CEW JULY 2016

CHRONICLING PROCESS INDUSTRY INNOVATIONS SINCE 1966

EPC Special Mumbai 2017

14-17, February 2017 Mumbai, India

VOL.51 | ISSUE 7 | JULY 2016 | TOTAL PAGES 80 | US $ 10 | ` 150

Chemical Engineering World

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

EDITORIAL

Editor Editorial Advisory Board Contributing Editors Assistant Editor Sub Editor

Maulik Jasubhai Shah Maulik Jasubhai Shah Hemant Shetty 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 Harshal Y Desai (harshal_desai@jasubhai.com) Bernard Rapose (bernard_rapose@jasubhai.com)

Design Team

Arun Parab

Subscription Team Marketing Co-ordinator Production Team

Dilip Parab Brenda Fernandes V Raj Misquitta (Head), Arun Madye

VOL. 51 | ISSUE NO. 7 | JULY 2016 | MUMBAI | ` 150 NEWS Industry News 12 Technology News 24

NEWS FEATURE Excellence in Project Execution 26

Place of Publication: Jasubhai Media Pvt Ltd

Navigating Innovatively in a Competitive World 30

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SALES

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Amit Bhalerao (amit_bhalerao@jasubhai.com) Prashant Koshti (prashant_koshti@jasubhai.com)

FEATURES An International EPC Company for Operating in Indian Space 32

MARKETING TEAM & OFFICES Mumbai

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8 • July 2016

- Sunder Kalyanam - Petrofac “Stability in Oil Prices Should Unlock Investment Decisions at Global Level” 36

- Scott Hughey, KBR KBR: A Global Technology Company 41 Recheck Your Heat Integration Project – Is It Really Energy Efficient? 43 - Ashish Wanjari – Aker Solutions Connecting IT with Operational & Engineering Technology for Asset Performance Modeling 47

- Bhupinder Singh & Anne-Marie Walters - Bentley Systems Asset Data Management & Integration Support - A Physiological Project Need 51

- Mayuresh Mokal & Dr Pratap Nair - Ingenero

Continued On Next Page...

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 Contents Stage- gate Process and Criticality of Front End Loading 54 - Shailesh Dhume – Infuse Consulting Mapping the Way to Controlling Nuisance Noise 57 - Arne Berndt – SoundPLAN GmbH

February 14 -17, 2017 Venue: Bombay Convention & Exhibition Centre Goregaon (East), Mumbai, India

Leadership MARKET INSIGHTS “Collaboration is the Key”- Resil Chemicals 59

Mr B Narayan, Group President (Procurement & Projects), Reliance Industries Chairman - CAB, EPC World Expo 2017

MARKETING INTIATIVES Bhastrik Mechanical Labs: Contribute to the Success of Customers around the Globe 61 Applying Vacuum in the Process Industries Solution from the Experts 62 High Quality Rubber Components with Modern Vacuum Technology 64

SPECIALTY

PRODUCTS

66

EVENTS

71

PROJECT UPDATE

72

WORLD EXPO 2017

Dr Raman Ramachandran, CMD, BASF India Ltd & Head - South Asia, Chairman - CAB Speciality Chemical World Expo 2017

BACK OF BOOK BOOK SHELF 74

Dr Deepak Parikh, Vice Chariman & Managing Director, Clariant Chemicals India Pvt Ltd, Vice Chairman - CAB Specialty Chemical World Expo 2017

AD INDEX 75 INTERVIEW 76 Getting Future Ready

Mr Rupark Sarswat, Managing Director Croda Chemicals (India) Pvt Ltd & Chairman, Sponsorship Committee Specialty Chemical World 2017

- B K Namdeo, Director - Refineries, HPCL

Mr G S Jha, Chairman - Central Water Commission, Ministry of Water Resources, Govt. of India Technical Chairman, Central Advisory Board, WaterEX World Expo 2017

Mr A B Pandya, Former Chairman, Central Water Commission, Ministry of Water Resources, Government of India, Convener, Central Advisory Board, WaterEX World Expo 2017 Concurrent Events

10 • July 2016

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

Chemical Engineering World

Committed to CHANGING LIVES The paint that brightens and protects our walls, the computers that we use to communicate, work and play, the cars that give us mobility; almost everything around has a bit of Dow in it.

2015

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Jaipur Foot. For 10 years now Dow India and NGO Bhagwan Mahaveer Viklang Sahayata Samiti (BMVSS) have been using science and humanity to help people get back on their feet.

This May, for the first time Dow India is taking the Jaipur Foot overseas. The camp in Dhaka, Bangladesh is the first step in helping people the world over fulfill their potential.

2010

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2016 marks 10 years of the polyurethane (PU)

2016

CEW Press Release Mandaviya Takes Charge as Minister of State for Chemicals & Fertilizers

Simon India Commissions 2000 TPD Sulphuric Acid Plant

New Delhi, India: Mansukh L Mandaviya will be the new Minister of State in the Ministry of Chemicals & Fer tilizers in New Delhi.

New Delhi, India: Simon India Limited, a leading EPC company and a part of Adventz Group, successfully commissioned 2000 TPD Sulphuric Acid plant at Paradeep Phosphates Limited, Paradeep, Odisha on EPC basis. The project also included a 23 MW HP steam based Captive Power plant and associated utilities systems. The unit is one of the few of its kind in India having an integrated heat recovery system licensed from Dupont MECS, USA. The scope of work included extended basic engineering, detailed engineering, procurement, supply, erection & construction and commissioning assistance. The unit was commissioned in first quarter of 2016.

After assuming the charge, speaking to media persons, Mandaviya said that in the last two years, there has been a dramatic improvement in the socio-economic conditions in the countr y. On the issue of fertilisers, he said that it is now available abundantly and in time.

Mandaviya said that he would work to improve the conditions of farmers and the common man, and would strive to rise to the expectations of the visionary Prime Minister Shri Narendra Modi.

Mansukh L Mandaviya is from Gujarat, elected to the Rajya Sabha in April 2012. He had been a member of Gujarat Legislative Assembly from 2002-2007. Mandaviya had earlier been a member of the Committee on Petroleum & Natural Gas, National Welfare Board for Seafarers, Committee on Chemicals & Fertilizers and also a Member of Select Committee of Rajya Sabha on Real Estate (Regulation and Development) Bill. As a Gujarat lawmaker, he has served the state as chairman of Gujarat Agro Industries Corporation Ltd. He was sworn-in as Minister of State in the Union council of ministers on 5th July, 2016.

Bentley to Advance Piping and Vessel Design with Expanded Global Design Code Coverage Mumbai, India: Bentley Systems has announce additional design code updates for the CONNECT Edition applications of AutoPIPE and AutoPIPE Vessel. These design code updates will reduce the cost and time to produce compliant piping and vessel designs for any plant project. AutoPIPE and AutoPIPE Vessel provide comprehensive design code coverage, ensuring project compliance anywhere in the world.

The addition of ASME B31 J to the CONNECT Edition of AutoPIPE will provide comprehensive design code coverage for users in the oil and gas industry, including those designing offshore structures.

The updates to the CONNECT Edition of AutoPIPE Vessel will enable users to stay current with the latest global code updates and address requirements in the Chinese market.

AutoPIPE allows users to save time and reduce errors when performing pipe stress analysis by offering a comprehensive set of design codes that EPCs have been relying on for more than 20 years. AutoPIPE Vessel offers comprehensive software for optimised pressure vessels, heat exchangers, air coolers or tank design, allowing engineers to deliver safer, faster, more costeffective vessel designs.

