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Contents CHEMICAL ENGINEERING WORLD RNI REGISTRATION NO. 11403/66 Chairman Publisher & Printer Chief Executive Officer
EDITORIAL
Editor Editorial Advisory Board Contributing Editors
Maulik Jasubhai Shah Maulik Jasubhai Shah Hemant Shetty
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Mittravinda Ranjan (mittra_ranjan@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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4 • February 2017
NEWS Industry News
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Technology News
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NEWS FEATURES “Outlining the Path from Building Digital Engineering Models to Asset Performance Modelling”
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Light-Driven Reaction Converts Carbon-Dioxide Into Fuel
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Specialty Chemicals in India -- Preet Singh, Executive Director – Industrials, Avendus Capital
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Industrial Sampling Systems - Pranali Kambli, Deputy Chief Engineer, Aker Solutions India
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Minimal Liquid Discharge: Adopting A ‘Less Is More’ Mindset - Fei Wu, Regional Marketing Manager- RO/NF, Dow Water & Process Solutions
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Amit Bhalerao (amit_bhalerao@jasubhai.com) Prashant Koshti (prashant_koshti@jasubhai.com)
MARKETING TEAM & OFFICES Mumbai
VOL. 52 | ISSUE NO. 02 | FEBRUARY 2017 | MUMBAI | ` 150
FEATURES
MARKETING INITIATIVE Right Lubrication Enables High Reliability: Essential for all Vacuum Pumps We Don’t just offer Blowers, Boosters and Vacuum Systems- We offer Solutions!!!
PRODUCTS EVENTS PROJECT UPDATE BOOK SHELF AD INDEX INTERVIEW
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56 64 65 66 67
“Consumer-Focused R&D is the Future” - Dr. Sudhakar Mhaskar, Chief Technology Officer, Marico Limited
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Disclaimer: The Editorial/Content team at Jasubhai Media Pvt Ltd has not contributed to writing or editing “Marketing Initiative.” Readers would do well to treat it as an advertisement.
Printed and published by Mr Maulik Jasubhai Shah on behalf of Jasubhai Media Private Limited, 26, Maker Chamber VI, Nariman Point, Mumbai 400 021 and printed at 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, 26, Maker Chamber VI, Nariman Point, Mumbai 400 021.
Chemical Engineering World
CEW Press Release IL&FS Engineering Services Wins ` 123.05 Cr Pipeline Laying Contracts from GAIL Hyderabad, India: : IL&FS Engineering and Construction Company Limited has announced that it has received Fax of Acceptance (FOA) from Gas Authority of India Limited (GAIL) for two pipeline laying contracts worth Rs. 123.05 Crores (plus Service Tax) in Kerala / Karnataka. Both the spreads are contiguous and are part of Kochi-Koottanad-Mangalore pipeline project. The details of the contracts are: • Spread IV A (24” x 70.32 Km.) : Laying and Construction of Pipeline along with Associated Works of Section IV A [(24”x70.32 Km.) Pipeline from SV 13M (At Approx. Chainage 242.175 Km.) to Approx. Chainage 312.495 Km. on 24” Ø Mangalore Spurline Including Piping and Associated Works at SV-14M, SV-15M, IP-3M, and SV-16M of Kochi to Mangalore Pipeline Project Phase - II in Kerala. The total value of this contract is Rs. 83.76 Crores (plus Service Tax), and is to be mechanically completed in 11 months from date of FOA and with additional 1 month for commissioning and GAS-IN.
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Spread IV B (24” x 34.83 Km.) : Laying and Construction of Pipeline along with Associated Works of Section IV B [(24”x34.83 Km.) Pipeline from Chainage 312.495 Km. (Approx.) to Receiving Terminal at MCF Mangalore (At Approx. Chainage 347.328 Km.) on 24 Ø Mangalore Spurline Including Piping and Associated Works at SV-17M, SV-18M, and Receiving Terminal at MCF Mangalore of Kochi to Mangalore Pipeline Project Phase - II in Karnataka. The total value of this contract is Rs. 39.29 Crores (plus Service Tax), and is to be mechanically completed in 11 months from date of FOA and with additional 1 month for commissioning and GAS-IN.
Kirloskar Brothers Limited to Demonstrate its Innovative Solutions for the Chemical Industry at CHEMTECH 2017 Mumbai, India: Kirloskar Brothers Limited (KBL) has announced that it showcased its range of product offerings for the chemical industry at this year’s CHEMTECH World Expo. Pumps play a very critical role in the chemical industry. The quality and reliability of a pump is of utmost importance for handling various types of hazardous liquids in the chemical industry. KBL is among the leading pump manufacturers in the country. The supreme standards maintained by the company during manufacture of pumps, especially for the chemical industry, considering the extreme nature of chemicals and liquids that these pumps are exposed to, make it one of the most trusted brand-names in the industry. KBL’s range of products on display at the CHEMTECH event included: 6 • February 2017
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ROMAK (RMK) pump: A magnetic drive pump with a size ranging between 32mm to 100mm. The pump has a discharge capacity of up to 300 m3/hr and can handle temperatures from -50°C up to +180°C. I-Can pumps: These pumps are capable of handling toxic, explosive, expensive, hazardous, cryogenic and corrosive fluids. The i-Can series pumps are designed in such a way that they reduce the maintenance time and total cost of ownership for small scale industries. ES: These are horizontal single-stage end-suction pumps used majorly for handling viscous and fibrous fluids in the paper, pulp and starch industry Air-cooled Thermic Fluid (AT) pump: Used in various process industries for handling thermic fluids up to 350°C KPD pumps: These pumps are developed for process applications and generally conform to API 610. These are ideal for air conditioning, condensate extraction, distilleries, edible oil, sugar and textile industries.
FARO Names Katrona Tyrrell as Chief People Officer Lake Mary, Florida: FARO® has announced the appointment of Katrona Tyrrell as Chief People Officer (CPO). She will report directly to Simon Raab, Ph.D., FARO’s President and CEO. Ms. Tyrrell will advise the senior leadership team as it works to scale FARO’s vertical sales organization while maintaining and strengthening FARO’s entrepreneurial culture, employee engagement, and career development. As CPO, she will guide all aspects of human resources for the company, including Human Resources business partnering, talent management and Human Resources Information Systems. “Our culture is a fundamental component to what makes our company special and high-performing,” said Simon Raab, Ph.D., FARO’s President and CEO. “We created the CPO role specifically to bolster this impor tant foundation. Strength in this area of our business allows us to succeed in everything else we do and is essential to propel our growth. Katrona’s extensive background and experience building, maintaining and leading talent and corporate culture strategies will complement the founder-CEO mentality we have returned to the company. I’m excited for her par tnership, perspective, and the contributions she’ll make.” Ms. Tyrrell joins FARO from IDT Corporation where she was the Global Senior Vice President – Human Resources, leading a team that was responsible for global succession planning, leadership development, performance management, employee engagement, and organizational effectiveness. Prior to joining IDT in 2006, Ms. Tyrrell held leadership and management positions at Towergate Partnership, Ltd. and Roberts & Partners Managed Services in the U.K. Ms. Tyrrell holds a post-graduate diploma in strategic management from Crawley College in the U.K. Chemical Engineering World
CEW Press Release Kirloskar Brothers Limited to Participate in KNIT TECH 2017 Pune, India: Kirloskar Brothers Limited (KBL) has announced that it participated in KNIT Tech 2017, held from 10th to 13th February 2017 at Tirupur Exhibition Centre, Tirupur. KBL is primarily participating in the event with an aim to showcase its technological prowess in the textile industry. At the event, KBL will be showcasing some of its premium products that find a wide range of applications in the knitting industry, such as the Hydro-Pneumatic (HYPN) system and Air-cooled Thermic Fluid (AT) pump. The pressure boosting HYPN is a conventional pumping system converted into an automated pumping system, which ensures energy and cost savings. AT pump is used for handling thermic fluids in various process industries. The pump can handle fluids up to 350°C. The 14th edition of KNIT Tech will be primarily focusing on the growth opportunities and possibilities arising from the latest technological developments taking place in the knitting industry. The event is spread across 15,000 sq. mt area and will host business visitors from domestic and international markets like – Sri Lanka, Bangladesh, Malaysia and Singapore, among others.
Chemtura Shareholders Approve Acquisition by LANXESS Cologne, Germany - Specialty Chemicals Company LANXESS has announced that it has taken a significant step forward in the planned acquisition of U.S. chemical company Chemtura. Chemtura’s shareholders approved the merger at a special meeting in Philadelphia, United States. 99.88 per cent of the votes cast were in favour of the merger, representing 81.77 per cent of Chemtura’s outstanding common stock. Under the terms of the merger agreement, Chemtura shareholders will receive USD 33.50 for each outstanding share in cash at closing of the transaction. Matthias Zachert, Chairman of the Board of Management of LANXESS AG, welcomed the vote approving the merger taken at the shareholders’ meeting. “We are pleased that Chemtura’s shareholders are so supportive of the planned acquisition. Their approval is an important milestone on LANXESS’s route to becoming one of the major players in the field of additives chemistry.” Clearance for the acquisition from the U.S. antitrust authorities was already received at the end of December 2016. LANXESS expects to close the transaction in mid-2017 after all remaining regulatory approvals have been received. Flame retardant and lubricant additives are the main pillars of Chemtura’s business and would complement the current LANXESS portfolio. After closing of the transaction, these two business activities are to be integrated with LANXESS’s Rhein Chemie Additives business unit to form a new segment. Today, Rhein Chemie Additives already supplies a broad range of special additives and service products for the manufacture of plastics, rubber, lubricants and coatings. It employs some 1,600 people at more than 20 sites around the world. 8 • February 2017
Alongside the additives, Chemtura’s portfolio also includes urethanes and organometallics, which will be integrated into LANXESS as well. Chemtura has about 2,500 employees globally and operates at 20 sites in 11 countries.
Covestro Raises Prices for Coating and Adhesive Raw Materials Mumbai, India: Effective March 1st, 2017, Covestro has announced that it will raise the selling prices for its standard aliphatic isocyanates by 15 per cent. Prices for other coating and adhesive raw materials will be increased at the same time; the magnitude varies by product line. The price increase will be applied globally. Contractual obligations will be honoured. With 2015 sales of EUR 12.1 billion, Covestro is among the world’s largest polymer companies. Business activities are focused on the manufacture of high-tech polymer materials and the development of innovative solutions for products used in many areas of daily life. The main segments served are the automotive, electrical and electronics, construction and the sports and leisure industries. Covestro, formerly Bayer MaterialScience, has 30 production sites around the globe and as of the end of 2015 employed approximately 15,800 people (fulltime equivalents).
HRS showcases Innovative Heat Exchangers & Systems at Chemtech 2017 Mumbai, India: HRS Process Systems Ltd has announced that it had participated in Chemtech World Expo 2017. The event was held from 14th to 17th Feb 2017 at Bombay Exhibition Centre, Goregaon, Mumbai and recognized as 2nd largest global event for the chemical processing industry. At this event, HRS displayed ECOFLUX* Corrugated Tube Heat Exchangers, HRS Funke Plate Heat Exchangers and Heat Exchanger based Systems - the innovative range of products most beneficial for efficient heat transfer applications in process industries. Process industries like chemicals, petrochemicals, speciality chemicals, agro-chem, pharmaceuticals, fertilizers, chloro-alkali, paints, and other allied sectors are on an upward curve and advanced processing technology will play a significant role towards this growth. Speaking about HRS’ participation at the event, Mr. V. Gokuldas, Managing Director, HRS Process Systems Limited said, “Energy efficient and cost effective thermal technology is the key requirement for process industry. HRS continues to enable this requirement with research and development in a varied range of applications across process industry. Our expertise to provide optimal designs, custom-made heat exchangers and systems, with stainless steel and exotic materials such as SMO, titanium, tantalum, inconel, hastelloy, duplex and similar, have helped our customers leverage on ECOFLUX* advantage to maximise return on investment. Chemtech has enabled us to further network with our customers and the entire value chain of the chemical process industry.” Chemical Engineering World
CEW Industry News Deepak Fertilisers Commences Production of NPK Fertilisers at New Taloja Plant
Germany's BASF ventures into Indian Crop Protection Market for Rice
Pune, India: Deepak Fertilisers & Petrochemicals Corporation Ltd has announced that it has initiated commercial production of NPK fertilisers, under its flagship brand Mahadhan, at its new plant in Taloja (Maharashtra). NPK fertilisers are predominantly composed of three main elements - nitrogen, phosphorus and potassium, each of these being crucial in plant nutrition.
Mumbai, India: BASF has announced that it has entered the Indian crop protection market for rice with the launch of a range of new solutions to enhance rice yields by managing diseases, weeds and pests. Rice farmers in India will be able to increase productivity and income with the help of BASF crop protection solutions for rice, now accessible in the country for the first time, claimed the company.
The new facility, installed with the latest Incro technology and built with an investment of ` 800 crores, has a provision of manufacturing multiple grades of fertilisers. This is the only fertiliser plant in India that has one-of-its kind fully automated bagging facility. The new facility is set to enhance the company's production capacity by almost four times from the existing 3 lakh tonne to 11 lakh tonne in a phased manner.
“Our goal is to support India’s rice growers to comprehend their full potential. We will dedicate BASF’s expertise in modern, sustainable farming to the needs of the Indian rice growing community,” said Markus Heldt, President of BASF’s crop protection division. BASF is a global leader in crop protection, with global sales of more than € 5.8 billion in 2015.
Maharashtra is the horticulture capital of the country with strong focus on grapes, pomegranate, banana, oranges, other fruits and vegetable crops which are responsive to NPK fertilisers. “Further, around 13 lakh MT of imported non-urea NPK fertilisers were consumed last year, providing a ready market for domestic NPK fertilisers and the capacity addition is an exceptional example of Make in India,” said the company.
Rice is India’s most imperative food crop, with more than 100 million metric tonnes produced per year. Additionally, India is a significant exporter of rice to the global market, exporting over 10 million metric tonnes per year with remarkable prospects to further increase output. “With our new offerings for rice in India, we are strengthening our contribution to meeting the mounting demand for farming technologies in India,” Heldt supposed.
W i t h t h e a u g m e n t e d c a p a c i t y, D F P C L w i l l b e t h e m a j o r manufacturer of NPK fertilisers in Maharashtra. In addition to its core markets of Maharashtra, Karnataka and Gujarat, the company will also gratify to new geographies in Southern and Northern agrarian markets of the country.
With this launch, BASF provides inclusive solutions that effectually manage major rice diseases, weeds, and pests, while meeting consumers’ expectations for healthy, high quality food. These comprise the fungicides Seltima and Adexar, which combat a number of persistent rice diseases, containing sheath blight and blast. Seltima is a BASF AgCelence fungicide, which not only controls diseases but also provides higher yields.
DFPCL offers a basket of over 48 traded products, which comprise bulk fertilisers, specialty fertilisers, water soluble fertilisers, micro nutrients and secondary nutrients. From the existing 4 million farmers, the company will now be able to provide crop nutrition solutions to over 7 million farmers.
BASF’s herbicide Basagran will also be launched in India, resolving difficult weed problems confronting Indian farmers. In the next three years, additional products will be launched in India to meet the growing need for modern farming solutions, comprising herbicides, fungicides and insecticides.
