback) Publisher: Universal Publishers About the book: Applying the principles in this book unleashes ingenuity that achieves, solidifies and perpetuates a new performance culture of mutual benefit. In this culture, project teams will prepare their work in task packages and enable workflow necessary to leave inefficiency of time and resource, literally, no place to hide. Project examples will help teams implement the principles that shorten cycle times, eliminate error, improve quality and reduce costs to succeed in meeting project commitments. Emerging Lean enterprise relationships between clients, EPC contractors and their entire supply chain will advance what constitutes the new, marketdifferentiating performance of individuals, project teams and companies - justifying high levels of trust and inter-organizational efforts to improve. Client executives will learn to recognize root causes of risk and sources of excellence to mitigate them. Well-developed strategic improvement is often constrained because the traditional way - current means and methods - fit squarely in everyone’s comfort zone. By learning to ask the right questions, top-client leadership will soon render overruns from the best traditional systems as not-good enough and strive for a new level of excellence. EPC executives will better engage creative voices from their best resources and stakeholders to resolve all concerns and define a unified vision for how to deliver on clients’ expectations without overruns during capital project delivery. Lean methods will effectively assure that vision; principles and best expectations are understood and implemented at the workface. Department, discipline and stakeholder leaders will align and no longer frustrate each other and their clients. They will plan and execute with increased efficiency and effectiveness. Cost reduction will accelerate, retaining only client-valued quality - enabling a nimble response to market opportunities and threats. Project and program managers will confidently accept intense, market-induced cost and schedule-reduction efforts. They will apply new metrics, measure potential and extract, align and pilot improvements. They will make workface progress transparent to simplify resource balancing, full utilization and workface flow during all project phases. The results will differentiate team members and their project’s performance on the world stage. Project professionals and the skilled labour force will gain confidence to make and keep increasingly difficult commitments and experience thereby increasing opportunity in an organization known for excellence. They will fully engage heart and mind for leaders who expect excellence and they trust to enable and reward best practice performance while they jointly eliminate root causes of problems before they happen. This book guides readers through each essential role for the transformation to Lean...not just at the lowest levels but of the entire business model and all the supporting processes. Resulting market recognition of sustained excellence of people, their systems and the way they work together will create a market-leading force. Chemical Engineering World

Fundamentals of Petroleum and Petrochemical Engineering (Chemical Industries) Author: Uttam Ray Chaudhuri Price: $159.54 No of pages: 411 pages (Hardcover) Publisher: CRC Press (1st Edition) About the book: The supply of petroleum continues to dwindle at an alarming rate, yet it is the source of a range of products - from gasoline and diesel to plastic, rubber and synthetic fiber. Critical to the future of this commodity is that we learn to use it more judiciously and efficiently. Fundamentals of Petroleum and Petrochemical Engineering provides a holistic understanding of petroleum and petrochemical products manufacturing, presented in a step-by-step sequence of the entire supply chain. Due to the advancement of technology, new petrochemicals are being invented and will continue to be relevant to the petroleum industry in the near future. Those entering the industry need a firm grasp of the basics as the field continues to open up new avenues of possibility, while at the same time being cognizant of the challenges that exist through the heightened focus on sustainable energy.

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

February 2019 • 59

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Chemical Engineering World

RNI No. MHENG/2003/13269. Date of Publication: 1st of every alternate month.

R.N.I. No. 11403/1966 Date of Publication: 29th of every month. Postal Registration No: MCS/095/2018-20 Posted at Patrika Channel Sorting Office, Mumbai 400001, on 30th of every month. Total Pages No.:62

Process Industry’s Gateway to Indian Market

ChemTECH

SPECIALTY

WORLD EXPO

International Exhibition and Conference

MUMBAI

HYDERABAD

24-27, February 2021

4-6, December 2019

Venue: Bombay Exhibition Center, Goregaon (East), Mumbai, India.

Venue: HITEX Exhibition Center, Trade Fair Office Building, Izzat Nagar, Kondapur PO, Hyderabad, India

CONCURRENT EVENTS

Engineering Procurement Construction

Reﬁning &

CHEMICALS

Bio Pharma World Expo

Industry

AUTOMATION

& Control

Pumps, Valves & Fittings

WORLD EXPO

WaterEX

WORLD EXPO

Develop Future Leaders

www.chemtech-online.com Supported by

Organised by:

Jasubhai Media Pvt Ltd rd

Taj Building, 3 Floor, 210, Dr. D N Road, Fort, Mumbai – 400 001, INDIA. Tel: +91-22-4037 3636, Fax: +91-22-4037 3635, Email: sales@jasubhai.com