12 • July 2016

One of the main challenges was to engineer to accommodate and construct the plant within a limited plot size in an existing operating plant. The challenge was successfully met. Being located in the cyclonic zone, the plant is designed for wind velocities as high as 270 km/hr and two cyclones in consecutive years were experienced in the region during the construction phase without any mishap.

Solid Edge ST9 Software Provides New Cloud Capabilities for Fast and Flexible Deployment Mumbai, India: The latest release of Siemens’ Solid Edge software (Solid Edge ST9) for mainstream Computer-Aided Design (CAD) provides flexible and easy access to the full capabilities of Solid Edge with cloud-based licensing, user preferences, and collaboration tools. In addition, the new built-in data management capabilities, with zero IT suppor t requirements, enable users to easily index their CAD models, while the new migration tools enable rapid conversion of legacy design data from virtually any CAD system. For more comprehensive data management capabilities, Solid Edge ST9 facilitates an easy upgrade to Siemens’ Teamcenter portfolio; the world’s most widely used digital lifecycle management software.

Solid Edge ST9 also offers significantly enhanced integration with Teamcenter to help simplify completion of critical data management tasks.

N ew c l o u d c a p a b i l i t i e s p r ov i d e fa s t e r a n d m o r e f l ex i bl e deployment options, improved user access and collaboration across remote designs teams. Licenses and user preferences can be stored on the cloud enabling users to access their personal environment anytime and anywhere. Solid Edge ST9 also adds data storage options via cloud-enabled vaulting so users can store and share design data in a controlled manner with external suppliers and customers, using popular software like Dropbox, OneDrive software, Google Drive online storage service and Box. While this allows users to efficiently work online, the option to work locally, i.e. offline, is always available. (Visit www.siemens. com/plm for more) Chemical Engineering World

CEW Industry News Vikas EcoTech Starts PVC Stabiliser Plant

LANXESS Presents New Trends in Leather

Ahmedabad, India: Vikas Ecotech - an emerging player in the global arena of the high end specialty chemicals players – has started the construction of phase I of its manufacturing plant and innovation center at Dahej, Gujarat. With an investment of about Rs 30 crores, the plant will produce 6,000 MT of organotin stabilisers (methyl tin mercaptide or MTM) and 5,000 MT of specialty polymer compounds annually.

Mumbai, India: Specialty chemicals company LANXESS, a world-leading manufacturer of leather chemicals, is unveiling leather trends for the upcoming 2017/18 season. The articles it is presenting reflect the future of leather fashions in terms of colours, structure, haptics and overall appearance.

While commenting on the development, Vikas Garg, Managing Director, Vikas Ecotech Limited, said, “The Dahej facility is in sync with our growth strategy of being near to customers and also producing premium specialty chemicals. With this facility, we will serve domestic customers in the twin markets of West and South India in lesser time and also reach our international customers faster. In FY 2015-16 exports contributed 48 per cent to our total sales and grew from ` 76 crores in FY 2014-15 to ` 149 crores.

The Dahej plant is of strategic importance, to cater to premium international markets and also to the imminent domestic demand for eco-friendly lead-replacement alternatives.”

As an integrated, multi-specialty product solutions company, it produces a wide variety of superior quality, eco-friendly rubber-plastic compounds and additives. Its rubber-plastic compounds and additives are process critical and value enabling ingredients used to manufacture a varied cross-section of high-performance, environment-neutral and safety-critical products.

Somani Group May Buy Stake in German Specialty Chemicals Company Mumbai, India: The Indian Somani Group has been reported to have submitted a non-binding letter-of-intent to become a shareholder in the company in the context of a financial restructuring, revealed the executive board of SKW StahlMetallurgie Holding AG. The Somani Group belongs to the famous Somani family of India. It was established in 1696 A.D. as a banking business. Subsequently trading and manufacturing activities were added.

According to the statement, Somani Group has proposed that a transaction should entail a significant reduction of the registered capital and a subsequent capital increase against cash with subscription rights for the shareholders. The letter-of-intent stipulates that the execution of the capital increase against cash is guaranteed by the Somani Group (‘backstop’) under the condition that the Somani Group is to hold at least 51 percent of the shares of SKW after the transaction.

The statement from SKW states that the negotiations are in a very early stage, and it is not secured whether a transaction with the Somani Group for the financial restructuring of the company is going to materialise.

14 • July 2016

At the company’s own competence center for upper leather in Santa Croce sull’Arno, Tuscany, Italy, LANXESS technicians and designers are busy creating future fashion collections 18 months in advance. After an inspiration phase, they choose the colors that are to characterise the leather collection. In the next step, the LANXESS experts develop the corresponding leather articles and recipes, and then present them to customers individually.

This approach enables tanneries to prepare for implementing these trends. They also are provided with valuable, practical application tips. The major trends for the Fall/Winter season 2017/2018 are: Autunno Rosa with bright red and pink tones, Transizione Verde, dominated by the colour green, Paesaggi Invernali with a variety of colour tones, and Scuro de Inverno, with primarily dark tones.

Ethanol Blending to Go Up to 22.5% New Delhi, India: According to Road, Transport and Highway Minister, Nitin Gadkari, government will soon come up with a new policy on non-conventional resources as it plans to take up ethanol blending in petrol to 22.5 per cent and in diesel to 15 per cent.

Gadkari informed that government is planning to take the blending limit of ethanol in petrol to 22.5 per cent and diesel to 15 per cent, as also second generation ethanol production from bamboo, rice straw, wheat straw, cotton straw etc to power vehicles. He also stated that if the government start making ethanol from bamboo in North-East, lakhs will get employment and several industries will come up.

Ethanol production could cut India’s huge crude oil imports bill, which is pegged at ` 7 lakh crore per annum.

AP PCIPIR Location Not Yet Finalised New Delhi, India: According to Joint Secretary, Union Ministry of Petroleum and Natural Gas, Sushma Rath, Petroleum, Chemicals, Petro-chemical Investment Region (PCPIR) will certainly come up in Andhra Pradesh and there is no rethink on the project. She, however, said that the location is yet to be finalised. She confirmed that the PCPIR will be in Andhra Pradesh state and agreed that there are certain issues to be resolved, and it is not yet finalised whether it should be in the Visakhapatnam-Kakinada region, as originally envisaged, or near Machilipatnam.

Chemical Engineering World

CEW Industry News Esdee Paints buys stake in Ethiopia-based Firm Mumbai, India: Esdee Paints Limited has acquired 50 per cent equity shares in Ethiopia-based Jelaram Pvt Ltd. Both the companies will form a joint venture to set up a manufacturing unit at Ethiopia. Esdee informed that it will jointly set up a manufacturing unit along with Ethiopian player, which is the sixth largest manufacturer of decorative paints in the country.

The company did not share the financial details of the deal.

Mahavir Dawra, MD of Esdee said that the company had invested in the acquisition of stake in the unit, which shall be utilised for setting up manufacturing activities in the Ethiopian unit. Esdee Paints Limited is a leading paint manufacturing company in India having excellence in Polyurethane Paints, Putties, Epoxy Coatings, High-Performance Coatings, specialised coatings such as UV coatings, Glass Coatings etc. Esdee Paints also develops tailor made products for OEMs.

Black Rose Industries to Expand Acrylamide Plant Mumbai, India: Black Rose Industries Ltd was established in 1990 as Asia Fab Limited, a textile manufacturing company.