Asian Paints Procures Sri Lankan Firm Causeway Paints Mumbai, India: Asian Paints Ltd, through its Singapore-based indirect subsidiary Berger International Pvt Ltd (BIPL), has announced that it has acquired Causeway Paints Lanka Pvt Ltd, the Sri Lankan paints manufacturing company. “Berger International Private Limited, Singapore, indirect subsidiary of the company, has entered into a share purchase agreement with the present shareholders of Causeway Paints Lanka Pvt Ltd (CPLPL), Sri Lanka, for procurement of 100 per cent stake in CPLPL in an all cash deal,” said Asian Paints Ltd. The acquisition will improve the group's presence in the Sri Lankan market where the company at present operates through its subsidiary, Asian Paints (Lanka) Limited. Though Asian Paints did not divulged the deal size, it said, CPLPL reported revenue of Sri Lankan Rupee 5,630 million (approximately ` 253.60 crore) in the preceding fiscal. 10 • February 2017
BASF employs a committed team of nearly 200 crop protection experts in India to safeguard a direct market presence, and is one of India’s leading providers of advanced crop protection solutions, covering all major crops, including soybeans, corn, cotton, wheat, fruits, vegetables and now rice. The company is constantly looking for new active ingredients that can control crop pests in distinctive ways. “With initiatives like Make in India, Smart Cities, and Swachh Bharat, India today is all about rapid, sustainable development. That means massive growth in the demands of the population for better food, housing, and mobility as well as clean food, water and air. This provides enormous opportunities for the chemical industry as well as BASF. And, BASF is capitalizing dynamically in India to comprehend these opportunities,” supposed Dr Raman Ramachandran, Chairman of BASF Companies in India. The BASF group has invested approximately € 300 million in India over the past four years, in both manufacturing and innovation, in supporting local industries comprising scientific agriculture and food manufacturing, in sustainable transportation, pollution and emissions control, and in energy-efficient buildings and infrastructure. Chemical Engineering World
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CEW Industry News Finolex Industries to Make Lubrizol's FlowGuard CPVC Pipes in India Pune, India: The US-based Lubrizol Corporation has announced that it has joined hands with Finolex Industries Limited for the manufacturing & sale of Finolex FlowGuard Plus pipes and fittings in India. The product will be launched in the market by Finolex Industries Limited in March 2017 and will gratify to the building and construction industry. “Lubrizol is committed to supplying the highest quality CPVC compounds to service the Indian hot & cold water plumbing markets. Our partnership with Finolex Industries highlights the need and importance of quality CPVC pipes and fittings made from timetested CPVC compounds provided by Lubrizol. Since January 2016, we have been manufacturing these global quality materials from a state-of-the art plant in Dahej, Gujarat. Our association with Finolex will further reinforce FlowGuard’s commitment to delivering reliability in India through Finolex’s wide spread network in the country,” expounded Matthew Timmons, Managing Director, Lubrizol Advanced Materials India Pvt Ltd. Lubrizol Cor poration presented the robust CPVC material into India nearly two decades ago. In January 2016, Lubrizol opened its CPVC compounding plant in Dahej, which involved an investment of about ` 325 crores. “Since we presented FlowGuard to the Indian market, we remained committed through our support of processors who continue to benefit from our more than 50 years of expertise in manufacturing and compounding. Furthermore, with the government’s recent focus on housing for all, the infrastructure status given to real estate, loans offered at cheaper rates, introduction of the Real Estate Regulatory Act (RERA), GST & many other initiatives, the need for quality products to be used in the country is greater than ever,” supposed Timmons. Prakash Chhabria, Executive Chairman of Finolex Industries Limited, further, “We are dedicated to strengthening the plumbing industry through our association with Lubrizol falls in line with the culture of Finolex Industries in providing quality products ‘Made in India’ for the Indian market. We are assertive about Lubrizol’s global expertise in compounding and appreciate the work done by them in shifting the plumbing industry from metal-based to CPVC–based piping. With FlowGuard’s raw material and support, our track record of providing superior products for Indian market gets reinforced. We look forward to a positive partnership.”
Budget Proposes ` 10k Crore to Clear Fertiliser Subsidy Dues: Ananth Kumar New Delhi, India: To moderate the burden of fertiliser subsidy backlogs, a special banking arrangement of ` 10000 crores has been sanctioned in this budget to clear fertiliser subsidy dues, said Ananth Kumar, Minister of Chemicals and Fertilizers. He added that the overall budget allocation for the Department of Fertilizer for the year 2017-18 is ` 74,235 crores. Stating that fertiliser has been one of the fastest growing sectors in the last quarter, the Minister said, “Fertilisers, along with power, has been the torchbearer of accomplishment of this government.” 12 • February 2017
According to Ananth Kumar, the government has taken crucial measures to make the country self-sufficient in urea and other fertilisers like encouraging energy efficiency in urea production, exploiting indigenous urea production, well-timed import of urea and other fertilisers, prepositioning of fertilisers with the states during lean season to safeguard adequate supply in the season and streamlining the subsidy. Such steps have resulted in highest ever production of 245 lakh metric tonne (LMT) of urea previous year, without adding additional capacity. Indigenous urea as well as imported urea has been neem coated. This has resulted in an increase in farm yield with less urea required and helped check black marketing and hoarding of urea. The Union Cabinet has already given its nod for recovery the three fertiliser units – Gorakhpur & Sindri units of FCIL (Fertilizer Corporation Of India Ltd) and Baruni unit of HFCL (Hindustan Fertilizer Corporation Ltd). Cabinet has also given its endorsement for setting up of new ammonia urea complex at Namrup within prevailing locations of Brahmaputra Valley Fertilizers Corporation Limited. Further, the Talcher plant will be the first ever unit to be revived based on the coal gasification technology, Ananth Kumar added. Keeping in pace with the international market, the Department has engaged fertilisers companies to reduce the prices of DAP, MOP and complex fertilisers by ` 125, 250 & 50 respectively per 50 gm bag from June, 2016. Prices of DAP has again been reduced by ` 65 per 50 gm during December, 2016. Informing about the implementation of policy of promotion of city compost, Ananth Kumar said that the Government of India approved policy on promotion of city compost in which Marketing Development Assistance (MDA) of ` 1500 per MT has been provided for scaling of production and consumption of city compost. A budget provision of ` 15 crores has been made for releasing the MDA during 2017-18 on sale of city compost. In the pharmaceutical sector, Ananth Kumar informed that under the Pradhan Mantri Bhartiya Janaushadhi Pariyojana (PMBJP) over 760 Jan Aushadhi Kendras are functioning across the country. With the government’s target to achieve 3000 JAKs, every tehsil would have one JAK soon. Currently over 450 medicines and 150 health supplements are available at around one-third the price of branded drugs at the JAKs. Further, the Minister that medical devices parks are coming up at four locations including Vishakhapatnam, Baddi (Himachal Pradesh) and others in Gujarat and Telangana. Ananth Kumar also informed about the coming up of National Institutes of Pharmaceutical Education and Research (NIPER), the latest been set up at Jhalawar, Rajasthan. These institutes would lead to path breaking research in pharma sector and give a boost to creating a strong force of pharma scientists in the country. Talking about achievements in chemicals & petrochemicals sector, Kumar informed about the focus of the government on establishing Central Institute of Plastics Engineering & Technology (CIPET) and Petroleum, Chemicals and Petrochemicals Investment Regions (PCPIRs) and plastic parks to give a boost to the Make in India mission. This step would lead to the generation of over 39 lakh employments prospects in times to come, he added. Chemical Engineering World
CEW Industry News GMR Inks MoUs for Manufacturing Units to come up at Kakinada SEZ Kakinada SEZ Ltd (KSEZ), a subsidiary of GMR Infrastructure Limited (GIL), has signed a series of MoUs with firms interested in setting up manufacturing units at the Kakinada SEZ. MoUs were signed during the CII Partnership Summit 2017 held on January 27-28, 2017 at Visakhapatnam, Andhra Pradesh. GMR Group is developing an industrial zone, Kakinada SEZ, spread over 8500 acres and an all-weather, multi-cargo, deep water port, with an estimated phase 1 capacity of 16 million tonnes. One MoU was signed by Gail, HPCL and Government of Andhra Pradesh for setting up of a cracker unit, which will involve investment of ` 40,000 crores. The cracker will come up in 2000 acres at Kakinada SEZ. Besides, MoUs were signed by KSEZ with 5 companies which include Oil Country Tubular, Kamineni Steel & Power, United Seamless Tubular, Deepak Phenolics and DCM Shriram for setting up manufacturing facilities with a total investment of ` 7,000 crore spread over 550 acres at Kakinada SEZ Ltd. These MoUs would be followed up with technical and commercial discussions for lease of land in Kakinada SEZ to the above mentioned firms over the following months. G M Rao, group chairman, GMR group, said, “GMR Group is proud to be partnering with the state of Andhra Pradesh in the development of a port based investment region near Kakinada in the East Godavari District. We strongly support Prime Minister Narendra Modi’s Make in India campaign, and Chief Minister N Chandrababu Naidu’s endeavours to cement the place of sunrise state of AP as the most attractive destination for global investments into India. GMR group’s Kakinada SEZ is all set to transform the industrial landscape of the Godavari Districts bringing in significant investments and employment.” Kakinada SEZ, which is centred in the Kakinada node of the Visakhapatnam-Chennai Industrial Corridor being developed by Asian Development Bank, would house various industries including petrochemicals, food & agro processing, discrete manufacturing, electronics, toys, sports goods & apparel etc. offering a combination of export oriented SEZs and domestic market oriented DTAs. The SEZ is already operational and has units which employ nearly 1000 people from the neighbouring villages, predominantly women. Several domestic and global business groups have shown interest in considering GMR’s Kakinada Special Investment Region (SIR) as their launch platform in Andhra Pradesh.
S u p r e m e Pe t r o c h e m C o m m i s s i o n s S w i n g Production Line at Nagothane Plant Mumbai, India: Supreme Petrochem Ltd has announced that it has commissioned a swing production line at its Wangani (Nagothane, Maharashtra) plant that is adept to manufacture styrene methyl methacrylate (SMMA) or polystyrene (PS). As result of this alteration, which was carried out in one of the three PS lines at the Wangani plant, the company will be able to produce 42,500 tonnes per annum of SMMA. 16 • February 2017
“The test runs for producing styrene methyl methacrylate by altering one of the polystyrene lines at the plant in Maharashtra into a swing line capable of producing either PS or SMMA have been concluded. This modified line with a SMMA capacity of 42500 TPA is now equipped for commercial production,” said Supreme Petrochem. Polysty Inc, USA, provided the technology for the modification, which involved investment of about ` 6 crore, of the PS line and production of SMMA. Styrene methyl methacrylate is commonly used for optical sheets and other applications such as homeware, office accessories, toys and medical devices.
HPCL & GAIL Inks MoU for ` 40,000 Crores Petrochemicals Complex in Andhra Pradesh Andhra Pradesh, India: Hindustan Petroleum Cor poration Ltd (HPCL), Gail India Limited and Government of Andhra Pradesh have announced that it has signed a memorandum of understanding for setting up a Greenfield, standalone petrochemical complex in Andhra Pradesh. The proposed complex, which will come in 2000 acres of GMR’s Kakinada SEZ, is expected to comprise investment of ` 40,000 crores. Kakinada is often referred to as the ‘Houston of India’ owing to the presence of hydrocarbon reserves and the oil & gas infrastructure. Conceding the advantage of Kakinada SEZ, which is the largest industrial area with port connectivity in this region, Indian Oil & Gas PSU majors will cooperatively build the new 1.5-million tonnes ethylene derivatives plant. The plant will produce an extensive range of petrochemical raw materials, which are used in the production of plastics, detergents, paints & coatings, cosmetics, textiles, adhesives, etc.
Asian Paints to Invest ` 650 Crores for Capacity Expansion at Ankleshwar Site Gujarat, India: Asian Paints Ltd has announced that it will capitalize Rs 650 crores to expand production of paints, synthetic resins and emulsion at its Ankleshwar (Gujarat) facility. In August 2016, the company had announced a proposal to modify its product mix at the manufacturing facilities at Ankleshwar by expanding the capacity of synthetic resins and emulsions by nearly 35000 MT. As per the new plan, the company will increase the prevailing manufacturing capacity of paints from 130,000 kilo litre (KL) to 300,000 KL per annum and of synthetic resins & emulsions from present 32,000 MT to 85,000 MT. “It would involve an estimated investment of `. 650 crores which would be met through internal accruals,” said Asian Paints. The company expects to complete the expansion project over the next 3 to 4 years. As part of this expansion plan, Asian Paints will phase out the production of phthalic anhydride and its associated products from this facility. Chemical Engineering World
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CEW Industry News Japan's Seiken Chemical Collaborates with Anand Group for Coolants Mumbai, India: Seiken Chemical Industry Company Limited has announced that it has joined hands with Ansysco Anand to gratify to the Indian automotive sector. Two companies have entered into a technical assistance agreement (TAA). “Anand Group is a reputable leader in the Indian automotive sector with substantial presence among major Indian OEMs. For the last two decades, Ansysco Anand has been one of the prominent manufacturer and supplier of radiator coolants, PVC adhesives, brake fluids and filter compounds to important OEMs in India. Ansysco Anand is motivated to enter into a technical assistance agreement with Seiken. This cooperation will open fresh opportunities for us to tap into the Japanese OEMs present in India,” stated Deepak Chopra, CEO, Anand Group. Yukio Maekawa, President, Seiken Chemical Industry Company Limited, added, “Our Seiken brand is well-known for trustworthy products not only in Japan but also all over the world. For better customer satisfaction, we are incessantly researching, developing, and supplying good quality products at a rational price. In Ansysco Anand, we see a dependable partner with whom we can co-operate to supply good quality coolants and brake fluids in India".
Polymer Industry to Advantage from Strategic Crude Oil Reserves: Ajay Durrani Mumbai, India: The Union budget is a composed budget focusing on providing a stimulus to the economy and offers promising measures for the tax payers. As expected GST, demonetisation has shepherded in tectonic changes for economy and the same was visible in the budget. There are several takeaways from the budget that is directed at enhancing consumption, skill development and highlights intensive efforts in the direction of creating enhanced living standards in the country. The reduction in the tax rate in the income tax slab of ` 2.5 lakh to ` 5 lakh to 5 per cent from 10 per cent will give rise to disposable income of individuals and boost consumption. Likewise, the subsidies offered for the MSME sector in the for m of tax rebate, reduction in income tax for SMEs with annual turnover up to Rs 50 crore, as well as, the extension of the profit linked deduction period available to the star t-ups to three years out of seven years will provide a stimulus to employment generation. The polymer industry will receive a boost from the proposed additional strategic crude oil reserves. Similarly, the proposed reduction in the basic customs duty on LNG from 5 percent to 2.5 per cent will provide a respite to the petrochemicals sector. The thrust on the ‘Housing for All’ scheme continues with the budget. The decision to give it an infrastructure status as well as interest subvention for housing loans and reduced lending rates by banks post-demonetisation is a welcome move. 20 • February 2017
The target of providing 1 crore houses for the houseless with a budget of ` 27,000 crore, spells good news for the sector. However, if the FM would have linked its affordable housing scheme with the agenda of making India an energy efficient nation, it would have served the greater good of scripting a brighter, better future of the nation.
Budget's Emphasis on Agriculture Promises Well for Agrochemicals: Sudhir Shenoy Mumbai, India: This is one of the least volatile budgets I have seen and does a rational balancing act. Happy to see that the fiscal farsightedness has not been negotiated with the deficit maintained at 3.2 per cent. Overall the Budget seems to be lopsided towards the rural and agriculture sector developments. From the chemical sector point of view, the announcements relating to agriculture, like easing the credit availability and the Krishi Vigyan labs should add an impetus to the agrochemicals sector. This will help farmers with access to products and technology on improving their yields and towards more sustainable practices. The budget has no noteworthy interventions on enabling access to feedstock, which is one of the crucial barriers restraining investments into petrochemicals. It is also disappointing to see that there is not anything on corporate tax except a proposal to cut corporate tax rate for MSMEs. However, the eradication of the foreign investment promotion board, along with the assurance of further liberalisation of the foreign direct investment (FDI) policy would have a positive effect on the sector in the medium term.