Now, Black Rose consists of three main divisions – chemicals, acrylamide, and textiles. The chemical division is engaged in the import, distribution, and export of a wide range of specialty and performance chemicals.

The acrylamide division operates India’s first and only acrylamide manufacturing plant. The textile division manufactures fabrics and made-ups for industrial applications. The company also has a fully owned subsidiary in Japan, B.R. Chemicals Co., Ltd., Japan.

IPL to Procure 7 Lakh Tonne Potash Mumbai, India: JSC Belarusian Potash Company will supply 700,000 metric tonne (mt) of potash to Indian Potash Ltd (IPL). The potash supply contract to the Indian market in 2016-2017 fiscal year was signed at USD 227 per tonne on a cost and freight (CFR) basis with 180 days credit. As per the agreement, Belarusian Potash will begin the shipment of the product at a new price from July 1, 2016.

According to Elena Kudryavets, Director General, JSC Belarusian Potash Company, India is an important market and the agreement will promote stability in the region.

Indian Potash Limited was incorporated under Indian Companies Act with the objective of import-handling, promotion and marketing of Potash in the entire country. The extension and promotional activities of IPL was recognised by the farmers across the nation, and was well appreciated by the Sivaraman Committee on Fertilisers as well as the National Commission on Agriculture.

16 • July 2016

AP Signs 10k-crore deal for Gas-based Fertiliser Project Hyderabad, India: The Government of Andhra Pradesh has signed an agreement (MoU) with a consortium, which includes ChinaHuanqin Contracting and Engineering Corporation, LEPL Ventures Private Limited and Isomeric Holdings, to set up a gasbased fertiliser project at Krishnapatanam. The government is planning to invest about ` 10,183 crore. The MoU was signed in China during the World Economic Forum’s 10th annual meeting of New Champions in Tianjin which was attended by Chief Minister N Chandrababu Naidu.

ChinaHuanqiu, headquartered in Beijing, is an affiliate of China National Petroleum Corporation (CNPC). Isomeric Holdings is a Malaysian company and LEPL is a infrastructure company that also runs an airline. The company is based in Vijayawada.

Asian Paints to Setup New Manufacturing Units Mumbai, India: With an investment of about 4000 crore rupees, Asian Paints, one of the leading paint manufacturing company in India, is planning to set up two manufacturing units Karnataka and Andhra Pradesh. According to media repor t, the company has finalised the land procurement process in both states in the previous financial year, and has taken possession of the land. According to Ashwin Choksi, Chairman of Asian Paints, The organisation would be investing in both these facilities to enable it to service the future demand adequately.

Grace Agrees to Purchase BASF’s Polyolefin Catalysts Business Columbia: W. R. Grace & Co has announced that it has signed an agreement to acquire the assets of BASF’s Polyolefin Catalysts business. The transaction is expected to close in the third quarter of this year pending regulatory approvals, required consultations with employee representatives, and other customary closing conditions. Terms were not disclosed. Grace is a leading supplier of polyolefin catalysts technology, as well as polypropylene (PP) process technology. Grace has the broadest portfolio of polyolefin catalyst technologies of any independent catalysts producer.

B A S F ’s Po l yo l e f i n C a t a l y s t s bu s i n e s s i n c l u d e s i t s LY N X high-activity PE catalyst technologies that are utilised commercially in slurry processes for the production of high-density PE resins such as bimodal film and pipe. LYNX PP catalyst technologies are used commercially in all major PP process technologies including slurry, bulk loop, stirred gas, fluid gas, and stirred bulk.

The acquisition includes technologies, patents, trademarks, and production plants in Pasadena, Texas and Tarragona, Spain, as well as approximately 170 employees globally.

Chemical Engineering World

CEW Industry News Solvay and Suzano Papel e Celulose to Build Hydrogen Peroxide Plant

JX Nippon Unveils Engineering Design for Polyisobutylene Plant Expansion in Japan

Brussels, Belgium: Solvay and its affiliate Peroxidos do Brasil have agreed with Suzano Papel e Celulose to build a small dedicated hydrogen peroxide production unit using Solvay’s myH2O2 technology, at Suzano’s pulp mill site in Imperatriz, Maranhão, Brazil.

To k yo , J a p a n : JX Nippon Oil & Energy Cor poration has announced that it has launched Front End Engineering Design for Polyisobutylene (hereinafter called “PIB”, product name “Tetrax” and “Himol”) plant expansion.

Walter Schalka CEO of Suzano Papel e Celulose

This is the first agreement that Solvay has signed for its myH2O2 peroxide technology, developed for installation at remote customer premises. This unit will use Suzano’s hydrogen feed-stock, utilities and site services and supply all of the site’s hydrogen peroxide needs for pulp bleaching.

It will be controlled from Solvay’s peroxides plant in Curitiba, about 2,700 km south of Imperatriz.

“We believe that this technology will help us to be more competitive and efficient, as it will allow us to reduce costs in the purchase of an important input that we bought from another state. The forecast volume includes our increased capacity, which will be implemented in 2017,” said Walter Schalka, CEO of Suzano Papel e Celulose.

GTM Holdings acquires Mexico’s High Chem Specialties Mexico: GTM Holding, S.A. (GTM) has announced that it has agreed to acquire a majority ownership interest in High Chem Specialties in Mexico. High Chem Specialties, a distributor of specialty chemicals, primarily serves the domestic Mexican market with a range of services in the graphic arts, construction, coatings, plastics and adhesives industries, amongst others.

The transaction is expected to close in the third quarter of 2016, subject to regulatory clearances. Terms of the agreement were not disclosed.

High Chem Specialties was founded in 2002, and today, is one of the most recognised distribution companies focused on the specialty chemicals industry in Mexico. In 2015, the company generated sales of approximately USD 40 million.

This acquisition will enhance GTM’s service capabilities in Mexico and the rest of Latin America and is aligned with the company’s strategy to offer a robust line of products and services to its customers. “The acquisition of High Chem Specialties supports our vision of creating a leading regional platform for GTM’s integrated and innovative solutions and services in the Americas”, explained GTM’s Chairman and Chief Executive Officer, Michael van Marle.

“In addition to expanding our footprint with more service centres in Mexico, High Chem Specialties has an expertise in application and formulatory services that can be applied to other markets where GTM has a presence.

20 • July 2016

PIB is transparent non-noxious high-viscosity liquid which is used for sealing compounds of multi-layered glass and medical use adhesive, etc. We have developed the PIB business based on original technology since 1980 in order to add value to C4 fraction (By-product of Ethylene plant) at Kawasaki, Japan.

Since the company has been strongly worked for the improvement of PIB technology over thirty five years, its PIB is highly evaluated by global customers on its quality. Currently, it has PIB plant which has production capacity of 7,000 tons/year, compared with 35,000 tons/ year (our estimation) of the global demand for PIB. The demand is forecasted to increase in Asia and over the world.

To respond to the demand for the long-term supply sustainably, the company will proceed to the further detailed-Feasibility Study to construct the new 5,000 tons / year of PIB plant. It will advance the presence of our PIB business by improving the quality, developing the applications and reinforcing the stable supply structure to support our customer’s business.

Monsanto, Sumitomo Chemical Enter Crop Protection Collaboration Missouri, USA: Monsanto Company and Sumitomo Chemical Company, Ltd announced a new global agreement that will focus on developing and delivering next-generation weed control solutions to further help growers manage tough-to-control weeds.