Incentivise R&D for Growth of Specialty Chemicals Sector: Dr Deepak Parikh Mumbai, India: The Indian specialty chemical industry is projected to grow almost threefold its existing size by the year 2020. This will be driven by demand from sectors like automotive, healthcare, agriculture, plastics, construction and FMCG. The country has a large population with low per-capita consumption of chemicals and a strong GDP growth outlook; this shows the stout potential of India’s specialty chemical demand. The country is already acquiring a prominent position as a manufacturing base for multinational chemical majors. Numerous mature products in the sector have already been commoditised or are at risk of the same. Specialty chemical manufacturers need to reinforce their focus on niche applications and product innovation in order to shield their margins. To give a further boost to India’s specialty chemical industry, the Union Budget for 2017 needs to factor three important recommendations: •
Lowering bilateral trade barriers between India and other Asian nations like South Korea, Japan, Taiwan, and others
•
Incentivising research & development activities to encourage launch of innovative products and thus place India as a leader in innovation
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Offering credits to chemical manufacturers that demonstrate exemplary corporate citizenship by exhibiting sustainability and Chemical Engineering World
CHEMICAL & PHARMA INDUSTRY
CEW Technology News Siemens PLM 2017 India Outlook and Focus Areas Mumbai, India: “The Indian Product Engineering organizations need to upgrade themselves to defining, designing, conceiving, manufacturing and setting up their supplier ecosystems to develop and deliver “SMARTER PRODUCTS” for the country in both - B2B as well as B2C space. The necessary changes need to be embraced and this will require preparation and transformation required within and across value chains. The traditional way of working is not going to work and incremental innovations will not suffice, our future demands transformational innovations’, said Gautam Dutta, senior director marketing, Siemens PLM Software India In a world of smart, connected products, where entire markets can vanish with a single innovation, manufacturers must now take a new approach to their business. That’s why manufacturing – the realization phase of innovation – will be vital in the coming year. We believe that manufacturers must weave a digital thread through ideation, realization and utilization. It’s not enough to digitize. That just mimics processes digitally for incremental improvement. Manufacturers have to digitalize. Digitalization makes the digital thread of knowledge a proactive agent in driving a business. With a fully optimized "Digital Enterprise", manufacturers are better equipped to initiate or respond to disruptive innovation. We at Siemens PLM Software, with our solutions, aim to continue helping companies weave the digital thread they need in product ideation all the way through product utilization. Through the products and solutions in our Smart Innovation Portfolio we intend to continue to provide the foundation our customers need to create a fully digital enterprise. This portfolio includes the products and solutions to transform operations now and meet any future needs. As a leading global provider of PLM and MOM software, system and services, in 2017 we aim to help our customers build their Smart Innovation Platform, enabling them with the following factors which will help them to gain competitive advantages in their respective global and domestic markets: • Engaged users • Sustainable Systems • Intelligent Models • Realized Products Our priority area in India for FY2017 will be to help the India engineering product development organizations adopt the cross-domain product development methodologies so that we can take advantage of the emerging Transformational technologies and develop “smarter” products for the global market place. India is on the cusp of a tremendous opportunity to become smarter product supplier to the globe. India is very strong on the systems software and software-driven manpower. We need to quickly adapt ourselves to this global need of subsystem and system supplier of smarter products for the new age and take advantage of these opportunities. This would mean working at three fronts simultaneously: re-skilling of our manpower, adopting new product development technologies & processes and establishing collaborative engineering value chains locally & globally. 22 • February 2017
B&R Innovation Day 2017: IIoT & Automation Software Takes Center-Stage Pune, India: Over the years, software is increasingly playing a vital role in industrial automation, encapsulating the entire automation pyramid – machines, factories and plants. With industrial internet of things, the manufacturing world is witnessing a convergence of the information technology (IT) and operational technology (OT). To gain business value it is inevitable to extract information from the generated field data, which is facilitated by software and vendor independent communication technologies. Innovation Day 2017, a conference on trend setting automation technologies, organized by B&R, focused on automation software providing higher business value to its customers. Today, users wish to have an Industry 4.0 implementation in their machines and plants. However, it is a herculean task to implement in brownfield projects. B&R provides unique solution for enabling not only Greenfield projects but also brownfield projects to become Industry 4.0 ready. “We offer secure and safe connectivity to the cloud from every level – machines, mechatronic units and sensors,” mentions Peter Gucher, General Manager International; B&R. Consumers are willing to pay a premium for personalized products. At the same time, increasingly responsive production technology is making it possible to create them under mass production conditions without a corresponding increase in unit cost. For manufacturers, the resulting margin boost is an enticing prospect. B&R's intelligent SuperTrak system is the reliable, industrialgrade transport solution for flexible production lines that enable mass customization. A live demonstration at the event displaying this conveyor system in tight synchronization with two Comau robots was a crowd puller. Apart from this, B&R displayed a slew of innovations – mapp View: web based HMI, mobile automation: automation solutions for outdoor applications, motion technology for next generation machines, virtual commissioning and secure remote maintenance. “One tool for all targets - has been a slogan for our highly acclaimed software tool Automation Studio. Owing to this software tool, every new innovation fits seamlessly into our existing matrix,” quoted PV Sivaram, Managing Director, B&R India. “It also provides longevity of developed application across generations of hardware, reducing the application effort and investment for newer hardware platforms,” he added. Guest speakers from Hitachi, Güdel, ACG Worldwide, and Windsor Machines provided their expert views on changing industry demands and technology trends. In their talks, they gave valuable insight into the adoption of the industrial internet of things (IIoT) in manufacturing units, and the pivotal role that software plays in its successful implementation. The delegates at the event also witnessed the launch of the 2nd edition of “Automation India”, a B&R technology magazine, comprising of various customer success stories from ACG Worldwide, A.T.E. Enterprises, IMA PG, Merck, AIM Machintechnik, Prasad Pneucon, PARI, Mahindra & Mahindra and Naveen Hydro controls. The launch took place at the hands of guest speakers, B&R management and customers who contributed towards the articles published in the magazine. This year’s Innovation Day witnessed a 35 per cent rise in delegates and was very successful. The guests gained a deeper understating of the role of software in successful implementation of industrial internet of things in their plants. Chemical Engineering World
CEW Technology News Two Leading Valve Operation Brands Merge to Form Sofis Karnataka, India: Netherlocks and Smith Flow Control have combined to form Sofis, a bigger, stronger, market-led company. Sofis’s customers will benefit from a more diversified organisation with a wider portfolio of valve safety and operation products. “One of the key customer benefits of our merger is that, as one team, we can offer a stronger, complementary range of products,” explained Daniel Ruiter, Sofis’s CEO. The new company will also offer better application engineering and after-sales service, while a new regional sales structure will deliver improved local support. Sofis’s dedicated business development managers and innovation teams will work closely with customers to design new solutions in each of its product groups: process safety, drive systems and valve monitoring. The new company will operate from 11 offices in nine countries. Since 1993, Dutch firm Netherlocks has been a leading manufacturer of industrial valve operation systems, including valve interlocks, valve position indicators, partial stroke testing devices and portable valve actuators. Smith Flow Control was formed in the UK in 1985. The organisation was the first to introduce the coded card linear key concept to interlocking, and specialises in mechanical valve control equipment, as well as portable actuator and remote valve operators.
Agilent Technologies Receives Dow’s WesTEC Awards for Technical Excellence and Innovation SANTA CLARA, California: Agilent Technologies Inc has announced it has received two awards in recognition of its contributions to a long-term strategic technical partnership with The Dow Chemical Company. The awards were presented to Agilent Technologies at WesTEC, an annual event that celebrates technical innovation, and technology breakthroughs that enhance work process efficiencies and process safety. The event was held at Dow’s Alberta Operations, Fort Saskatchewan Site in Canada. “Dow’s partnership with Agilent Technologies has spanned more than 28 years,” says Gonzalo Beltran, Vice-President of Dow Chemical Canada ULC and Site Director of Alberta Operations. “Our vital collaboration has elevated Dow’s analytical expertise, reliability and manufacturing performance. I extend my sincere appreciation to the Dow team and to our Agilent partners.” Agilent received two WesTEC Awards for the following joint product development projects. • The Agilent Intuvo 9000 gas chromatography system, which uses advanced technologies to significantly increase laboratory productivity. • The Agilent 8355 sulfur chemiluminescence detector, which represents a major advance in sulfur chemiluminescence detection, making the technology more reliable and easier to use. 24 • February 2017
“The Dow Canada 2016 WesTEC awards signify that Agilent is on the right track for delivering innovative and applicable separation technologies that will help Dow achieve superior outcomes in their laboratories,” said Shanya Kane, who leads the Gas Phase Separations Division at Agilent. “The presentation of the awards by Dow executives was viewed as an honour by our development teams, due to the significance of this external recognition by the world’s largest chemical company”.
Digitalization Key to Sustainable Success of Indian Machine Tool Industry Mumbai, India: Digitalization entails the ever closer meshing of processes and applications in the virtual and the real world. With a wide spectrum of integrated software and hardware solutions, including state-of-the-art SINUMERIK controllers, Siemens India is supporting both machine manufacturers and operators on their way to become a digital enterprise. Showcasing its Integrated Engineering approach at IMTEX 2017, Siemens is demonstrating how machine tool industry can respond faster to the needs of the market, increase their flexibility to meet the customer’s individual requests and also develop products efficiently.Ashish Bhat, Country Division Lead, Digital Factory, Siemens India, said, “Siemens follows a holistic approach towards digitalization. In the machine tool space, we focus on three main areas through the lifecycle of the machine tool, which is build (during production), operate (during operation) and optimize (of the process / machine tool). The machine tool industry plays a critical role in the entire industrial landscape and also the success of Make in India, and it is imperative that it transitions into a digital enterprise at the earliest.” Siemens is the only solution provider offering both a seamless CAD/ CAM-CNC process chain and solutions for integrating machine tools and higher-level IT systems. Using these integrated products and software solutions, machine tool and other manufacturers can benefit considerably from the opportunities offered by digitalization and enhance their competitiveness. For the first time ever in India, Siemens is showcasing cutting-edge digitalization solutions that help develop a digital twin for virtual part production and cloud-based data services – Mindsphere, which can support machine and plant data evaluation using special tools in order to assess and optimize the condition of machines and plants. Other highlights include a comprehensive range of CNC and metal-cutting machine tool technologies, products and solutions – for the smallest job shop to the complex production environment in every segment of the industry, from tool-and-die and mold-making to primary automotive, aerospace and medical part manufacturing. Visitors to the stall will also get a glimpse of the Technology & Application Centre (TAC), a state of the art knowledge sharing and training facility created by Siemens in India at Peenya, Bangalore. Also on offer are smart financing solutions for Siemens and third-party equipment and technology from Siemens Financial Solutions. These financial solutions are designed to help businesses of all sizes grow and to fuel the pace of technology adoption. Chemical Engineering World
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CEW News Features
“Outlining the Path from Building Digital Engineering Models to Asset Performance Modelling” “As operations technology (OT) leverages the Industrial Internet of Things (IIoT) with sensors on virtually everything generating a huge volume of big data, this is driving a remarkable convergence with IT resulting in improved security, information sharing, and data management. But making sense of all this information and turning it into actionable intelligence is where engineering technology (ET) plays a role,” says AnneMarie Walters, global marketing director, Bentley Systems speaking at the ARC Industry India Forum 2016 in Mumbai. In a tete-a-tete with CEW, she deliberates about progressive IT, OT, and ET convergence, key challenges and opportunities in the Indian market, Bentley’s asset performance management solutions, and market competition.
D
uring her presentation, Anne-Marie Walters underlined the convergence of information technology (IT) with operational technology (OT) and engineering technology (ET), outlining the path from building digital engineering models to asset performance modelling.
develop the digital DNA of their assets to personalize asset maintenance, avoid asset failures, and maximize uptime. So, fundamentally, using engineering technologies along with operational and IT technologies really does improve asset performance.
While deliberating about IT, OT, and ET convergence, Walters said the Industrial Internet of Things (IIoT) fundamentally adds real-time operational data for your assets that is available beyond the operational control systems to enterprise systems, enabling new ways to control production, operations, and maintenance. The explosion of readily available sensor information and enterprise-level management processes is driving OT and IT convergence.
Key Challenges of Integration Process Organizations miss out on opportunities to improve asset performance as a result of having to make use of data from their OT and IT systems. Part of the reason is attributed to digital engineering models developed during the engineering stage of capital projects that normally do not play a role in operations. Walters says a lack of standardization across the industry presents a challenge.
However, when it comes to determining whether to retire, replace, or revamp an asset that is wearing out or underperforming, then Bentley brings engineering technology to the table in that same interactive environment. Predicting how an asset is performing and how it might perform better is the job of the engineer. Digital engineering models are the digital DNA for infrastructure assets. They contain information about how the asset was designed, of what it is capable, and of what it consist down to every nut, bolt, and screw. Organizations can 28 • February 2017
“Take, for example, a pump supplier. You might identify the pump in your operational technology system one way and in a different way in your information technology system. The pump might be called something else again in the engineering system, so the task is to bring the engineering and operations systems in line with information and the assets. The information about the assets across the system is the key, which is one of the areas where engineering technologies can really help. “Bentley’s reality modelling technologies, which combine actual photographs of an existing asset into a 3D mesh model, presents what is actually there, so you can
see and identify the asset through a photograph of, say, a name plate with a geographical location that provides the necessary information to make a link to information you already have in your operations and enterprise systems. So, it’s the ability to link things together by locating something through its geographic location. Not only does the realistic 3D model help you locate and identify assets, it also gives everyone a very clear view of the as-is condition of the asset – rust spots, dents, damage, and so on. Another issue organizations face is ensuring that engineers are working with a model that has been updated with that latest information when considering a change. When information is not updated, the results of using incorrect information are obvious. Chemical Engineering World
CEW News Features Opportunities and Challenges for Integrating IT, OT, and ET The convergence of IT, OT, and ET provides users with actionable information, analyses, and proactive performance management prospects. Walters said, while large organizations in India are integrating IT, OT, and ET, many smaller organizations are lagging. She adds these organizations typically do not have a single information management system that can help them understand what assets they have. But some organisations are taking steps to digitize their existing assets using Bentley’s asset management system. Indeed, recent innovations to the industry provide the ability to work in a complete modelling environment, leveraging 3D reality mesh technology, such as Bentley’s ContextCapture, and connecting with the Industrial Internet of Things through asset management and predictive analytics software. ContextCapture converts photographs into 3D reality meshes that can be used alongside laser scanning. High-resolution photographs taken with a simple digital camera can be processed into mesh models in the cloud, providing a much more compact and efficient 3D model than a laser-scanned point cloud. Among the projects in India that have implemented ContextCapture, Walters said, is the Nagpur Metro project. The project team deployed drones mounted with digital cameras to survey the site and convert the photographs to 3D surface models for designing the actual metro routes. This same technology is being proposed for the Nagpur-Mumbai expressway, and Tata Steel is using ContextCapture to monitor its stock piles and calculate volumes using 3D reality models. OT, IT, and ET in Practice Walters cites the South Australia Water desalination project as a prime example of converging OT, IT, and ET. The state of South Australia is one of the driest on earth, and SA Water designed a high-capacity desalination plant with a north-south interconnecting pipeline to address its water distribution challenges. SA Water used predictive and real30 • February 2017
time operational analytics to determine demand for water and improve customer service while reducing operational costs. To create a demand forecasting tool, SA Water needed to gather information from the operational and IT sides of the organization in real time. The organization selected Bentley’s Operational Analytics application as the operational intelligence platform for its real-time ability to connect and capture data from a wide variety of sources. The application can also be used to perform complex calculations and analysis, and for its remarkable visualization capabilities. On this project, SA Water collected real-time monitored sensor data from reservoirs, water treatment plants, valves, flowmeters, and pumps spread across the pipeline network. This operational data was pooled in real time with climate, energy, cost, and population data and displayed on dashboards. Bringing these data sources together has brought huge benefits, including enhanced performance, superior understanding of inter-relationships, improved decision making, and more precise predictions of short- and long-term demand. Converging of IT, OT, and ET allows the organization to take advantage of lower forward market pricing for electricity, Walters said. Bentley’s core technology strength, though, in this industry is designing and building water resources, water treatment plants, and water networks, and enabling engineering firms to design, build, and cost-effectively operate these assets. A good example of this is MWH, a global EPC player operating in India. MWH designed and built the sewage network for Taiwan using Bentley applications, and will operate it for 35 years before handing it over to the government. Asset Performance Management Solutions In an organisation’s quest for operational excellence, asset performance management (APM) plays an essential role in accomplishing business goals – safeguarding assets at a minimal cost while functioning in a safe and environmentally
accountable manner. From operational predictive and prescriptive analytics to asset reliability, process safety, and integrity management programs, Bentley’s APM solution brings operations, engineering, and maintenance together to manage business processes in a structured decision-support environment. “Bentley’s success is our ability to integrate or take technologies and bring them into operations and maintenance, and link it with IT and OT systems to support optimal operations,” Walters said. Leveraging Cloud Technologies and Mobile Applications Organizations and EPCs often use engineering products and cloud technology to make information accessible to operations and maintenance personnel, Walters said. This makes it easy for them to identify failures on the go, using handheld devices. “Users can feed the information and get it updated in the system. That’s the part of digital engineering model,” Walters explained. “It can be used for optimal operations. I previously mentioned our ContextCapture technology that can create a digital engineering model. The ContextCapture technology converts simple photographs into a 3D surface model that can help identify the state of asset, and the data model is updated with accurate information.” Walters also touched on Bentley’s 30-plus-year relationship with Microsoft that helped Bentley establish protected and secured systems for their user base. For example, oil and gas organizations demand rigorous security systems for real-time update of information at their refineries. “So, when Bentley researched cloud service providers, Microsoft offered us secured processes in terms of cloud and network security,” she added. Microsoft Azure-provisioned connected data environment digitally connects and converges the people, processes, data, and technology to yield significant results. She cites the 2016 Upstream Oil and Gas Digital Trends Survey, which states digital technologies have added value to upstream oil and gas companies by Chemical Engineering World
CEW News Features helping to reduce costs, make faster and better decisions, and increase workforce productivity. She continued, “Our philosophy at Bentley is whether you are looking at information at the office through laptops or other information displaying devices, it’s the same information. The model is going to have same interface displaying the same information. One of the key things where we have spent a huge amount of R&D on for the past five years is developing mobile applications for our solutions. The convenience of using a mobile phone or an iPad in the field to immediately capture information in the field and relay it to distributed team members cannot be overstated. This information can be hosted in the cloud and viewed in real time by the other project-team members.”
Competition in the Indian Market Lastly, Walters addressed the differences between Bentley’s solutions and those of other software vendors in the region. “Most of our competitors in the Indian market are point solution providers. We are one of the few service providers that has end-to-end and integrated solutions to offer the market, which separates us from our contemporaries. Our solutions can come into play at conceptualization stage, feed level, and design level. We can also dynamically contribute at prevailing plant levels as well, which gives our users a competitive edge.” Walters explained that some Bentley technologies are so unique to the industry that competition isn’t a factor. She cited the offshore sector as an example, where its SACS is a leading technology in the
industry. SACS is used for structural analysis of offshore platforms, especially those situated in shallow water as many of the offshore platforms near India are. Walters also said Bentley has integrated its MOSES application with SACS to meet industry requirements. MOSES, Bentley’s integrated offshore simulation software helps users minimize risks and explore design alternatives with the efficiency and flexibility of a unified modelling environment. “We are very multi-discipline in terms of engineering application services. Our approach is appreciated in the Indian market, specifically in the asset management sector,” she said.
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CEW News Features
Light-Driven Reaction Converts Carbon-Dioxide Into Fuel Duke University researchers have developed tiny nanoparticles that help convert carbon dioxide into methane using only ultraviolet light as an energy source. In the past two decades, scientists have explored new and useful ways that light can be used to add energy to bits of metal shrunk down to the nanoscale, a field called plasmonics.
H
aving found a catalyst that can do this important chemistry using ultraviolet light, the team now hopes to develop a version that would run on natural sunlight, a potential boon to alternative energy. Chemists have long sought an efficient, light-driven catalyst to power this reaction, which could help reduce the growing levels of carbon dioxide in our atmosphere by converting it into methane, a key building block for many types of fuels. Not only are the rhodium nanoparticles made more efficient when illuminated by light, they have the advantage of strongly favouring the formation of methane rather than an equal mix of methane and undesirable sideproducts like carbon monoxide. This strong “selectivity” of the light-driven catalysis may also extend to other important chemical reactions, the researchers said. Despite being one of the rarest elements on Earth, rhodium plays a surprisingly important role in our everyday lives. Small amounts of the silvery grey metal are used to speed up or “catalyze” a number of key industrial processes, including those that make drugs, detergents and nitrogen fertilizer, and they even play a major role breaking down toxic pollutants in the catalytic converters of our cars. Rhodium accelerates these reactions with an added boost of energy, which usually comes in the form of heat because it is easily produced and absorbed. However, high temperatures also cause problems, like shortened catalyst lifetimes and the unwanted synthesis of undesired products. In the past two decades, scientists have explored new and useful ways that light can be used to add energy to bits of metal shrunk down to the nanoscale, a field called plasmonics. Henry Everitt, an Adjunct Professor of Physics at Duke and Senior Research 34 • February 2017
Scientist at the Army’s Aviation and Missile RD&E Center at Redstone Arsenal, AL said “Effectively, plasmonic metal nanoparticles act like little antennas that absorb visible or ultraviolet light very efficiently and can do a number of things like generate strong electric fields”. He also said that for the last few years there has been recognition that this property might be applied to catalysis.
Now the team plans to test whether their light-powered technique might drive other reactions that are currently catalyzed with heated rhodium metal. By tweaking the size of the rhodium nanoparticles, they also hope to develop a version of the catalyst that is powered by sunlight, creating a solarpowered reaction that could be integrated into renewable energy systems.
Xiao Zhang, a graduate student in Jie Liu’s lab, synthesized rhodium nanocubes that were the optimal size for absorbing near-ultraviolet light. He then placed small amounts of the charcoalcoloured nanoparticles into a reaction chamber and passed mixtures of carbon dioxide and hydrogen through the powdery material.
According to Liu, “Our discovery of the unique way light can efficiently; selectively influence catalysis came as a result of an on-going collaboration between experimentalists and theorists.”
When heated, the nanoparticles to 300oC, the reaction generated an equal mix of methane and carbon monoxide, a poisonous gas. When he turned off the heat and instead illuminated them with a high-powered ultraviolet LED lamp, Xiao was not only surprised to find that carbon dioxide and hydrogen reacted at room temperature, but that the reaction almost exclusively produced methane. According to Everitt “We discovered that when we shine light on rhodium nanostructures, we can force the chemical reaction to go in one direction more than another. They got to choose how the reaction goes with light in a way that we cannot do with heat.” “This selectivity - the ability to control the chemical reaction so that it generates the desired product with little or no side-products - is an important factor in determining the cost and feasibility of industrial-scale reactions.” Said Zhang He also added, “If the reaction has only 50 per cent selectivity, then the cost will be double what it would be if the selectively is nearly 100 per cent. And if the selectivity is very high, you can also save time and energy by not having to purify the product.”
Professor Weitao Yang’s group in the Duke Chemistry department provided critical theoretical insights that helped us understand what was happening. This sort of analysis can be applied to many important chemical reactions, and we have only just begun to explore this exciting new approach to catalysis. This research was supported by the National Science Foundation and the Army Research Office. Additional support was provided by Duke University’s Katherine Goodman Stern Fellowship, the National Defense Science & Engineering Graduate Fellowship (NDSEG) Program and the Center for the Computational Design of Functional Layered Materials, an Energy Frontier Research Center funded by the US Department of Energy (DOE), Office of Science, Basic Energy Sciences (BES).
Jie Liu Department of Chemistry Duke University
Henry Everitt Adjunct Professor Duke University Chemical Engineering World
CEW Features Technical Article
Specialty Chemicals in India – Turning Opportunity to Reality Given its defensibility and growth prospects, Specialty chemicals is one of the most attractive segments within the Indian manufacturing space today. The sector is positively influenced by macro-economic factors such as shift of manufacturing to India; growth at the end-user level, domestic demand driven by rising incomes, rural growth, premiumisation; move towards natural products etc. Additionally, Indian companies are becoming increasingly equipped to give MNCs a run for their money, with significant time, money and efforts being spent on upping regulatory compliance standards, systems and processes and efforts towards creating intellectual property. Specialty chemicals constitute a significant part of the Indian chemical industry and find use across a wide multitude of enduse segments. With increasing demand for value added high-performance products in all spheres of the life of an average Indian, we expect growth in demand for specialty chemicals that add important functionalities to products. The growth for specialty chemicals is driven by both domestic consumption and exports. Specialty chemicals finding applications across consumer (eg. personal care chemicals), industrial (eg. water chemicals) and infrastructure (eg. construction chemicals) segments are driven by the overall growth of the Indian economy. Agrochemical growth has a strong linkage to the growth of the rural economy. Overall, the shift of manufacturing to the East and India’s export competitiveness is expected to strengthen India’s position as a manufacturing hub for specialty chemicals. A glimpse of India’s emergence as a major export hub is already seen in segments such as agrochemicals and colorants, in which a significant part of India’s production is exported.
The nine key segments comprising Agrochemicals, Flavors and Fragrances, Dyes & Pigments, Surfactants, Polymer additives, Personal care ingredients, Construction chemicals, Water chemicals, and Textile chemicals cumulatively constituted a market of $ 18.8 bn in 2014 in India and are expected to grow at 12 per cent p.a. to reach $ 33.2 bn by 2019. This is over 2x the global market growth rate of 5.2 per cent p.a.,which is expected to expand the market size from $ 247 bn in 2014 to $ 318 bn in 2019.
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36 • February 2017
1) Shift in Manufacturing to Asia Many MNCs are focusing on Asia (especially India and China) as their manufacturing hub, as a result of tighter environmental norms in the West. Lower cost of production and availability of skilled manpower in Asian countries have further aided this process. This has been particularly evident in relatively standardized products with low differentiation, such as textile chemicals and dyes and
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Specialty Chemicals Market In this article, we have looked at the key growth drivers of the Indian Specialty Chemicals market:
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Figure 2: Indian Specialty Chemicals Market
pigments, wherein IP protection hasn’t been a significant threat. Recently, tightened pollution control norms in China have led to multiple plant shutdowns in chemicals and other manufacturing segments. As a result, Indian chemical manufacturers have gained from production shift to India visibly in segments such as Dyes and Pigments. 2) Increase in Adoption by End-Users In several industries in India, the per-capital usage of specialty chemicals is dismally low compared to other economies implying significant headroom for growth in this space. For example, the Indian construction industry is very price sensitive and has not been an active consumer of construction chemicals, hence the value of construction chemicals as a per cent of the construction cost in India is a fraction of global averages. With the adoption of global construction techniques, the use of construction chemicals is expected to rise rapidly. In water chemicals, increasing penetration of solutions such as negative ion therapy, stain releases, anti-microbial effect (growing at 20 per cent CAGR over FY11 to 17) are additionally driving market growth. Higher adoption will also drive growth in agrochemicals and polymer additives. 3) Increasing Usage of Natural Ingredients, Green Processes, and EcoFriendly Products The shift towards naturals can be attributed to consumer awareness of health issues and stricter government regulations prohibiting the use of certain synthetic compounds. In the USA and Europe, several synthetic Personal Care ingredients have been banned or highlighted as potentially unsafe in the recent past due to their adverse health effects. Such cases have led to greater demand for Chemical Engineering World
CEW Features Agrochemical
Flavors
Dyes
&
&
Fragrances
Pigments
Surfactants
Polymer additives
Con-
Water
Textile
Care
struction
Chemi-
Chemi-
Ingredients
Chemicals
cals
cals
Personal
Shift in Manufacturing to Asia Increase in adoption by end-users Increasing usage of Natural ingredients, green processes, & eco friendly products Rising disposable income, increasing rural penetration Premiumisation Innovation Figure 3: Impact of key drivers across various sub sector
natural ingredients for personal care products. India, with an abundance of natural F&F and Personal care ingredients, is expected to greatly benefit with the move to naturals. In sectors such as Dyes and Pigments, natural colors are gaining popularity in food and beverage applications. The use of ecofriendly colorants such as low impact dyes is emerging with features such as low water requirement to rinse off residues during dyeing and rinsing process leading to lower pollution. With the tightening of environmental norms both globally and in India, the polymer additives market is shifting to environmentally safe, higher value products. 4) Rising Disposable Income, Increasing Rural Penetration With rising disposable income and increasing rural penetration of goods & services positively impacting the end-user segments, several specialty chemical sub-sectors are expected to benefit. Encouraged by various government schemes such as minimum support prices, farmer income has risen on an average and they are able to afford more agrochemicals. Further there is greater availability of credit from banks and NBFCs for agriculture. Improved economic environment and increasing purchasing power of the Indian population and marketing by FMCG companies has created demand for categories like deodorants, room fresheners and perfumed soaps in rural markets. This has opened up a new opportunity for the currently underpenetrated fragrance market (penetrated only to an extent of 0.5 per cent of the potential market). Growth of aspirational products and growth of the rural retail sector will also help in driving demand for flavors & fragrances, personal care ingredients and surfactants. 38 • February 2017
5) Premiumisation As Indian consumers graduate from using basic soaps and detergents to higher end products such as skin creams, lotions, hair gels and other specialized cosmetic products, the quality and value of the flavors and fragrances used in these products is expected to increase. In the beverage space, fruit-based drinks (expected to grow at 30 per cent p.a.) are becoming popular and consumers are demanding unique flavors. These require high value flavoring ingredients. India is also witnessing increasing consumption of higher end, discretionary and prestige products which typically use higher value active ingredients driving growth in the ingredients market. For instance, nearly 50 per cent of the total new launches in the personal care space were premium brands driven by increase in disposable income, rising young working population and growth in organized retail. Premiumisation will provide a significant fillip to segments like flavors and fragrances, surfactants, personal care ingredients and nutraceutical ingredients. 6) Innovation Product innovation is vital in many segments of specialty chemicals. In the case of agrochemicals, pests develop immunity against commonly used agrochemicals over time, as a result of which agrochemical manufacturers constantly need to focus on new product development that can protect crops against resistant strains of pests. Some of the leading agrochemical companies in India make considerable investments in maintaining a strong product pipeline and compete with global majors. In the F&F space, blenders add value by creating unique scents. These are created by unique combinations of numerous aroma ingredients and additives to produce balanced blends. There is usually considerable IP involved in creation of scents. Blenders have to be able to keep
innovating, creating unique fragrances and flavors as the market demands. The global F&F houses spend an average of 9 per cent on R&D. There is a lot of collaborative development involving end-users as well in order to keep with consumer trends. Indian companies in this space are taking significant strides on technical grounds as well, competing with global giants, not only in India but also in export markets. Innovation and differentiation is critical for players to maintain profitability and prevent commoditization of ingredients. Regulatory environment is another driver of innovation as a number of synthetic active ingredients have been banned across the globe due to potential health hazards. Ingredient manufacturers have to focus on R&D to develop safer natural or synthetic ingredients to replace such products. Innovation and differentiation has been the focus for Indian players constantly looking out for newer requirements from the USA and European markets and focus their R&D efforts accordingly. These drivers along with several government initiatives across the space including ‘Make in India’ which promote domestic production and export of chemicals, various agricultural initiatives and rural benefit schemes will significantly benefit the specialty chemicals space in India. Authors’ Details
Mr. Preet Singh Executive Director – Industrials Avendus Capital Email Id: preet.singh@avendus.com Chemical Engineering World
CEW Features Technical Article
Industrial Sampling Systems Some basic points to be considered while selecting a system are below:
Sampling is the process of taking a limited volume of material from a process stream that precisely echoes the The media being sampled – whether gas, liquid, solid, powder, slurry, steam, water, etc. characteristics of the complete lot, batch or the process stream. Contamination of a sample can generate incorrect test The frequency of sampling The properties of media – viscosity, density,through boiling point, particle size, results and cause further process complications. Contamination can be initiated reaction withetc.the environment The nature of the media – flammable, toxic, corrosive, explosive etc. where the sample is being taken – of pipeline or equipment, etc. lingering within the or with the container in which it is stored, but isFrom more often caused by traces the former sample What kind of analysis is required – Fe analysis, moisture content, etc. sampling system. To attain accuracy in the sampling selection of an appropriate Processprocess, conditions the – pressure, temperature, flow rate etc. system is very important. The article highlights more on the necessities of gas and liquid sampling systems than those for solid sampling. Sampling Methods
What is Process Sampling? Sampling Methods
Sampling is the act of capturing a limited volume of material from a process stream that accurately reflects the characteristics of the entire lot, batch or the process stream. A sample taken from a process pipeline or equipment must truly represent the exact constituents of the process without any contamination. Contamination of a sample can create incorrect test results and cause further process complications. Contamination can be caused through reaction with the environment or with the container in which it is stored, but is more often caused by traces of the previous sample remaining within the sampling system. To achieve accuracy in the sampling process, the selection of an appropriate system is very essential. Some basic points to be considered while selecting a system are below: • The media being sampled – whether gas, liquid, solid, powder, slurry, steam, water, etc. • The frequency of sampling • The properties of media – viscosity, density, boiling point, particle size, etc. • The nature of the media – flammable, toxic, corrosive, explosive etc. • From where the sample is being taken – pipeline or equipment, etc. • What kind of analysis is required – Fe analysis, moisture content, etc. • Process conditions – temperature, flow rate etc 40 • February 2017
pressure,
Conventional Methods Grab Sampling
Advanced in-line Methods
Bottle Configuration (Open Sampling System)
Liquid Samplers
Slurry Samplers
Cylinder Configuration (Close Loop Sampling System)
Gas Samplers
Liquid Samplers
Liquified Gas Samplers
Gas-Liquid Samplers
Conventional Methods of Sampling
It has been observed that one system Conventional Methods of Sampling the past, sampling methodwas was used to collect samples from the process In theIn past, the the grabgrab sampling method is not ‘fit for all’, and thus a number stream. This was a simple method where an isolation valve installed offline in the process used stream to collect samples fromsamples the process alternatives suitable separate for various was used to collect in a beaker of or a bottle. In some applications, bypass used for takingwhere the samples. stream. Thisloops waswere a simple method an applications have been developed. These isolation valvemethod installed in the designs continue evolvethrough as customers Another for offline sampling fromprocess a reactor or tank was to take ato sample a traditional ram y-pattern sample valve at therealize bottom the of the reactor. stream was used to type, collect samples in a beaker capabilities of sampling system or a Though bottle. these In some applications, separate manufacturers push them to improve methods were economical, they increased the risk ofand contaminated samples bypass loops were used taking theincluded samples.potential considerably. Otherforhazards toxic and dangerous theirexposure existing to systems. substances for the operators, as well as greater environmental pollution.