Monsanto has a robust pipeline of multi-generational herbicide trait upgrades in its research and development pipeline that are designed to provide multiple and additional modes of action for weed control well into the future.

This includes PPO-herbicide tolerance traits, which are in the early phases of research and development and are expected to be included in Monsanto’s future generation multi-herbicide tolerant trait stacks. In addition to its existing portfolio, Sumitomo Chemical has been developing a new generation PPO chemistry that has shown broader spectrum control with application flexibility that has the potential to enhance current and future weed control systems.

Under the new global agreement, Monsanto and Sumitomo Chemical will work together and in parallel to create an integrated system of germplasm, biotechnology and crop protection that will represent this new generation of weed control solutions.

Chemical Engineering World

CEW Industry News Saudi Aramco and SABIC Sign HoA on Feasibility Study for Oil-to-chemicals Complex

Wison Engineering’s First EPC Project In UAE Breaks Ground

Dhahran, Saudi Arabia: S a u d i A ra m c o a n d S a u d i Arabian Basic Industries Cor poration (SABIC) have signed an agreement to conduct a feasibility study o n t h e d eve l o p m e n t o f a Saudi Aramco was represented by Abdulaziz Judaimi, Business Line Head, Downstream while f u l l y i n t e g r a t e d c r u d e SABIC was represented by Uwaidh Alharethi, oil-to-chemicals complex to Executive Vice President, Chemicals be located in Saudi Arabia.

The heads of agreement contains key principles of cooperation that will form the basis for the companies to establish a joint venture, if the joint study reaches a positive conclusion.

Shanghai, China: Wison Engineering, one of the leading chemical engineering, procurement and construction management (EPC) service and technology providers in China has announced that the company has kicked-off its first EPC project on site in the United Arab Emirates (UAE), taking an important step forward in the strategic Middle Eastern market.

D e r i v e d f r o m i m p r o v e d r e f i n i n g t e c h n o l o g y, t h e c r u d e oil-to-chemicals process will involve innovative configurations with proven conversion technologies. This will create a fully integrated petrochemical complex which maximises chemical yield, transforms and recycles by-products, drives efficiencies of scale and resource optimisation and diversifies the petrochemical feedstock mix in the Kingdom.

The project not only signals the company’s breakthrough into the core market of the Middle East but also showcases Wison Engineering’s wide recognition among project owners in the Middle Eastern region.

Saudi Aramco president and CEO, Amin H Nasser said, “Our agreement with SABIC reflects our vision to build on Saudi Arabia’s global leadership in crude oil production and commodities export by substantially increasing the production of oil-based petrochemicals and further optimising value across the entire hydrocarbons chain. This agreement will help spur a new era of industrial diversification, job creation and technology development in Saudi Arabia, particularly through downstream conversion of specialty chemicals by small and medium sized enterprises.”

Clariant Doubles Annual Production Capacity for Water-based Pigment Basel, Switz erland: Clariant, a world leader in specialty chemicals, inaugurated its new production plant for water-based pigment preparations in Mexico. The new plant located in Santa Clara doubles Clariant’s Mexico annual production capacity for water-based pigment preparations and enhances its ability to serve customers across North and Latin America.

Pigment preparations are aqueous dispersions based on pigments.

Compared to powder pigments, pigment preparations offer faster and more cost-efficient production, and better dispersibility. In addition, they provide more flexibility through the possibility of tailormade solutions. The capacity increase for water-based pigment preparations will enable Clariant to improve its support for the regions’ current and emerging market segments including decorative coatings, non-impact and flexo printing, industrial coatings, and specialties like home care, personal care and stationery.

22 • July 2016

This project, located west of Abu Dhabi, is a part of the ethylene plant expansion project of a leading provider of innovative, value creating plastics solutions. Wison Engineering’s work scope includes engineering design, procurement and construction services. The project is scheduled to be mechanically completed in October, 2017.

To offer more customised services to local project owners, the Company has established a project execution center and set up a local design, procurement and project management team in Abu Dhabi, which will allow the company to allocate its resources more efficiently and respond faster to local project needs.

INEOS Announces Multi-million Pound Investment at Its Hull Manufacturing Plant London, UK: INEOS Oxide has announced a multi-million pound expansion of its Hull manufacturing facility to increase production of Ethyl Acetate (EtAc) by 100,000 tonnes per year. It is expected that the additional capacity will be available by the end of next year. EtAc is in high demand for use in pharmaceuticals, cosmetics, inks and flexible packaging and the Hull plant is already at full capacity. This new investment will enable the company to continue to serve customers across Europe for many years to come. This is the first major UK investment decision to be made following the Brexit vote and reflects INEOS’ confidence in the UK economy and its ability to continue to deliver for its customers.

Jim Ratcliffe, INEOS founder and chairman, said, “We believe in British manufacturing and will support it wherever we can. Our Hull plant is at capacity and this extra investment will enable us to significantly increase production that we will sell all over Europe and across the world.” The Hull site will also benefit from INEOS’ USD 1-billion decision to import US Shale gas to Scotland.

A pipeline linking INEOS’ petrochemicals plant at Grangemouth with INEOS Oxide in Hull means the site will be able to use ethylene produced from imported US shale gas, as its main raw material.

Chemical Engineering World

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CEW Technology News Converting Solar Energy into Fuel

Scientists Unlock 'Green' Energy from Garden Grass

Villigen, Switzerland: Researchers at the Paul Scherrer Institute PSI and the ETH Zurich have collaborated t o d eve l o p a gr o u n d - b r e a k i n g alternative to this approach. The new procedure uses the sun's thermal energy to convert carbon Caption: Ivo Alxneit, chemist at the Solar dioxide and water directly into Technology Laboratory, Paul Scherrer Institute synthetic fuel. "This allows solar (PSI), preps for an experiment energy to be stored in the form of chemical bonds," explains Ivo Alxneit, chemist at the PSI's Solar Technology Laboratory. "It's easier than storing electricity." The new approach is based on a similar principle to that used by solar power plants." Alxneit and his colleagues use heat in order to trigger certain chemical processes that only take place at very high temperatures above 100 0 C.

London, UK: A team of UK researchers, including exper ts from Cardiff University's Cardiff Catalysis Institute, have shown that significant amounts of hydrogen can be unlocked from fescue grass with the help of sunlight and a cheap catalyst. It is the first time that this method has been demonstrated and could potentially lead to a sustainable way of producing hydrogen, which has enormous potential in the renewable energy industry due to its high energy content and the fact that it does not release toxic or greenhouse gases when it is burnt. Co-author of the study Professor Michael Bowker, from the Cardiff Catalysis Institute, said, "This really is a green source of energy.

E n g i n e e r i n g R e s e a rch e rs S t r i v e t o C r e a t e Third-generation Solar Cells GA, USA: Sandip Das, Assistant Professor of Electr ical Engineering in the Southern Polytechnic College of Engineering and Engineering Technology, along with a team of three undergraduate research assistants, has recently fabricated the delicate solar cells, which are about 100 times thinner than a human hair. The future of solar power generation is in these flexible solar cells, Das said. He and his research team are investigating various nano-materials to fabricate the third-generation solar cells. The researchers hope to develop a superior photovoltaic technology that produces cheaper and more efficient solar cells.