Another method for sampling from a reactor Advanced In-line Sampling Methods or tank was to take a sample through a traditional ram type, y-pattern sample valve at the bottom of the reactor. Though these methods were economical, they increased the risk of contaminated samples considerably. Other hazards included potential exposure to toxic and dangerous substances for the operators, as well as greater environmental pollution. Advanced In-line Sampling Methods Nowadays processes in the chemical, petrochemical and oil & gas industries are getting more and more complex in nature. This growing complexity demands consistently safe and high quality sample extraction for further analysis. Extracting the correct representative sample is a crucial factor in ensuring precise product verification.
The key benefits of Advanced In-Line Sampling include: • Providing reliable analysis results • Saving money and downtime
by
and reducing
accurate waste
• Protecting operators and the environment • Ensuring product quality and environment regulatory compliance As indicated in the figure, Advanced In-Line Sampling Systems are further divided into: • Bottle configuration (open sampling system) • Cylinder configuration (closed loop sampling system) Chemical Engineering World
CEW Features
(Courtesy: Flowline Instrumentation Pvt. Ltd)
Bottle configuration (open sampling system) This type of sampler is generally used for liquid or slurry applications. Configuration: Usually consist of a sampling valve, bottle, sealed septum, shroud, cap, tubing and fittings. Operating principle: When sampling, open the sampling valve. The sample can flow into the sample bottle under system pressure, while air and gases in the bottle are being vented through the vent port. When the required amount has been taken, turn off the sampling valve. Application: High temperature, high pressure, high viscosity, strong corrosive, strong toxicity and dangerous liquid/slurries which can cause damage to the environment. 42 • February 2017
(Courtesy: Flowline Instrumentation Pvt. Ltd)
Sampling Valves In a bottle configuration system, the sampling valve is the heart of the process. The selection of the valve depends on several process parameters such as temperature, pressure, nature of fluid, its viscosity, density, toxicity and many other factors.
These valves generally used in for liquids. They have no dead space, which prevents contamination of the sample and ensures that a representative sample is taken each time. Many accessories and customized solutions are available to cater to the specifications of the process stream and the safety of the operator.
Some of the types of sampling valves available are listed below:
Cylinder Configuration (Closed Loop Sampling System) These samplers are generally used for gas or liquefied gas applications.
Piston Type Sampling Valve Piston type sampling valves are widely employed in the sampling of thick slurries and viscous materials because their design provides no dead space within the valve and vessel or line connection. The piston completely fills the valve and connection bores and provides a self-cleaning (selfpigging) action during the closing stroke of the valve. A true representative sample is always assured with this type of sampling valve.
Configuration: The system generally consists of a sample cylinder equipped with needle valves and quick-connect couplings at both ends. The sampling loop consists of a sample probe, tubing, flexible hoses, valves, fittings and instruments. Auxiliary items such as sample coolers and knock-out pots are also available as per process requirements. Chemical Engineering World
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CEW Features adsorb strongly to metal surfaces in sampling, storage, and transfer lines. This results in false analysis of sulfur compounds. These compounds are also slow to desorb from untreated metal surfaces, which can further lead to inaccurate results.
(Courtesy: Oliver Valves)
(Courtesy: Oliver Valves)
Operating principle: The sample flows through the sample cylinder via the sampling loop. When the required volume has been taken, turn off the needle valve at both ends, then disconnect the cylinder from the sampling system.
they are more compact, rigid, lighter and safer than the conventional sample probe. Sample Unloading Station
Application: High temperature, high pressure, corrosive, strong toxicity, strong volatile and dangerous liquid gas mixture or gas which can cause damage to the environment. Mounting type: Wall-mounted, bracket, clamping slot.
support
Some of the auxiliary items available as per process need are: • Sample probe
A sample unloading station is typically used for handling gases or liquefied gases. Basically these are used in plant laboratories for safe unloading of the sample without spillage or contamination. Material Options Available In Sampling Systems • Generally, 316 or 316L stainless steel is used to handle various non-critical process streams. • For highly concentrated acids and corrosive fluids, exotic materials such as Monel, Alloy 20, Hastelloy are generally used.
• Sample coolers • Knock-out (KO) pot • Thermal shut off valves • Sight glass • Closed cabinets • Sample unloading station • Instruments such as temperature gauge and flowmeter
• Apart from the process fluid, the selection of the material of construction is also based on the elements to be analyzed. For example, Sulfinert and Silcosteel are preferred options for sulfur analysis. In some cases, if the temperature is low, PTFE lined CS or SS are preferred.
Sample Probe The sample probe is an integral part of the close loop sampling system, and basically helps to extract the sample from the process line. The typical conventional sample probe is as indicated below.
Sulfinert Sampling Systems • Sulfinert sampling systems are special purpose sample points ideally used for sulfur analysis, wherein the metal surfaces require special surface treatment. The available options include Sulfinert and Silcosteel.
Pre-engineered solutions such as compact sample probe valves are also available. These simplify the sampling operation as
• Many organo-sulfur compounds like hydrogen sulfide, methyl mercaptan, and ethyl mercaptan,
A few auxiliary items are explained below:
44 • February 2017
• Sulfinert is a proprietary chemical vapour-deposited internal coating specifically designed to improve the inertness of steel, stainless steel, alloys, glass and ceramics. It is used to passivate sampling cylinders, transfer tubing, fittings and other inline items to prevent sulfur adsorption along the sample path. The material of construction is generally specified by the process licensor, depending on the criticality of fluid or elements to be analyzed. However if such guidelines are not available, this can be discussed with the sampling system vendors. Conclusion Due to the changes in industrial rules and regulations, environmental regulations, and industry practices, the process industry is compelled to reevaluate their current sampling methods. Companies are now opting for new and more sophisticated sampling systems, which are available for a variety of applications, and enable accurate and safe sampling.
Author’s Details
Pranali Kambli Deputy Chief Engineer Aker Solutions India Chemical Engineering World
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CEW Features Technical Article
Minimal Liquid Discharge: Adopting A ‘Less Is More’ Mindset Minimal Liquid Discharge (MLD) is a cost effective water management approach that helps increase recovery and also mitigates discharge. If zero liquid discharge (ZLD) is too costly and the associated infrastructure is a latent deterrent, water reuse and sustainability can still be prioritized and realized through MLD. It can assist municipal and industrial plants to make substantial gains in minimizing liquid discharge and help plants considerably abate their capital and operating costs, since achieving the final 3-5 per cent of liquid elimination to accomplish ZLD can prove contemptibly expensive. The article deliberates in-depth on benefits of adopting MLD approach over ZLD approach. It also explains its role in reducing CAPEX, OPEX and other environmental impacts.
Industry challenge Due to urbanisation and industrialisation, India faces major challenges in the water sector with the per capita availability going down and demand going up. Inefficiency of water use in agriculture, over-exploitation of underground water and contamination are other issues associated with water management in India. Since the amount of water available is more or less constant, rising demands due to increasing population and economic growth are straining the demand-supply balance. Also with environmental norms becoming increasingly stringent and water becoming a “scarce commodity”, treating water to make it reusable has become an imperative for water intensive industries across the globe. As we are heading towards developing a circular economy, where raw materials are recycled and reused, many industries realise that the wastewater they generate could well be their cheapest & most reliable source of water and MLD technology can lead the way in that direction. Why MLD? Maximizing the efficient use of water by industry is critical for both the environment and the bottom line. Depending on individual regulatory and environmental needs and requirements, as well as the capital and operating budget, MLD can be a good fit for many industrial and municipal sites. By conducting a water audit to match waste streams and appropriate water requirements, companies can better 46 • February 2017
identify how much wastewater requires processing and the approach that will most economically and sustainably match their plant’s needs. MLD can help municipal and industrial plants make substantial gains in minimizing liquid discharge and help plants significantly minimize their capital and operating costs, since achieving the final 3 to 5 per cent of liquid elimination to achieve ZLD can prove outrageously costly. (See graphic below.) Benefits of MLD over ZLD While zero liquid discharge (ZLD) — a water treatment process in which all wastewater produced is purified and recycled, leaving zero liquid discharge at the end of the treatment cycle — is a viable solution for some companies;
it’s not the most realistic solution for all. Due to the additional material, energy and disposal resources they typically require, it is technically daunting, highly expensive and not necessarily environmentally friendly. Hence when facing significant discharge mitigation costs, businesses often wonder, “What are my other options besides ZLD?” One solution is minimal liquid discharge (MLD), a more cost-effective and sustainable way for companies to improve their water footprint, enabling up to 95 percent liquid discharge recovery at a fraction of ZLD’s costs. Coined by Dow, the processes on which it is based rely on proven water filtration technologies such as ultrafiltration, reverse osmosis (RO), and nanofiltration.
Cost Comparison Of Minimal Liquid Discharge (MLD) VS Zero Liquid Discharge (ZLD)
Chemical Engineering World
CEW Features New MLD-related technologies are enhancing these efforts. For e.g., for municipal desalination plants, it’s possible to get to 93 per cent recovery using a traditional dual-membrane treatment system, chemical adjustments and precipitation. It’s typically a combination of brackish water reverse osmosis, nanofiltration and seawater reverse osmosis. To dispose the remaining concentrate, for many desalination plants, the preferred method of concentrate disposal is discharge into the ocean and if that is not an option, alternatives vary by geography.
Minimal Liquid Discharge
An excellent example of an MLD mind-set in action can be found at the General Motors (GM) vehicle assembly plant in San Luis Potosi, Mexico. The plant, which employs up to 1,800 and has an annual capacity of 160,000 cars, is located in an arid, remote area with no receiving stream or municipal sewer available to discharge wastewater. Yet by using a combination of RO technology, a proprietary high-rate chemical softening process, the plant can convert up to 90 per cent of its tertiary wastewater into reusable water, leaving less than 10 percent of liquid waste for discharge into adjacent solar ponds for evaporation. MLD provides users with a spectrum of options to achieve the results most optimal for a particular plant, based on a variety of factors. For some, it could be 90 percent, for others, it could be 80 or even 70 per cent. Diversity of Dischargers – MLD Solutions The diversity of types of discharge 48 • February 2017
streams across industries, markets and municipalities calls for MLD solutions tailored to individual needs. Potential discharge sources and opportunities for MLD-driven improvement include
In the United States, which primarily has small-scale desalination plants, the primary locales for concentrate disposal are evaporation ponds and injection wells. But in much of Asia, given its population densities and environmental factors, surface- or injection-based concentrate disposal are not viable options. In such instances, a reverse osmosis system is typically used to pre-concentrate the brine. Newer technology enhancements for this process include disk tube reverse osmosis, in which an open-channel structure RO system is fed by a turbulent feed water flow system. Through this process, the system can avoid settling of suspended solids carried in the feed water inside the membrane module.
Cooling tower blowdown – in heavy industry and power plants Ion exchange regenerative streams – particularly in food and beverage processing Flue gas desulfurization – wet wastewater stream Municipal potable water systems – wastewater streams Process water reuse – from agricultural, industrial and municipal streams
Another newer technology variant is the use of forward osmosis, which uses a water permeable, salt-rejecting membrane to separate water from dissolved solutes. The driving force for this separation is an osmotic pressure gradient, so that a “draw” solution of high concentration (relative to that of the process feed solution) is used to induce a net flow of water through the membrane and into the draw solution. This process helps eliminate the need and use of high-pressure pumps and can thus potentially operate using a lower energy footprint than evaporative technologies.
In general, all of these discharge sources can be broken into two main themes: volume streams and complexity streams. A tailored approach for MLD will depend on whether it’s tackling a volume stream, a complex stream, or some kind of combination, as well as the geography.
Reduced CAPEX, OPEX and Environmental Impact The cost of membrane-based pretreatment and filtration technologies applied in MLD is relatively minimal compared with the exponentially greater capital and operating costs of ZLD-related Chemical Engineering World
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Evaluating MLD Needs So what is the best way to determine if your plant is a candidate for MLD? Often, the first step is to conduct a water audit to identify the sources and types of wastewater generated in a facility, especially in terms of flow and total dissolved solids content. By matching waste streams and appropriate water requirements, you can better identify how much wastewater (if any) requires processing and the approach that will most economically and sustainably match your plant’s needs. For e.g., some
wastewater sources, such as condensate and storm water require minimal cleaning while those with high concentrations of organic compounds, salts, metals and suspended solids, will likely require more rigorous treatment. Similarly, cooling water and process water do not need to be treated to the same standards as potable water. The most important factor is that an MLD approach enables your plant to address the substantial ‘limbo’ that exists between minimizing discharge, and go-for-broke ZLD.
environmental impact while reducing operating costs, the mill owners partnered with Dow Water & Process Solutions (DW&PS). As a result of this engagement, the research team in DW&PS developed a new product line called FORTILIFE™, which is designed to handle the most challenging water applications such as waste water reuse and MLD and give these applications the reliability and efficiency they badly need. With success of the existing pilots, the FORTILIFE™ products are now well on their way to be rapidly adopted by the industry.
Real-Life MLD Approach Benefits: India Due to considerable effluent discharge by the textile mills of Tiruppur, Tamil Nadu, the Madras High Court, in February 2011, decreed that all dyeing units in Tiruppur would have to shut down for violating pollution norms and would only be reopened when they implemented zerodischarge protocols in order to protect the surrounding farmlands and rivers. In their effort to comply with regulation, minimize
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Fei Wu Regional Marketing Manager- RO/NF Dow Water & Process Solutions
INSIGHT INTO THE PHARMACEUTICAL AND BIOTECH INDUSTRIES
evaporators and crystallizers. That’s why the advent of new technologies, such as disc-tube reverse osmosis and forward osmosis, is so important to users. They not only extend recovery but can also minimize or even eliminate the size or need for evaporators and crystallizers. Waste heat can be used from some of these operations to provide additional benefit to an MLD approach.
Jasubhai Media Pvt. Ltd.