"The most fascinating part of doing this research is the enormous potential that this new technology offers, such as integrating flexible solar cells on wearable electronics, backpacks and self-charging cell phones and electricity-generating layers on windows, especially on skyscrapers, and solar power's ability to supply a large amount of clean, renewable and cheap energy for the future," said David Danilchuk, an Electrical Engineering major who is an undergraduate Research Assistant on the project. (Read more at www.kennesaw.edu/)

Modeling Predicts which Counties could Store More Carbon in Soil by Growing Bioenergy Crops GA, USA: To help stakeholders in government and business make smart decisions about the best types of land and local climates for planting bioenergy crops, researchers at the U.S. Department of Energy's (DOE's) Argonne National Laboratory are using computational modeling to predict which counties could see increases in soil organic carbon from cultivation of crops like switchgrass for biofuels. Increasing carbon stored in soil is one way to help mediate the amount of carbon dioxide released into the atmosphere. (Read more at www.anl.gov) 24 • July 2016

"Hydrogen is seen as an important future energy carrier as the world moves from fossil fuels to renewable feedstocks, and our research has shown that even garden grass could be a good way of getting hold of it." The team, which also includes researchers from Queen's University Belfast, have published their findings in the Royal Society journal Proceedings A. Hydrogen is contained in enormous quantities all over in the world in water, hydrocarbons and other organic matter. Up until now, the challenge for researchers has been devising ways of unlocking hydrogen from these sources in a cheap, efficient and sustainable way. A promising source of hydrogen is the organic compound cellulose, which is a key component of plants and the most abundant biopolymer on Earth. In their study, the team investigated the possibility of converting cellulose into hydrogen using sunlight and a simple catalyst -- a substance which speeds up a chemical reaction without getting used up. (Read more at www.cardiff.ac.uk)

Scientists Create New Thin Material That Mimics Cell Membranes WA, USA: Materials scientists have created a new material that performs like a cell membrane found in nature. Such a material has long been sought for applications as varied as water purification and drug delivery.

Referred to as a lipid-like peptoid, the material can assemble itself into a sheet thinner, but more stable, than a soap bubble, the researchers report this week in Nature Communications. The assembled sheet can withstand being submerged in a variety of liquids and can even repair itself after damage. "Nature is very smart. Researchers are trying to make biomimetic membranes that are stable and have certain desired properties of cell membranes," said chemist Chun-Long Chen at the Department of Energy's Pacific Northwest National Laboratory. "We believe these materials have potential in water filters, sensors, drug delivery and especially fuel cells or other energy applications." (Read more at www.pnnl.gov) Chemical Engineering World

CEW News Features

Excellence in Project Execution Technip in India, like elsewhere in the world, is keen to support the E&P players and the local hydrocarbon supply chain industry with their excellence in Project execution in all three business segments i.e. Onshore, Offshore and Deepwater subsea, says Bhaskar Patel, Managing Director, Technip India Ltd.

T

oday’s oil & gas exploration has gone deeper to deeper from past shallow reservoirs to even greater.

Patel believes that since the shallow water hydrocarbon reservoirs are getting depleted, the focus is shifting onto the deepwater developments. Technip, worldwide, has been the leader in shallow to Deep to ultradeepwater subsea development projects.

Doing engineering for such projects has been its strength, which is further augmented by its innovatively developed product line such as Flexibles & Umbilicals and installation assets, capable of installation upto 3000 m of water depth. There is also a huge focus on R&D work related to subsea.

Patel explains further that since seventies, as the world moved to deep water and then to ultra-deep water, Technip has kept itself abreast with its pioneering Engineering capabilities, R&D work on Design & product line and upgrading the installation fleet to overcome challenges in Deep to ultraDeepwater developments. Importantly also to note, Technip has done strategic alliances like with FMC Technologies to offer a complete optimised solution from surface development to commissioning. “With regards to Offshore EPC project activities in India, Technip has already executed and successfully handed over HRD Process platform project to ONGC. This project was executed in Consortium with Afcons - India and THHE - Malaysia in year 2015. This was a project where Technip’s proprietary Unideck Floatover Technology was used for the first time in India for Floatover installation of a Deck. This is the first project ever in India, where the Floatover deck design was done by an Indian company,” he reveals.

While updating on the ongoing project of Technip in domestic market, Patel reveals that the company is Building a 6 MMSCMD onshore terminal at Odalarevu, Andhra Pradesh, India, for ONGC as part of their

26 • July 2016

Integrated Development of Vashishta (VA) & S1 Fields.” VA & S1 fields are located at 30-35 km off the Amalapuram coast in KG Basin, East Coast of India at water depths of 250-700 m. The Onshore Terminal worth of 100 MN Euros awarded to Technip is one of the critical components of Integrated Development of VA & S1 Fields. Initially there was delay to commence the project due to certain local issues but now site work is going on full swing,” he adds.

Technip has recently awarded a project by Air Products to provide project management, as well as Engineering, Procurement and Construction Management (EPCM) services for a new industrial gas complex for the Bharat Petroleum Refinery Limited (BPCL) located in Kochi. Being built on a “Build, Own and Operate” basis (BOO), the industrial gas complex is designed to supply industrial gases (hydrogen, nitrogen and oxygen) to BPCL’s Kochi refinery as part of its Integrated Refinery Expansion Project (IREP). This project will increase BPCL’s crude refining capacity to 15.5 million metric tons per annum (approximately 310,000 barrels per day) and produce clean transportation fuels to meet Euro IV/V specifications.

Besides, CDU/VDU Heaters for BPCL Kochi Refinery, Largest Ethylene Cracker Plant for Reliance in Jamnagar, Largest PTA Plant with BP Technology for JBF Mangalore, Plant capacity enhancement and FEED flexibility project through the revamp of RIL Ethylene plants at Dahej, Nagothane and Hazira, and Lumpsum EPCM contract including high end process studies/Basic Engineering for CDU/VDU, ARU, FG Treating unit, Utilities & Offsite for leading client HMEL are the other major offshore activities of the company.

Further, the Indian Team at Technip has also par tnered in Execution of Group

Bhaskar Patel

Mega Projects. Mumbai Centre, in collaboration with Technip North America, is delivering engineering services for USGC Petrochemicals Project for Chevron Philips Chemical Company (CP Chem which aims to build world’s largest PE capacity at single location. Further, Almost 400 engineers in Chennai Operating Centre are working closely with other entities of the Group to carry out the engineering, procurement, supply, construction and commissioning of an integrated facility for natural gas liquefaction in arctic environment for Yamal LNG project in Russia. Technip, leader of a consortium with JGC, was awarded this project by JSC Yamal LNG, owned by NOVATEK (80%) and TOTAL (20%).

Technologies and Contacting Models According to Patel, Technip’s strengths lie in our technology and vessels pertaining to Offshore, Subsea and Deepwater which differentiate us in the offshore market. While commenting on how Global E&P majors are switching to Onshore from Offshore development, he says, “Prima facie, the current oil price USD 40-50/barrel seems not economical viable in developing offshore & deepwater fields. We firmly believe that the supply-demand curve will escalate and the price will reach about USD 60-70 per barrel which will be a good price for sustainable deepwater development. Traditional rich hydrocarbon geographies like Mexico, East and West Africa have been started a lot of deepwater discoveries which will further Chemical Engineering World

CEW News Features accelerate the growth of deepwater filed developments. The recent discussion of FMC Technologies merger with Technip is a part of our continuing philosophy of building our strengths in deepwater where FMC will be complement to our Offshore and Subsea market.” He also talks about the qualification criteria and contracting strategies in bagging EPC contracts in Indian oil & gas industry vis-a-vis globally at length and confirms that India is highly price sensitive market.

“So players in the industry tend to offer ‘fit for purpose’ to win the project. The recognised model of project execution in India is the Lumpsum EPC model. In some cases, depending upon own resources, some clients prefer a EPCM services model, where the contractor has to provide all services for Engineering, Procurement and Construction management, but the actual purchase of equipment and doing the civil construction and erection of the plant are done under the direct responsibility of the client through orders placed with concerned vendors/ contractors.”

According to Patel, globally the most popular model is to adopt a FEED converted LSTK-EPC model wherein the client selects a contractor based on a FEED bid along with stipulated conversion norms to an LSTK-EPC. After the FEED, it is normal for a contractor to give highly accurate cost estimate of the project.

In India Technip has a mix of clients from PSUs and Private sector and according to Patel, the company is comfortable working with both. Combination of proven technologies for value added products and Refinery – Petrochemical Integration, Conducting studies to upgrade technologies for improved operation to enhance efficiency of the existing units, Project execution capability on License plus EPC basis for all its technologies, Manufacturing process technology driven proprietary products - Heaters, Burners, Convection Modules, WHB and Competency in Offshore Process Platform are some of the USPs of the company. “We have demonstrated our resilience despite the economic headwinds. Leverage Technology Competency and R&D leadership to reduce clients project cost, Early involvement and fully integrated approach, Global footprint, 28 • July 2016

Commitment to safety, environment, security and quality, Optimizing our cost base and increasing competitiveness, Solid backlog and Solid backlog Our focuses in current slowdown,” Patel claims.

Growth Drivers Patel also explained future growth drivers a n d bu s i n e s s o p p o r t u n i t i e s fo r E P C service providers in India pertaining to its hydrocarbon industry. He believes that In the Hydrocarbon industry the hydrocarbon demand to local production gap and the government’s policy to reduce hydrocarbon import dependency by 10% in next 5 years is the key growth driver for the Indian EPC service providers in years to come.” Also, a door of opportunities will open in future for these service providers, with implementation of ‘Make in India policy’,” he adds. He says, while the above picture looks quite bright, there is a big responsibility on the Indian EPC service providers to execute the projects with truly international class technologies, quality and HSE standards. Further commenting on the policy reform, patel emphasises that various policy reforms will attract the E&P companies to do developments in India and this will trigger implementation of new projects, which will be favourable to the Indian EPC industry as well. At the same time there will be ownership with the E&P companies to maintain efficient operations leading to creation of a positive pressure on CAPEX and OPEX, which will make optimisation drive in the supply chain quite intense.

Measures to Boost Competitiveness & Ensure Quality Projects in Energy Sector in India • LSTK–EPC Model: It minimises the

•

•

-

• •

Patel acknowledges that PSUs are dominant share in contracting market in India. “See, almost all the PSUs’ Refinery upgradation works for upgrading the fuel quality of Euro VI are with EIL. But we have to see how EIL is able to cope with the amount of works with its limited manpower because all refineries have to upgrade their fuel quality (BS VI) by 2020. We hope that some of the upgradation works we are able to take part in a comparative environment.”

He however opines that India has a lot of opportunities for the private players in the form of petrochemicals complexes. Private players have the advantage of cheaper feedstock in India. The only thing is ontime execution of projects which is faced

•

definition uncertainties, improves the accuracy of the estimate for equipment and bulks and provides the right basis for construction costs. Also, it reduces the project execution time. This integrated client-contractor approach is applied by most of the large IOCs (International Oil Companies) for their projects. This mode of execution is yet to become popular in India.

Bidding process in India is quite simple – lowest bid win the award.

There should be a balanced weightage distribution to technology/ quality vs price: Best price vs Best operating plan.

Competent civil and erection contractors to deliver high safety & quality standard and infrastructure should be improved May be appointment of external, independent moderator can evaluate the objections more efficiently and negate the baseless ones to avoid unnecessary delay in bidding process Client and Contractors have to work more in an integrated manner Enhanced transparency, balanced sharing of risks, adequate and timely funding and partnering with a professional EPC contractor having a good hold on long lead equipment deliveries Technology innovation is mostly misinterpreted here as a costly affair but in reality it can reduce the capex and operational cost over a long period of time. FEED design competition can be proved as a better way to work.

constraints like funding, land acquisition, environmental clearances, etc.

- Mittravinda Ranjan & Rakesh Roy Chemical Engineering World

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CEW News Features

Navigating Innovatively in a Competitive World ARC Advisory Group’s fourteenth India forum for process and discrete industries, titled Industry in Transition: Navigating the New Age of Innovation attracted close to 270 delegates.

T

he theme was apt because the industr y is transitioning through constant changes in terms of new and innovative technologies; and only those companies that can navigate through all the available information and technology and effectively implement them will emerge successful. In today’s marketplace innovation is the buzzword, and this innovation is not confined to just product changes - it encompasses innovation at all levels of the value chain from the shopfloor to the end user. It is about becoming collaboratively networked enterprises, managing dispersed centers

of technology, engineering, production, and resources. This two-day forum (July 7-8, 2016) was structured to disseminate information and technology effectively and provide end users, solution providers and decision makers an oppor tunity to network and get an overall view of the market and its requirements.

Industr ial growth hinges on effective networking and collaborating – and ARC forums provide the right platform and visibility to all attendees. New technologies, such as cloud computing, mobility, social technologies, Industrial

From left to right: G Ganapathiraman, Country Manager, ARC Advisory Group, India; Bob Gill, General Manager, SE Asia, ARC Advisory Group; Inez Costenoble, Analyst Relations, Siemens; Dr B Ashok, Deputy Project Director, Aeronautical Development Agency ; B R Mehta, Senior Vice President, Reliance Industries; Achyuta Ghosh, Head of Research, NASSCOM

Attentive audience

30 • July 2016

Inter net of Things, big data/analytics, and digitalisation have now taken centerstage; and most of the presentations at the Forum emphasised these topics.

The session topics were: Automation and Enterprise Trends; Advancement in Control Strategies and Asset Performance Management; Industrial Cybersecurity, Automation & IIoT Trends; Strategies to Achieve Operational Excellence; and Smart Manufacturing, Energy Efficiency Trends for Growth. There were close to 30 presentations – the core of which was implementing new technologies to forge ahead in a competitive market. Sessions e n d e d w i t h i n t e ra c t i ve Q & A w i t h t h e session speakers on the dais.

Andy Chatha, President & CEO, ARC Adv is or y G roup’s v ide o p r e s e n ta tio n highlighted how digital transformation is gaining momentum across all industries and how innovative companies are disrupting the status quo. He said that today’s propr ietar y systems are r ipe for next-gen digital transfor mation as process plant assets are usually more t h a n 3 5 ye a r s o l d a n d a r e p r o n e t o failures and incidents. The other keynote addresses which set the tenor for the forum were given by B.R. Mehta, Senior Vice President, Reliance Industries; Achyuta Ghosh, Head of Research, NASSCOM; Bob Gill, General Manager, SE Asia, A R C A d v i s o r y G r o u p ; a n d B. A s h o k , Deputy Project Director, Aeronautical Development Agency. Speakers were from the sponsors, industry association sponsors, and invited end user speakers.

At the end of ARC’s two-day forum it was clear that although the road ahead has many obstacles, these can be overcome by adopting new processes and technologies.