For Details Contact
Jasubhai Media Pvt. Ltd. Taj Building, 3rd Floor, 210 Dr D N Road, Fort, Mumbai - 400 001 Tel: 022-4037 3636, Fax: 022-4037 3635 Email: industrialmags@jasubhai.com
50 2017 62 •• February October 2016
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Right Lubrication Enables High Reliability: Essential for all Vacuum Pumps
A
s a u s e r o r p o t e n t i a l bu ye r o f Vacuum Pump, It’s most important to accurately define gas contamination and percent for volume of gas to be pumped out. An impor tant feature of a Vacuum Pump is its ability to achieve the required outlet pressure regardless of the Molecular weight or gas composition. The compression process that starts should not change. If par ticular contamination of the Gas, Solid or Liquid exists in large quantities, Erosion and lubrication p r o bl e m s m ay r e s u l t . I t i s t h e r e fo r e necessary to install the required knock out, Separator and or Filters upstream of the Vacuum Pump inlet. Semi Dry Vacuum Pump is fitted with slide Vane and exhaust value. The contributed oil injection maintains the high efficiency of the Pump. These Pumps are generally constant speed Machines. Suction throttle capacity
control may be used for such pumps. Oil must be compatible with the gas. The lubricant usually determines the maximum temperature that the gases are allowed to reach. For mineral oil the maximum permitted temperature is 80o C to 90 o C. Some synthetic lubricants will permit higher temperatures almost upto 100oC. For Temperatures above 100o C the design of the Vacuum Pump should be carefully understood to ascertain the effect of thermal Growth / Expansions on the internal clearances. Mineral Oil Viscosity drops rapidly with rising temperature, but can also be affected by some gases, especially when temperature exceeds 80 o C. Synthetic lubricants can operate at higher temperature have high viscosity indices, can be used or are stable over larger Temperature range and are more chemically
stable and are being increasingly employed. Factors to be considered when selecting the lubricant include: •• •• •• •• •• ••
Oxidation Condensation Viscosity Foaming Separation Performance Chemical Reaction
Some of the associated problems can be solved with specially selected oil grades. Cost is usually a concern with synthetic oils. However the service and life much match of the lubricant and the lubrication requirements. For specific process and chemical services, some lubricant qualities should be sacrificed in order to obtain a fluid compatibility with the process gases. While the requirements may make such operations somewhat special, the life of the Vacuum Pump and its services can be greatly improved. O i l L u b r i c a t i n g P u m p s a r e r e l a t i ve l y new for chemical applications; therefore it is strongly recommended that all the auxiliary systems be thoroughly reviewed in the initial stage. Special care should be given to oil selection, Separator retention time, Proper Temperature Control, Cooler and Oil Filters, and Vendor experience for similar Applications.
Contact Details: Toshniwal Instruments (Madras) Pvt Ltd 267, Kilpauk Garden Road Chennai - 600010 Contact: +91 44 26445626 / 8983 Email: sales@toshniwal.net Website: www.toshniwal.net
52 • February 2017
Chemical Engineering World
Advanced Liquid Ring Technology The most advanced Manufacturing Technology in Liquid Ring Vacuum Pumps acquired over 70 years has created a new improved Liquid ring pump. It offers optimum performance and high reliability. Toshniwal leader in Vacuum Engineering over 40 years, now provide further solution to your vacuum needs.
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54 • February 2017
Chemical Engineering World
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Highest cost-effectiveness: in Pharma, Food, Dairy, - No pipe works Ceramic, Fertilizer and Chemical - No process shut-downs industries - Virtually maintenance-free
CEW Products Magnetic Level Indicator
Spray Balls
The operating principle is based on magnetic field coupling. Float chamber is typically constructed with non-magnetic pipe having process connections that matches to the vessel connections. Float size and weight is determined by the process fluid, pressure, temperature and the specific gravity of the process fluid. Float contains magnets to provide 360o
Cipriani Harrison’s fixed/ static spray balls are made from SS-316L are highly polished and have 2.5” and 3.5” dia balls. They come standard with a slip-pin connection for 1” and 1.5” size tubing. They are available in four different spray patterns for cleaning all types of tanks and process equipment.
It finds application in solvent tank, filler tank, brine tank, water tank, bulk storage tank, oil and crude tank, acidic and alkaline tank, etc.
Cipriani Harrison’s rotary spray balls are made from SS-316L and are highly polished and are suitable for 1” and 1.5” ISO/DIN pipe. Four different spray patterns are available for cleaning all types of vessels.
For details contact: Filpro Sensors Pvt Ltd No: 130, 10th Cross, Petechennappa Indl Estate Kamakshipalya, Magadi Main Road Bengaluru, Karnataka 560 079 Tel: 080-23286463 E-mail: sales@filprosensors.com
For details contact: Cipriani Harrison Valves Pvt Ltd 1901, GIDC, Phase IV, Vallabh Vidyanagar Vitthal Udyognagar, Gujarat 388 121 Tel: 02692-235082, 235182 Fax: 91-02692-236385 E-mail: info@harrisonengineers.com
magnetic flux field.
or Circle Readers’ Service Card 1
or Circle Readers’ Service Card 2
Digital TRMS AC/DC Clamp-On Multimeter Kusam-Meco offers a new digital TRMS clamp-on multimeter Model KM 2776 / KM 2777. It has features, functions and ranges never seen before in one digital clamp-on multimeter. It has 6,000/1,999 counts LCD display with 5/sec update rate. It can measure fundamental voltage and frequency of most variable frequency drives. It has CAT IV 1 KV high safety transient protection. The digital clampmeter has unbeatable 400 KHz DC + AC performance and VFD features. It has high basic accuracy of 0.5% (DCV) and resolution 1 mV DC. It has auto and manual ranging functions. Manual ranging function is not available in Hz and capacitance function range. To provide clear reading of the displayed value in the dark, it has backlight LCD display. It measures digital logic level duty cycle %, also measures digital logic level frequency up to 1 MHz. The voltage measurement is up to 1,000 V AC/DC with high impedance; also it can measure noisy high voltage AC frequencies up to 1999 Hz in dual display. It has dB function with 20 selectable reference impedance values. It has PC interface capability with optional purchase of USB cable with data recording software. It has temperature measurement, diode test, data hold, max, min. avg reading function. It can also read conductance thereby virtually extending the resistance measurement to the order of gigaohms (very useful for leakage measurements). It can do continuity tests at very fast speed. For process control industry it displays the process parameter in range 0-100% for 4-20 mA input. It has high speed capacitance measurement function up to 25 mF. It measures AC and DC current up to 10 Amps. It has transient protection up to 12 KV (1.2/50 µs) providing excellent protections for those who are safety conscious. It comes with a protective holster. It has fire retardant case. Optional magnetic hanger is also available. For details contact: Kusam Electrical Industries Ltd G-17 Bharat Indl Estate, T J Road, Sewree (W), Mumbai 400 015 Tel: 022-24156638, 24124540, 24181649 , Fax: 91-022-24149659 E-mail: kusam_meco@vsnl.net or Circle Readers’ Service Card 3
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Products CEW Fuel Optimizer An intelligent fuel optimizer unit SFO-904, optimises the usage of genset operations in telecommunication towers in the event of mains failure condition. Instead of turning on the genset immediately upon mains failure, it checks the shelter battery voltage condition as well as the shelter temperature before activating the starting of the genset. By the optimised usage of genset, this unit will reduce fuel consumption. This unit can be smoothly integrated to any AMF panel currently installed in telecom towers. It continuously monitors the EB supply healthy condition. In case of EB supply failure this unit will start checking the BTS battery voltage and shelter temperature. If either of the parameters found to be outside the set limits, this unit will issue command for starting the genset. Once the battery voltage or shelter temperature becomes normal then the fuel optimiser commands the genset to stop. 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 4
Clamp-Meter Kusam-Meco having 14 Models of clamp meters in their range for diverse applications offers a new clamp meter Model 2754A / 2754A-T (TRMS). This clamp meter is auto ranging and has many measuring functions with a wide range not available in most clamp meters. It has a display of 4,000 counts and a jaw opening of 50 mm. It is average sensing for Model 2754A; True RMS for Model 2754A-T. The measurement rate is 3 per second nominal. It has function display on LCD. It has transient protection up to 6.5 KV (1.2/50 uS) lightning surge and meets the requirements for CAT III 600 V AC and DC. It meets EMC requirements EN61326 (1997, 1998 / A1), EN61000-4-2 (1995) and EN61000-4-3 (1996) and IEC 61010-2-032 (2002), EN-61010-2032 (2002), UL61010B-2-032 (2003). It has overload protection in all ranges. The clamp meter 2754A / 2754A-T can measure current up to 1,000 A DC and 800 A AC; DC voltage: 400 mV/4 V/40 V/400 V/600 V; AC voltage: 400 mV/4 V/40 V/400 V/600 V; resistance: 400 ohm/4 Kohm/40 Kohm/400 Kohm/4 Mohm/40 Mohm; capacitance: 500 nF/5 uF/50 uF/500 uf/3,000 uf. It has function of diode test. It has data hold and max hold function. Backlight display function is available in Model 2754A-T. It has auto power off for increasing battery life and low battery indication. It is supplied with carrying case, test leads, batteries installed and operating manual. For details contact: Kusam Electrical Industries Ltd G-17 Bharat Indl Estate, T J Road, Sewree (W), Mumbai 400 015 Tel: 022-24156638, 24124540, 24181649, Fax: 91-022-24149659 E-mail: kusam_meco@vsnl.net or Circle Readers’ Service Card 5
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February 2017 • 57
CEW Products Fluid Bed Dryers Fluid bed technology offers several advantages such as no product lump formation/caking, no particle overheating/cooling, a well defined product residence time uniform product quality, better energy economy due to lower specific heat requirements, etc. In fluid-bed the material is suspended in an upward moving hot-air and the mass behaves like a boiling fluid after fluidisation. This is the state of fluidization. The fluid-bed dryers are most suitable for drying granular, crystalline, coarse or similar material. It is also possible to dry very fine crystals or very coarse material. The air is passed from the bottom of the container which has got perforations of SS fine wire mesh. Hot air passes through the product container and therefore the turbulence in the product is obtained and hence the product moves up and down in the product container. Due to this the heat transfer is very quick and the product is dried very fast without appreciable loss of heat. The fluid bed dryers are not suitable for drying liquids of pasty materials. The fluid bed dryer will be complete with 2,800 RPM, TEFC motor blower, control panel with timer, 2 temperature gauge, filter bag, SS-316 quality container with trolley and heater or steam radiator.
For details contact: Brilliant Process Machinery Pvt Ltd Unit No: 1, 2, 14 Mordan Indl Estate Opp: Ipol, Waliv Phata, Vasai (E) Dist: Thane, Maharashtra 401 208 Tel: 0250-3293636 E-mail: brilliantprocess@rediffmail.com or Circle Readers’ Service Card 6
Solar Power Meter Kusam-Meco offers a new professional grade solar power meter Model KM-SPM-11 which can measure the solar light intensity and solar radiation. A much needed product for checking the correct angle for installing the solar panels so as to get the max power generated from the solar panel. The KM-SPM-11 has a 3½ digit 2,000 counts LCD display. The sampling time is approx 0.25 second. The angular accuracy is cosine corrected to <5% for angles <60 o°. It has end mount light sensor for easy measurement and sensing. It has an extended measurement range of 2,000 W/m 2² 634/BTU/(ft 2 * h) with high accuracy within ±10 W/m 2² or ±5% whichever is greater in sunlight. It has high resolution of 0.1 W/m 2², 1 BTU/(ft 2² * h). Its main application is for use in solar radiation measurement for measuring the effectiveness of solar film, solar power research physics and optical, laboratories, identify high performance windows, car windows light intensity measurement, measurement of the sun’s transmission through transparent and film glass for energy saving. It has data hold/max/min function. Users can select either power or transmission functions depending on the requirement. The instrument is light in weight (approx 150 g). For details contact: Kusam Electrical Industries Ltd G-17 Bharat Indl Estate, T J Road Sewree (W), Mumbai 400 015 Tel: 022-24156638, 24124540, 24181649, Fax: 91-022-24149659 E-mail: kusam_meco@vsnl.net / sales@kusam-meco.co.in or Circle Readers’ Service Card 7
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Products CEW Tube Fitting Excel Metal & Engg Industries offers wide range of instrumentation fitting and valves for use in diverse range of industries and are capable to provide their customers with best possible solutions to meet their various requirements. The production process followed is of higher standards with its modern production and quality assurance facilities where due attention is paid at every level with maximum resource utilization. Excel Metal & Engg Industries offers tube fittings in size 1/16-2 in and 2-50 mm compression type double ferrule fittings, roll threaded construction in variety of configurations with excellent vibration resistance and leak-proof sealing, gauge-ability and retightening in SS, brass, carbon steel, alloy, etc. For details contact: Excel Metal & Engg Industries 177/181 J T Bldg, 3rd Kumbharwada Lane Mumbai 400 004 Tel: 022-23892476, 66394004 Fax: 91-022-23884109 E-mail: info@excelmetal.net / excelmetal@mtnl.net.in or Circle Readers’ Service Card 8
Blenders The blender is an efficient anti-versatile blending machine for mixing and lubrication process of dry granules and powder homogeneously. Two-third of the volume of the cone blender is filled to ensure proper mixing. It can be used for pharma, food, chemical, cosmetic products, etc. Customers can avail from their superior quality of pillar type bin blender. These column type bin blenders are also available in conta bin blender and bin blenders in the market. These pillar type bin used for mixing, lubricating and blending in pharma, nutraceutical, food, chemical, food industries, ceramics, pesticide, plastics and other allied industries of dry powder. It can perform homogenously dry mixing of free flowing powders, granules requiring low shearing force, mixing and blending of particles. For tablets, capsules, dry powder, injection and API manufacturing for efficient mixing/blending of dry powder granules.Highly effective for low volume active blending with a low as 1% active; processing of different size of production batched in single equipment with scale up data; docking and undocking of the bin; proxy sensors at entry door and other important parameters to avoid accidents; flexibility of accepting variable bin signs providing wide range of batch volume; cGMP construction with cladded SS sheets charging hole with cover is provided on top with quick opening and closing arrangements with dust-proof points for particle-free transfer. For details contact: Shefa Industries Gala No: 1, U K Quari Compound Gandhi Nagar, Vikhroli (W), Mumbai 400 083 Tel: 022-25942473 E-mail: shefaindustries@yahoo.co.in or Circle Readers’ Service Card 9
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CEW Products Hydraulic Pipe Fittings Excel Metal & Engg Industries offers wide range of instrumentation fitting and valves for use in diverse range of industries and are capable to provide their customers with best possible solutions to meet their various requirements. The production process followed is of higher standards with its modern production and quality assurance facilities where due attention is paid at every level with maximum resource utilization. Excel Metal & Engg Industries offers hydraulic pipe fittings socket welding and screwed types having pressure 2000, 3000, 6000, 9000 psi and ANSI and JIS Standards in SS, brass, carbon steel, alloys, etc. For details contact: Excel Metal & Engg Industries 177/181 J T Bldg, 3rd Kumbharwada Lane, Mumbai 400 004 Tel: 022-23892476, 66394004 Fax: 91-022-23884109 E-mail: info@excelmetal.net excelmetal@mtnl.net.in or Circle Readers’ Service Card 10
Customized Electronic Pressure Controllers or Circle Readers’ Service Card 10
Alicat Scientific has added two new families of electronic pressure controllers specifically for high volume OEM. The EPC family with single proportional valves and EPCD family with dual valves, provide customized pressure control in embedded systems. The small footprint instruments respond quickly to upstream fluctuations to provide fast, accurate control of pressure in an economical, easyto-integrate package. Alicat offers a choice of valves, valve orifices and process connections to fit customer specifications. EPC instruments are ideal for use in OEM gas chromatographs, fluidics dispensing for flow cytometry and anywhere responsive pressure control is needed. EPC and EPCD instruments have a 100 ms control response to still upstream pressure fluctuations in real time. NIST-traceable accuracy is 0.25% full-scale. The EPC family’s single proportional valve provides stable control of pressure in flowing applications, such as maintaining flow of carrier gas through the sample injection point in gas chromatographs. The EPCD features a second exhaust valve to provide efficient control of pressure in closed volumes, such as controlling the head space above a fluid for dispensing. Alicat offers NPT, SAE, downport and NeSSi process connections. Both digital (RS-232, RS-485, Modbus) and analogue (0-5 V, 0-10 V, 4-20 mA) communications are available to suit a range of end-user products. A choice in valve type and orifice allows for configuration to specific flow requirements for the best speed and stability. For details contact: Halma India Prestige Shantiniketan Gate No: 1, Tower C, 7th Floor ITPL Main Road, Whitefield Mahadevapura, Bengaluru, Karnataka 560 048 Tel: 080-67475300 E-mail: sunil.balan@halma.com or Circle Readers’ Service Card 11
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Products CEW Interactive Air-conditioning Solution Trane’s all new Interactive air-conditioner Series HW4 provides loads of Interactive features that optimize performance and enhance comfort, while providing energy savings, lower installed costs, reliable indoor air quality and overall superior system performance. The air-conditioner Series will be available in five variants. This highly efficient and sustainable solution features a reliable gold condenser along with bestin-class temperature reliability tested up to 52o°C. The unit also offers innovative and expanded system controls like multi-room control, which enable control of up to 18 Trane Interactive AC from one place and energy-efficiency meter which guides user to save power. HW4 Series is also compatible the Trane’s recent launched web gateway. Through web gateway HW4 Series models can be controlled through smartphone from anywhere through internet. For details contact: Ingersoll Rand India Plot No: 35, KIADB Indl Area, Bidadi, Bengaluru Karnataka 562 109 E-mail: airsolutionsindia@irco.com or Circle Readers’ Service Card 12
Inspection & Safety Services Precision Inspection Services is an emerging company in the field of third party inspection and safety. The company serves India’s leading and reputed companies. Vendor surveillance inspection provides the purchaser assurance that the receiving materials are met with the specified requirements. Precision’s experienced and competent team is capable to offer tank calibration services. Precision offer inspection of storage tanks in a construction shop and at site, as well as storage tank in service inspection in operational plants as per API 653 Standards. Their NACE Certified staff is experienced in commercial, industrial, architectural and institutional coating inspection, design and project management throughout India. They offer as per API 1104, API 5L, ASME Sec-IX, ASME B 31.3, AWS, BS and other codes and standards including welding consultancy and equipment consultancy. Precision offers innovative and cost-effective solutions for your mechanical integrity needs such as corrosion mapping, thickness monitoring, risk-based inspection, etc. Provide services for stagewise and final inspection of fabricated equipment along with inspection of bought out components required for the equipment. Precision offers inspection of goods being exported prior to the shipment by a mandated pre-shipment inspection agency. Precision offers shutdown inspection of most of the static equipment in a plant and offers various testing for all kinds of cranes and lifting tackles. Other services include testing and certification of plant/pressure vessels/pressure pipeline, lifting tackles and construction equipment, chartered engineer services, safety services, NDT serviccs, dimension inspection, design verification, AutoCAD services, expediting, calibration of instruments, valuation, etc. For details contact: Precision Inspection Services 2/52B, Vrindavan Society, Thane, Maharashtra 404 601 Tel: 022-25409654 E-mail: precision.india@gmail.com or Circle Readers’ Service Card 13
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CEW Products Manual Electric Stacker
Electric Lifting Platforms
JAY manual electric stackers are used for wide range of lifting and shifting palletizing load applications. These are battery-operated versions where lifting is effected by electro-hydraulic pump and is ideal for applications requiring frequent lifting and lowering of loads. The stacker’s forks are raised and lowered by pushbutton controls. Electro-hydraulic power pack unit in-built pressure relief valve prevents overload. The lowering speed of fork is controlled by flow control valve. The push/pull handle is spring-loaded for easy movement. Manual electric stackers are available in other options as wide version, load platform and roller platform and can lift up to a height of 4,200 mm with load capacity of 1,000 and 1,500 kg.
Electric lifting platforms are for exclusive handling only. No persons are allowed to travel in the lift cage/platform. The electric lifting platform is useful to transfer goods from one floor to another and the platform can be flushed with floor level when pit installed. It is ideal for stores and mezzanine area to transport material from one floor to another in a multi-level complex. ELP-10 design is offered with a single hydraulic cylinder. Hydraulic power pack with AC motor control panel and pendent stations form control functions of the lift. It is suited for weighted applications up to 1,000 kg and lift height up to 12,000 mm.
For details contact: Jay Equipment & Systems Pvt Ltd Plot No: 47, Survey No: 66/1, Sativali Road, Valiv Phata Village Valiv, Vasai (E), Dist: Thane, Maharashtra 401 208 Tel: 0250-6586749, 6454749, 6060749 E-mail: sales@jayequipment.com or Circle Readers’ Service Card 14
For details contact: Jay Equipment & Systems Pvt Ltd Plot No: 47, Survey No: 66/1 Sativali Road, Valiv Phata Village Valiv, Vasai (E) Dist: Thane, Maharashtra 401 208 Tel: 0250-6586749, 6454749, 6060749 E-mail: sales@jayequipment.com or Circle Readers’ Service Card 15
Peristaltic/Hose Pumps Shanbhag & Associates is the authorised, national distributor for the entire range of BOYSER hose pumps. We have introduced BOYSER laboratory and industrial peristaltic/hose pumps manufactured for the past 25 years by Bombas Boyser SL of Spain. A tubular element inside the casing is compressed by the rotary action of the rotor and its corresponding rollers or shoes; it recovers its initial shape creating a vacuum, thus suctioning the fluid into the hose. The fluid gets into the cavity formed by the rollers that press the tube and is gently pushed to the outlet by the following roller. Therefore, the pump is a positive displacement volumetric pump with exceptional features. Tubes are available in NR, NBR, EPDM, thermoplastics (Norprene, Hypalon, Chemsure, Silicone, Tygon) and food-grade (NR-A, NBR-A). End connections are available in SS, PP, PVDF in threaded, TC and flanged options. Casing can be provided HALAR coated to prevent damage in case of hose leaks. Hose leak detectors, vacuum for suction are optional features avail. Suction lift of up to 9 metres and can even run dry without damage; seal-less and silent in running; reversible rotation; resistant to abrasion and corrosion; dosing application of ±1% accuracy; easy to maintain and consumes less power compared to AODD pumps of similar application. Pump can deliver pressures to 15 bar. BOYSER pumps find application in transfer and dosing of chemicals, viscous liquids, sludge, lime slurry, mortar, filter press feed, clay slurry, carbonates, slurries, kaolin, paints, glues, inks, latex, pigment, oils, detergents, acids, peroxides, milk products, mayonnaise, meat products, fruit juices, etc. Dosing is accurate with very small flows For details contact: Shanbhag & Associates B-50 Nandbhuvan Indl Estate Mahakali Caves Road, Andheri (E), Mumbai 400 093 Tel: 022-40365700, 40365711, Fax: 91-022-40365712 E-mail: info@shanbhags.com or Circle Readers’ Service Card 16
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Products CEW Scissors and Maintenance Platforms JAY scissor lift is innovative handling equipment for loading/unloading operation, where difference in level exists between loading area and transport vehicle, machine bed, etc. This is a versatile equipment to bridge height differences and to move goods between different levels in production lines. It saves labour, eliminates accidents and maintains product quality on handling. Scissor lifts are made available in electric scissor lift, where the equipment in lowered position is pit installed, flushes with floor level, hence does not interrupt other movement when not in operation. Scissor lift table (mobile) are simple and compact in design, it makes almost any job easier and is useful wherever lifting, positioning, assembling, stacking/unstacking, transportation is concerned. Scissor work platform is a type of platform that usually moves vertically. It operates with electric lifting and manual push pull. It provides assess to 14,000 mm height with load capacity of 500 kg. For details contact: Jay Equipment & Systems Pvt Ltd Plot No: 47, Survey No: 66/1, Sativali Road, Valiv Phata Village Valiv, Vasai (E), Dist: Thane, Maharashtra 401 208 Tel: 0250-6586749, 6454749, 6060749 E-mail: sales@jayequipment.com or Circle Readers’ Service Card 17
Motorised Double Diaphragm Pumps The DELLMECO DME Series is an electro-mechanical double diaphragm pump which is highly energy-efficient. Instead of running the double diaphragm pumps on compressed air or Ni gas, which are the most expensive plant utility, Dellmeco offers energy-efficient electric geared motor as the driver for the double diaphragm pumps. The pump technology is especially designed for universal applications, which require low pressure up to 6 bar. Its compact, special design does not require hydraulic fluid and preventive maintenance is easy to carry out.The DELLMECO DME unique design concept and low energy consumption enable Shanbhag to combine hightech with proven reliability and quality for the most demanding of customers. DME Series pumps housing is machined from PE and PTFE conductive blocks and also in aluminium, cast iron, AISI 316 industrial and AISI 316 L hygienic combinations; temperatures up to 120°C; dry-running, low shear, versatile fluid handling capability, smooth product transfer; constant flow rate against variable pressure and viscosity; withstands highly corrosive chemicals; long life fully enclosed diaphragms; abrasion resistance with their robust design; capacity up to 650 l/min without variable freqency drive (VFD) flow control; optional VFD flow control for process performance (from 35-70 Hz); wide range of optional accessories available; etc. For details contact: Shanbhag & Associates B-50 Nandbhuvan Indl Estate, Mahakali Caves Road Andheri (E), Mumbai 400 093 Tel: 022-40365711, Fax: 91-022-40365712 E-mail: info@shanbhags.com, or Circle Readers’ Service Card 18
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February 2017 • 63
Water India 2017
2017 GlobalChem Conference and Exhibition
Dates: 10-12 May 2017 Venue: Pragati Maidan, New Delhi Event: This event showcases products, services and solutions available in the water industry worldwide. The event will provide comprehensive insight into the water industry–best practices, latest technologies, alternative solutions, emerging opportunity and business prospective.
Dates: 22-24 February, 2017 Venue: Washington D.C, USA Details: The event will include discussions about how the industry can support the U.S. Environmental Protection Agency’s efforts to effectively and efficiently implement key provisions of the LCSA; how the new law have a meaningful impact on consumer and marketplace confidence in the safety of chemicals; and, how the LCSA can serve as a risk-based model for chemical regulation internationally. Organiser: American Chemistry Council Contact: (202) 249-6500 Email: ashley_musselman@40americanchemistry.com We b s i t e : h t t p : / / w w w. c ve n t . c o m / eve n t s / 2 0 1 7 - g l o b a l c h e m conference-and-exhibition/event-summary-4d55dab517b94088a 0bef8c286526096.aspx
For details contact: Organiser: Exhibitions India Group Email: mumbai@eigroup.in Website: www.waterindia.com Contact No.: +91 9821062872 Machine Tools Engg & Technology Expo Dates: 12-14 May 2017 Venue: Brilliant Convention Centre, Indore Details: METEX caters to industrial products and equipment, heavy and light machines, engineering systems and services, industrial equipment and accessories, industrial technologies, software and hardware, and other parts and components. It is an exciting event that witnesses the best buyer and seller relationship, and brings out the best of products and services. For details contact: Organiser: Indore Infoline Pvt Ltd Email: info@indoreinfoline.in Website: www.ind-expo.com Contact No.: +91-731-2703000 Plastasia 2017 Dates: 08-11 July 2017 Venue: Pragati Maidan, New Delhi Det ails: This event has built a reputation as the ideal place to discover the latest innovations in plastics, live demonstration/s, share ideas and most impor tantly secure orders. Today, Plastics has become omnipresent and an integral par t of day-to-day activities. For details contact: Organiser: Triune Exhibitors Pvt Ltd Email: info@plastasia.in Website: http://www.plastasia.in/ Contact No.: 080 - 43307474 India Machine Tools Show Dates: 28-31 July 2017 Venue: Pragati Maidan, New Delhi Details: IMTOS a biennial event showcases path breaking ideas and innovation in machine tools, material handling and automotive technology. The show witnesses participation from over 500 companies every year.. For details contact: Organiser: K & D Communications Ltd Email: kandd@engimach.com Website: http://www.kdclglobal.com/ Contact No.: 079-26460624 64 • February 2017
China International Machine Tool Exhibition Dates: 9-12 March 2017 Venue: Tianjin Meijiang Intl Convention & Exhibition Center, Tianjin, China Event: China Tianjin International Foundary Heat Treatment and Industrial Furnace Exhibition is a major event based on the upcoming modern heating and furnace technologies and applications. Huge and advance varieties of products and services will be displayed in the event providing varied options of the visitors and exhibitors to fulfill their preferential requirements. Retailers, manufacturers and buyers associated with this sector will show their active participation in the conference. For details contact: Organiser: Tianjin Zhenwei Exhibition Co, Ltd Contact: Tel: +(86)-(22)-66224066, Fax: +(86)-(22)-66224099 Email id- events@sesallworld.com Website- www.sesallworld.com Tooltec Dates: 4-7 April 2017 Venue: Singapore EXPO Convention and Exhibition Centre Event: Tooltec will showcase wide variety of drilling and die casting based equipment and services associated with this field. Thus an event like this will gather all the eminent and distinguished exhibitors from this field and in turn they will showcase products and services like angle measuring devices, balancing systems, bending machines, blowers, dryers, boring machines, drilling and taping machines associated with this sector. Beside this the event will cordially invite all the eminent and distinguished experts from this field For details contact: Organiser: Singapore Exhibition Services Pte Ltd Contact: Tel: +(65)-62336638,Fax: +(65)-62336633 Chemical Engineering World
Project Update CEW New Contracts/Expansions/Revamps The following list is a brief insight into the latest new projects by various companies in India.
CHEMICALS M Chemicals proposes an expansion from 10-TPM to 35-TPM of its synthetic organic chemicals manufacturing unit in GIDC Sachin, district: Surat, Gujarat. The estimated cost of the expansion is ` 12-million. The current status of the project could not be ascertained. According to MoEF sources, EIA report has been prepared by Aqua-Air Environmental Engineers. The existing plant manufactures 10-TPM 6-Nitro, 1-Diazo, 2-Napthol, 4-Sulphonic Acid. The expansion entails addition of new products namely, 25-TPM G-Salt, R-Salt, Amido G-Acid, Aniline 2,4 DSA, Aniline 2,5 DSA, Para Nitro Chloro Benzoyl Sulphonic Acid, Sulfo Tobias Acid, Para Cresidine Ortho Sulphonic Acid, Schaffer’s Acid, Broenner’s Acid. Total plot area is approximately 1,650-sq m, out of which, 300-m 2 has been used for green belt development. 5-KLD effluent will be treated in-house ETP and 10-KLD effluent will be sent to common MEE of MEPL for evaporation.
Modvadar, district: Kutch, Gujarat. The current status of the project could not be ascertained. According to MoEF sources, existing products are 3-million sq m per month plywood, flush door, block board and veneer. The manufactured resin will be used for in-house consumption at the wood products plant. The project will come up on 11,603.62-sq m of existing land. The greenbelt area is 600-sq m. A base platform will be constructed for the resin plant; remaining will be MS structure.
Mamta Texdyes (Samba) proposes a synthetic organic chemicals manufacturing unit in GIDC Sarigam, district: Valsad, Gujarat. The project is spread over 2,250-sq m. The estimated cost of the project is ` 32-million. The current status of the project could not be ascertained. According to SEIAA sources, Eco Chem Sales Services is the environmental consultant. The proposed products are 200-TPM sulphur black grains, 300-TPM sulphur black liquid and the by-products are 250.1-TPM sodium thio sulphate crystal and 47.12-TPM sodium chloride salt. 700-sq m area has been proposed for green belt development. Industrial waste water will be treated in primary and tertiary treatment plant and treated waste water will be discharged into CETP Sarigam.
Eternis Fine Chemicals proposes an expansion of synthetic organic chemicals manufacturing unit from 42,200-TPA to 60,000-TPA in MIDC Kurkumbh, district: Pune, Maharashtra. The current status of the project could not be ascer tained. According to MoEF sources, total land area is 100,400-sq m and built-up area is 42,710-sq m. 33 per cent will be developed as green belt area. The project will entail: 1) capacity expansion of existing products and by-products; 2) addition of similar products and by-products; 3) introduction of new eco-friendly biomass boiler as replacement to furnace oil. Project involves manufacturing of fragrance from organic raw materials by chemical process like hydrogenation, esterification, Diels-Alder reaction, cyclisation, dehydrogenation, aldol condensation, etc, followed by distillation to match precise quality standards. By-products capacity will be augmented from 11,400-TPA to 20,000-TPA. The estimated cost of the project is ` 1,050-million. The power requirement 12,000KVA will be available through Government Electricity Board.