Chemical Engineering World

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Vol - 3 Issue - 6 • JUNE - JULY 2011 • ` 100

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CEW Features Guest Column

An International EPC Company for Operating in Indian Space Scale, speed and skill are intrinsically important ingredients in India’s future growth; specifically in the Oil & Gas upstream and downstream industry. India is well positioned to push forward growth initiatives in the upstream, refinery and petrochemical space, writes Sunder Kalyanam, Regional Managing Director, E&C, Petrofac.

A

successful in negotiating and tailoring the base lumpsum EPC model to suit specific execution styles and legislative frameworks. This has allowed the parties to focus on the activities within their respective spheres of control and rely upon their partners within the extent of the contract to manage other execution fronts. Simply put, interests have to be aligned at the very outset with one common agenda – delivering a successful project collaboratively; safely, on time and within budget. It is so much more than just executing a contract.

ligning with reliable partners can be the catalyst towards a greater realisation of the country’s growth dreams. International contractors can bring a wealth of technical and execution experience and are likely to offer the right partnership; supporting a sustainable and local model.

Well established and understood, the lumpsum EPC model has been successfully implemented in the Oil & Gas industry the world over and still continues to be used to great effect. Over time the EPC model has varied but the core, which is ‘optimum risk sharing’ has remained intact. Globally, clients and contractors alike have been extremely

If we look at the illustrations (Chart 1) above the scale of things to unfold is clearly ambitious and substantial. That a

30 billion, USD

For India the last decade or so has not seen a major push forward in the refinery and petrochemical space; for a variety of perfectly logical and economic reasons.

However, one of the consequences of a slowdown in any market can result in local skills erosion and movement of skills away from the local environment. This is where international EPC contractors can offer a meaningful partnership, aligning with local businesses and implementing a ‘global-local’ model to great effect.

With complementary strength and depth being brought into the local market, it provides a great recipe for stimulus.

An increased appetite for simultaneous project sanction, as projects would be supported by resources otherwise not immediately available or ready and a significant risk element can be taken up by the international EPC partner businesses.

35

25 20 15 10 5 0

2015-20 2021-25

Natural Gas

Chart 1: Annual Investment in the Period, India

32 • July 2016

big wave is set to rise is quite emphatic.

What is required is that we are prepared and equipped to ride and harness this wave. Success cannot be realised without skill and speed.

2026-30 2031-35

Oil Sector

2036-40

New Policies Scenario, IEA

State owned public sector undertakings and the large private players only stand to benefit if the bidding slate comprises competition from strong and competent national and international EPC contractors. Reputable international lumpsum EPC contractors are financially Chemical Engineering World

CEW Features mb/d

1,500

9 6.0

6

1,000

4.9 3.5

3

500

0.3

0

19

90 19 95 20 00 20 05 20 10 20 14 20 15 20 20 20 25 20 30 20 35

0 India - Production (Mtoe) India - Consumption (Mtoe)

(BP Energy outlook -2016)

Chart 2: Energy Production/Consumption Forecast, India

robust, have a solid and tested reputation for safe project delivery, underpinned by well-honed processes and governance covering all aspects of project execution.

This has developed and evolved over the years as a result of exposure to multiple clients in diverse geographies from which best practices have been learned and embedded in business protocols ensuring adherence to high standards of international safety, quality and integrity.

A competent and reputable EPC contractor will offer a strong in-house engineering capability resourced with highly motivated, talented and experienced engineers and designers.

This forms the bedrock of EPC delivery.

Experienced buyers with exposure to international suppliers will help leverage the relationship built over a period of time and the quantum of ongoing business.

Cost and schedule benefits will benefit the end user in securing competitive quotes from the EPC contractor during the bidding phase, and will see delivery assurances in execution. Construction and completions management teams bring in a wealth of construction best practice.

In addition to cost management on projects, HSSE and quality performance and delivery have long been well

-4.2

-3.9

United European Japan Russia South Indonesia Brazil Middle China States Union Africa East

India

IEA, WEO 2015

Chart 3: Change in oil demand by selected countries and regions in the New Policies Scenario, 2014 - 2020

documented considerations which have the Indian infrastructure/construction industry alarmed. There have been step changes in improvement in HSSE and quality with standards improving at all levels in the supply chain, all the time.

Most international firms are operating with best in class auditing requirements and have an established track record which could help local businesses manage their projects with less supervision; the net result being a reduced cost.

India is ambitious, hungry for success on the world stage and is working hard towards realising these goals; attracting the highest quality of investments and corporate interests in the country.

International firms bring their particular niche experiences and capabilities in executing multiple commercial models; EPC lumpsum, hybrid EPC with open book procurement, reimbursable convertible to lumpsum. Listening to what a client wants is always extremely important and through an open dialogue, there are numerous ways to achieve optimal commercial outcomes.

A number of international contractors also have the capability to bring in finance or work with export credit agencies.

Evolved international contractors having worked with multiple global customers

A competent and reputable EPC contractor will offer a strong in-house engineering capability resourced with highly motivated, talented and experienced engineers and designers. This forms the bedrock of EPC delivery.

34 • July 2016

0.8

-0.8

-3 -6

0.6

-0.1

over time have developed tried and tested “fit for purpose” delivery models with safety, schedule and cost being the pillars of quality delivery. This experience and capability allows customers to award work with basic functional specifications and rely-upon data which competent EPC contractors grow and develop to provide the desired end result.

This approach will help gain overall time by cutting short the pre-bid and tendering time and will help the Indian nation realise its dream of ‘speed’.

Leadership and empowerment are quintessential for successful project management and project execution.

Leadership has to be understood in the context of ownership and self-drive.

International contractors are well placed to identify and hire talented current and potential leaders from a larger and diverse international pool due to their reach.

A proven track record, the leadership and the lessons learned along the decades of execution are the three of the most important differentiators for a global delivery firm.

In summary, an international EPC company can fit perfectly well in the current and near-future economic environment and growth ambitions in India. They offer complementary tools and experience to support the local growth path that India is looking forward to. Indian industry needs reliability and assurance from all stakeholders in the path forward.

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CEW Features Interview

“Stability in Oil Prices Should Unlock Investment Decisions at Global Level” - Scott Hughey, KBR KBR provides innovative solutions to the refining and petrochemical industry to help clients stay competitive.

With stricter environmental regulations, demand in developing countries is changing to cleaner fuels, says Scott Hughey, Senior Vice President - Sales & Marketing, KBR Technology & Consulting. In an email interaction with Harshal Y Desai, he further highlights the effect of falling crude oil prices, future challenges for refiners and significance of technologies in increasing GRMs. Hughey also talks about KBR’s simulation, design and operations domain and chemical technology portfolio.

How has oil price in recent past affected the refining scenario across the world?

With oil price - which now seems to float around USD 50/barrel in the near future, how do you expect the refining activities to move forward now?

Falling oil prices have generally been beneficial to the refiners, for example in Asia and Europe, to the extent that their input cost decreases. As the readers know, the profitability of a refinery is measured in terms of Gross Refining Margin (GRM), which is the difference between the total value of petroleum products coming out of a refinery and the price of crude oil.

Indian refiners have been able to improve their profit margins with reduced oil prices.

However, with low oil prices comes uncertainty and uncertainly often leads to postponement, delay or cancellation of big projects. Also, retaining the same level of refinery efficiency is challenging due to volatility in crude oil prices, which affects the earnings. Moving forward, in India, there are various projects lined up to meet new fuel specifications viz. BS-V and BS-VI. IndianOil has announced plans for USD 6 billion investments to meet future demand. Another mega refinery is planned in India at a cost of USD 30 billion.