Resipol Adhesives proposes an expansion of synthetic organic chemicals manufacturing unit in village: Rajpur, district: Mehsana, Gujarat. The estimated cost of the expansion is ` 40-million. The current status of the project could not be ascertained. According to SEAC sources, the manufacturing of existing products, 2.0TPM benzyl alcohol, 1.1-TPM benzyl benzoate, 3.0-TPM benzoic acetate, 1.4-TPM sodium benzoate, 1.8-TPM sodium acetate will be discontinued and 300-TPM polyester resins (different grades) and alkyd resins (different grades), 90-TPM melamine formaldehyde resin and 85-TPM urea formaldehyde resin will be manufactured as new products. The plot area is approximately 6,033.00-sq m. Unit has proposed 2,000-sq m area for green belt development. Industrial effluent of 0.42-KLD after primary treatment will be evaporated in kettle type evaporator. Two DG sets each of 65-KVA will be provided. It was decided to recommend the project to SEIAA, Gujarat for grant of environmental clearance. Royal Wood proposes a 90-TPM phenol formaldehyde resin, urea formaldehyde resin, melamine urea formaldehyde resin and melamine formaldehyde resin manufacturing unit in village:
Panoli Intermediates (India) proposes an expansion of its specialty chemicals manufacturing unit and a new 10-MW coal-based captive power project in Unit-III, GIDC Nandesari, district: Vadodara, Gujarat. The estimated cost of the project is ` 100-million. The current status of the project could not be ascer tained. According to MoEF sources, the total plot area is 15,480-sq m. The capacity of isomers and DNCB such as 2:4 DCNB, 2:6 DCNB, 2:5 DCNB is to be augmented from 200-TPM to 2,200-TPM, or tho anisidine/para anisidine from 100-TPM to 1,100-TPM, or tho nitro aniline/para nitro aniline from 300-TPM to 2,300-TPM, isomers of DCA from 80-TPM to 1,080-TPM, isomers and DCNB such as 2:3 DCNB, 2:5 DCNB. isomers of DCNB such as 2:3 DCNB, 2:5 DCNB, 3:4 DCNB from 200-TPM to 2,200-TPM, H-acid from 50-TPM to 500-TPM and addition of a new product namely, 1,500-TPM derivatives of nitro phenol and a new 10-MW coal-based captive power project. 10-MW power requirement is to be met from MGVCL and 10-MW from the captive power project. The effluent will be treated in proposed effluent treatment plant.
Chemical Engineering World
February 2017 • 65
CEW Book Shelf Analysis, Synthesis and Design of Chemical Processes 4th Edition Authors : R. Turton, R. C. Bailie, W. B. Whiting, J. A. Shaeiwitz & D. Bhattacharyya Price : USD 125.26 Pages : 1104 (Hardcover) Publisher : Prentice Hall About the Book : This book presents design as a creative process that integrates both the big picture and the small details–and knows which to stress when, and why. Realistic from start to finish, this updated edition moves readers beyond classroom exercises into open-ended, realworld process problem solving. The authors introduce integrated techniques for every facet of the discipline, from finance to operations, new plant design to existing process optimization. This fourth edition adds new chapters introducing dynamic process simulation; advanced concepts in steady-state simulation; extensive coverage of thermodynamics packages for modeling processes containing electrolyte solutions and solids; and a concise introduction to logic control. ‘What You Have Learned’ summaries have been added to each chapter, and the text’s organisation has been refined for greater clarity.
Production Chemicals for the Oil and Gas Industry, 2nd Edition Author : Malcolm A. Kelland Price : USD 174.95 Pages : 454 (Hardcover) Publisher : CRC Press About the Book : This book discusses a wide variety of production chemicals used by the oil and gas industry for down-hole and topside applications both onshore and offshore. Incorporating the large amount of research and applications since the first edition, this new edition reviews all past and present classes of production chemicals, providing numerous difficult-to-obtain references, especially SPE papers and patents. The author then briefly discusses all chemical and nonchemical methods to treat the problem and provides in-depth descriptions of the structural classes of relevant production chemicals. He also mentions, when available, the environmental properties of chemicals and whether the chemical or technique has been successfully used in the field.
The Future of the Chemical Industry by 2050, 1st Edition Author : Rafael Cayuela Valencia Price : USD 79.96 Pages : 331 (Hardcover) Publisher : Wiley-VCH About the Book : Discussing the technological supremacy of the chemical industry and how it will adopt a leading position to solve some of the largest global challenges humans have even seen, this book details how the industry will address climate change, aging populations, resource scarcity, globality, networks speed, pandemics, and massive growth and demand. Following a detailed introduction to some of the megatrends shaping our world over the forthcoming decades, the book goes on to provide several scenarios of how the world could look by 2050, including ‘business as usual’ and a ‘sustainable’ one. 66 • February 2017
Industrial Catalytic Processes for Fine and Specialty Chemicals, 1st Edition Editors : Sunil S Joshi, Vivek V. Ranade Price : USD 200 Pages : 432 (Hardcover) Publisher : Elsevier About the Book : Industrial Catalytic Processes for Fine and Specialty Chemicals provides a comprehensive methodology and state-of-the art toolbox for industrial catalysis. The book begins by introducing the reader to the interesting, challenging, and important field of catalysis and catalytic processes. The fundamentals of catalysis and catalytic processes are fully covered before delving into the important industrial applications of catalysis and catalytic processes, with an emphasis on green and sustainable technologies. Several case studies illustrate new and sustainable ways of designing catalysts and catalytic processes. The intended audience of the book includes researchers in academia and industry, as well as chemical engineers, process development chemists, and technologists working in chemical industries and industrial research laboratories. Discusses the fundamentals of catalytic processes, catalyst preparation and characterisation, and reaction engineering; Outlines the homogeneous catalytic processes as they apply to specialty chemicals; Introduces industrial catalysis and catalytic processes for fine chemicals; Includes a number of case studies to demonstrate the various processes and methods for designing green catalysts Chemical Engineering World
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February 2017 • 67
CEW Interview INTERVIEW
“ C o n s u m e r- F o c u s e d R&D is the Future” Citing journey into product development for hair care category as an example, Dr. Sudhakar Mhaskar, Chief Technology Officer, Marico Limited shares his expert views on the Evolution and Critical role of R&D in the FMCG sector, Challenges to balance cost-efficiency with novel product development, Need for collaboration and the Trends in future for the growing consumer aspirations in FMCG in an exclusive interview with Mittravinda Ranjan. Share some insights on the evolution of R&D in the FMCG sector as the strongest driver for business growth? The role of R&D in any organised industry is to create future growth through innovations which satisfy consumer needs emerging out of evolution of society. The evolution can be in many spheres - economic, social, and cultural or exposures to new things. In FMCG, R&D is more challenging, as consumers experience the product first hand. In cosmetic industry, the challenges become more acute, as consumers wear the product on the body, in other words, there is an intimate experience with the products. In the FMCG space, the consumer buys a product to avail of a certain benefit and to also create an experience. In this case, the experience is functional, which is a tangible benefit, as well as sensorial, which is about 68 • February 2017
making a product acceptable for prescribed usage. This is where the role of FMCG R&D differs from a typical chemical research lab. The acceptance is based on meeting expectations from the product, which is out of a virtual image created in the consumers’ mind. This virtual image is created out of the past experiences, i.e. cultural beliefs, previous product experience, climate, etc. The role of R&D is to understand the consumer framework of product evaluation proactively, and imbibe it in the design stage. For instance, a consumer has used numerous hair oils while growing up, and based on his or her own experience formed an expectation from any new hair oil being launched. The name itself creates a list of requirements that the new product needs to attain. For example, Ayurvedic oil should be green, day hair oil needs to feel light, and rose oil needs to smell like rose.
Of late, product needs are changing at an ever-increasing pace due to the rapid evolution of consumer habits. Hence, it becomes critical for companies and their R&D teams to spend substantial time with consumers to understand their changing habits, which essentially requires a good amount of resource and time. How does changing consumer behaviour impact the FMCG sector, along with the role of R&D with new innovations coming to play, such as developments in product packaging and so on? How are companies responding to this massive change? As everything in life is moving to be quicker and more effective with time, it has not left the FMCG industry untouched. Specifically speaking about the personal care industry, there are three main trends that have emerged over time - effectiveness, faster Chemical Engineering World
Interview CEW to act and multifunctional. As the products evolve, consumers are demanding higher benefits and efficacy. The demand for higher potency is pushing R&D teams across the world to discover and synthesize new molecules. Consumers are also seeking greater results in a shorter time span. Additionally, consumers do not want to use multiple products for varied functional benefits. This has led to the generation of multi-functionality of benefits in products. For example, if a product provides hair nourishment, the consumer would also like to have anti-hair fall or maybe anti-dandruff benefits in the same hair care solution. Basis this demand, the evolution of BB, CC and DD creams have taken place. When consumers buy the product, the thinking process actually has many stages, called moments of truth (MOT). In the personal care industry, consumers experience their products in the real sense, only when they buy it and take it home. Hence the decision to buy the product, which is called ‘Trial’, is based on the touchsee process in the store. The packaging of the product, which is known as ‘First Love’ in consumer language, decides the success of trial stage. As a result of this, packaging in FMCG has gained immense importance along with many other attributes of the product. Packaging conveys to consumers its benefits, value, premiumness and utility. Packaging evokes emotions in consumers which compels him to select a particular product amongst various choices. Thus, the role of consumers in shape and design has been greatly emphasized and studied lately. In order to stay ahead of competition and also serve consumers better, R&D verticals are actually changing their operating model. The model is not to invent everything in the company, but leverage the strength of many others outside the company. So suppliers, vendors, institutions and trained experts are all roped in to make the innovation cycle faster and more effective. Research is being done at universities where the best of talent and infrastructure is available with the mindset of exploring the unknown. Changes in the bottom-of-the-pyramid are another occurrence in India. As affordability starts spreading across population, Chemical Engineering World
consumers wish to move to level-next or the higher-end product category. If you observe the consumers at the bottom-of-the-pyramid, people use basic material because of cost constraints. So, a user of unbranded soap would wish to move onto branded soap bars and perhaps further to an international one or body wash. In order to help this move, companies develop bridged products with intermediate cost and sensorials. How do you ensure affordability of products to the consumer? It is known that in a developing market, the affordability of the product drives penetration and consumption. Affordability for the consumer is not only the MRP, but it is the experience delivered by the product at its best benefit-cost ratio. This is also called Total Value for Money (TVM) which the consumer creates in his mind in a very unique way. There are many ways in which companies can achieve affordability. A very logical one is to reduce the cost of the product formulation and packaging. Several companies have on-going cost effective programs not only around product mixes, but across the entire value chain. The cost effective programs in Marico has yielded us good savings in packaging raw material cost. Other way, is to make Low Unit Price (LUP) packs which is highly prevalent in most developing countries. The entire sachet market in the shampoo category is borne out of this consumer angle. This helps consumer to buy for an occasion or for a shorter period rather than investing in larger packs. It enables aspirational consumers to experience product at a lower outlay. The small product grammage also allows consumer to get fresh product at regular intervals and also allows them to switch the product if they do not like the one in use. Another aspect that consumers look at is multi-functionality. As mentioned before, the new trend in skin creams is that of multi-functional creams like BB, CC and
DD creams. It enables consumers to save their expenditure on separate products for different benefits. How important is it for the marketing team to work out on a plan to create consumer awareness, considering there are many products in the market and each product is looking at creating a differential? How does marketing work towards projecting the relentless efforts of R&D in the right light? In any FMCG company, the convergence point of Marketing and R&D is the end consumer. Suffice to say it is imperative that marketing and R&D teams need to understand the consumer and his requirements in depth. Many personal care products are launched every year, possibly in thousands, but very few succeed. It is therefore pertinent for products to be distinct and differentiated. Marketing actually understands the market construct in terms of product benefits, positioning and the value equation. This is the basis for identification of a new space for creating a differentiated product. On this brief R&D makes the product and tests with consumers in the market. The product can be great in delivering the benefits, but if the saliency and relevance of the benefit is not called out to the consumer, the win is elusive. Marketing needs to know the pulse of their target consumers and communicate the product’s benefits in a very effective way. This needs development of some specific clinical protocols, certain sensory cues or simple diagnostic tools. However this should be understood by and relevant to the target consumer. Have there been any incidents wherein information from the consumer has been brought to the marketing, where R&D teams have worked on it to develop a new product or come up with a new formulation? It is a tradition in India to use coconut oil for dry skin in winters, as it moisturises the skin and if used before bath, reduces the dryness of skin. But this tradition has been relegated only to the low-end consumers since progressive consumers demanded sophisticated products like body lotion for sensorial experience and functional benefits. Market research findings highlighted that February 2017 • 69
CEW Interview there were 2-3 players that dominated the market. It was of paramount importance to thus create a product which will have a unique differentiator. How do you develop a product that exactly meets your consumer demands? How do you know what the consumer is actually looking for and what is the miss in the currently available products? Consumer research indicated the limitations of existing products in meeting the holistic expectations from a body moisturiser. A unique product containing coconut oil which could withstand the tropical as well as dry climates in India along with delightful sensorial, was thereby created. The product, today, is a market success. The best way to create a new product in any category is to target dissatisfied consumers or lapsers as these are the ones who are still using your product despite being dissatisfied. They are crucial because they have a need which the existing products do not satisfy. Does the above mean, some formulation/ modification has already been done, which is not equal to developing a new product from scratch? This depends on the type of product and business objective. If the objective is to make a product for premium consumers, there is some cost advantage; hence you can take liberty of building on the existing formulation. However, if the objective is to create a product for the mass consumers or a low cost product for the current category, the ZERO based approach is adopted. At Marico, we have successfully implemented a new model Called “Connect and Develop” where the intellectual property created by several people outside the company is tapped and brought into the company. In this model you leverage the global efforts and save the time required to create within the company. Is Marico collaborating with other R&D institutes such as those by the GoI to source new information from outside or collaborating with academia, or reaching out to students trained at R&D in the company? We, at Marico, have three types of collaborations in seeking new knowledge 70 • February 2017
from outside. We have a research advisory committee comprising of senior university professors and retired industry experts to guide us through the science/product development process. Secondly, since we cannot run all types of basic research programmes at our R&D centre, we sponsor projects at selected technical institutes. The third collaboration is for infrastructure support and capability. We work with many laboratories in India and internationally, who have specific sophisticated instruments. These facilities enable us to solve the critical business problems quickly. When you ship products to International markets, what is expected of the R&D at Marico? We are an international organisation, operating in 6 to 7 countries. In every country, the consumer ethnicity, culture and usage patterns are different. At Marico, we create capability in every region to understand the consumer habits and behavioural patterns. Product creators have to pick these consumer patterns and understand them, because it is critical for product design development. Also Marico has two regional technology centres in South East Asia and the MENA region. Whichever place the product is created; it is always tested on target consumers in that country. This is important as the sensory requirements are different across geographies. Are there any business collaborations with other firms in International markets, to push the products not from an R&D perspective but from a marketing and distribution viewpoint? Marico has acquired companies across developing regions in its course of inorganic expansion. These companies had their own products under different brands in the host countries. When the integration is completed, the GTC of Marico looks at these products several times for learning and in a few cases for improvement.
If you look at the future in terms of products, focus on naturals is growing as consumers are increasingly becoming conscious of the health cons of using excessive chemicals. Therefore, Naturals is an area which is booming with new opportunities, and the presence of Ayurveda makes the journey in India possible and challenging at the same time. The beauty from within, i.e. through foods, is catching up in the western world. Nutrition is linked to overall health and hence it will also deliver beauty and wellness. New concepts like pollution prevention, epigenetics and genomics are making an entry in order to make new-age personal care more scientific and also cause-targeted. As the longevity is increasing in India, senior consumers will demand products with specific benefits for them. Customisation is a new trend which is picking up as every consumer feels that he has a different physiology and therefore needs a different product. Cost-efficiency is a trend which is going to stay in the country for long, because most people belong to the bottomof-the-pyramid. Also, premiumisation on products is another trend to be witnessed soon in terms of better sensorial, naturals, multi-benefits and short-time. Tell us more about the Marico Science Day? Marico Science Day is an activity which started about four years ago to attract experts from outside to share their rich experience in Science and Technology, the theme being “Science inspired by Science”. Many eminent speakers from the different science streams have spoken at this forum. On this platform, our senior partners from R&D also speak and exhibit possible new directions for the business.
What will be the future of FMCG and the role of R&D to drive the business? The future trend in the FMCG sector is all about seeking higher benefits at a lower cost, incorporating multi-benefits and shorter time frames for benefit delivery. Chemical Engineering World