Scott Hughey Senior Vice President - Sales & Marketing KBR Technology & Consulting 36 • July 2016

We expect to see stability in the oil prices in the near term and it should unlock investment decisions at the global level leading to growth in the refining sector.

What are the future challenges that the refiners need to prepare for right now and the key technologies that the refiners need to adopt for long term sustainable growth?

With the current level of crude oil prices, light oil is available at prices favourable to the refiners. But considering the cyclic nature of the oil and gas industry, refiners need to retain flexibility to process the heavy, lower-priced oil as the situation changes in order to maintain their GRMs. Worldwide, there has been a trend of refining-petrochemical integration to enhance profit margins. However, this is not enough to protect the refining margins. For example, in the Middle East, as per a November 2015 joint report issued by McKinsey & Co and the Gulf Petrochemicals and Chemicals Association, there is a need to focus on integration of refining operations and make strategic decisions in investing further downstream, to maintain current growth rates. Recently, Saudi Aramco and SABIC announced plans to conduct a joint feasibility study for development of a fully integrated crude oil-to-chemicals complex in Saudi Arabia.

These investment decisions are pointers to the future direction of the refineries.

The keyword is flexibility for technologies that can help to adjust the feedstock and product slates as per the market conditions to maximise profitability.

Chemical Engineering World

CEW Features Growth in the world economy means more energy is required; the energy consumption is increasing, in the range of 34 per cent between 2014-2035, according to BP’s Energy Outlook 2016 report.

How has the technology front in the refining and petrochemical sector evolved in retaining the profit margins and global competition with the ever changing market demands, fuel mix (both heavy and light), stricter environmental regulations, and fuel quality norms, etc.? As a technology developer and licensor to the Refining Industry, how has KBR evolved its expertise in this regard?

KBR provides innovative solutions to the refining and petrochemical industry to help clients stay competitive. With stricter environmental regulations, demand in developing countries is changing to cleaner fuels. Growth in the world economy means more energy is required; the energy consumption is increasing, in the range of 34 per cent between 2014-2035, according to BP’s Energy Outlook 2016 report.

To meet increasing demand for diesel in certain countries, KBR offers MAXDIESEL TM technology that repurposes existing fluid catalytic cracking (FCC) units to increase diesel yields at a fraction of the capital investment required for other grassroots options.

KBR has an alliance with Shell Global Solutions to offer its hydroprocessing and hydrotreating technologies. In alliance with Exelus Inc., KBR offers Solid Acid Alkylation Technology K-SAAT that maximises the yield of motor fuels and enhances production of an ultra-clean blendstock.

To comply with new, tougher regulations to reduce sulfur levels, refiners need more hydrogen in their hydroprocessing units than currently available from their existing refinery hydrogen plants. KBR offers low-cost refinery hydrogen plants using our proprietary technologies and equipment: KBR top-fired steam methane reformer (SMR), the KBR Reforming Exchanger System (KRES™) and KBR autothermal reformer (ATR).

38 • July 2016

KBR acquired several companies recently – all of them are already established in their respective domains. What will be KBR’s strategy and vision to grow these companies globally - together? How KBR has strengthened its proprietary technologies portfolio with the acquisitions?

We are keen to acquire or form alliances with companies with technologies that fit our portfolio and bring value to our customers. For example, our subsidiary Weatherly is engaged in developing and applying process technology for the chemical industry including fertilisers and this complements our Ammonia technology offerings, where KBR is a technology leader.

KBR subsidiaries, PLINKE and Ecoplanning, offer superior technologies in acid treatment, evaporation and crystallisation, but their global reach was somewhat limited by the lack of sales presence in some regions.

However, we are now leveraging KBR’s global salesforce to bring those technologies to growing markets, such as India.

Recently, KBR has formed an alliance with RRT Global, a Russian company, to offer its isomerisation technology under the brand name MAX-ISOM. This unique technology adds to our innovative and cost-effective refining technology portfolio and we expect it to be in demand in India, for example.

Global refining industry automation and software market is expected grow. Will you please throw some light on KBR’s simulation, design and operations domain? How is this business gaining significance within KBR? KBR has more than 60 years of experience in the automation industry and has provided many “firsts” to the industry, such as the first completely

integrated cost-effective ammonia plant Operator Training Simulator (OTS). The world’s first general purpose flowsheet simulator was also designed by KBR in the early 1960s. Drawing on these experiences, KBR developed Ammonia Insite ® solution and recently deployed it at a client’s ammonia plant on which we are working in the U.S. This is a first-inkind operations performance monitoring system that combines a state-of-theart data acquisition, monitoring and visualisation system with proprietary algorithms and statistical methods for predictive analysis, to deliver value-added analysis of the ammonia plant performance and the health of critical equipment and proactive advisory services in real-time and from anywhere in the world. We offer similar systems for refining and olefins production plants.

In the area of Industrial Internet of Things (IIOT), KBR has developed numerous other service offerings that leverage multiple state-of-the-art technologies for performance monitoring of assets in the process industries. For example, refineries aim to leverage IIOT to monitor process equipment such as pumps, compressors, heat exchangers, furnaces, and steam systems, and realise its benefits in areas like energy management, asset maintenance and reliability and supply chain optimisation.

KBR offers automation solutions along with its licensed technologies for refining and petrochemicals and these solutions are of greater significance than ever before.

Will you also talk about KBR’s chemical technology portfolio?

Please comment on the scope for biobased chemicals, current trends and challenges associated with it?

The global demand for chemicals produced from natural gas, petroleum, coal or biomass is challenging operators to seek more efficient processing solutions. KBR’s best-inclass technologies meet these needs, delivering high-quality intermediate and specialty chemicals at a lower cost and reduced environmental impact.

Chemical Engineering World

CEW Features KBR offers technologies for Phenol, BPA, PVC, Vinyl Acetate Monomer (VAM), Acetic Acid, Ethyl Benzene, Styrene Monomer and others.

For more than 60 years, KBR has been has been at the forefront with more than 50 phenol projects worldwide. Producers have come to depend on our technology to deliver profitable high yields and the highest purity in the industry, with total organic impurities less than 25 ppm. In partnership with Mitsubishi Chemical Corporation (MCC), KBR offers Bisphenol A (BPA) technology, which is an economical technology application that improves yields and reduces by-products.

In partnership with JNC, KBR offers low-cost, high flexibility Advanced PVC Process and Vinyl Chloride Monomer (VCM) removal technologies which are reliable, energy efficient and environmentally-friendly with lower VCM emissions, delivering high return on investment.

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In alliance with Showa Denko (SDK), KBR is the only licensor of Vinyl Acetate Monomer (VAM) technology from an active VAM producer operating since 1978.

KBR, in partnership with Chiyoda, offers the only open-licensed technology of advanced Methanol Carbonylation for the production of acetic acid.

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In alliance with Versalis, KBR provides Ethylbenzene (EB) and Styrene Monomer (SM) technologies. The KBR-Versalis alliance is the only licensor with extensive production experience and a continual improvement program.

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Asia has become the engine for global product demand growth, led by developing countries such as China and India. Will you please elaborate the statement?

Asia has indeed been the engine for global product demand growth.

With the Asian economy’s growth, comes the emerging middle class, with more purchasing power and demanding consumer goods and transportation fuels. The recent slow-down in the Chinese economy has been offset to some extent by growth in other countries in Asia. The challenge to these countries is to keep up with investment in production assets to meet domestic demand for consumer products. If local production is not available or is not competitive with the price of imported goods, the country and local producers lose opportunities to grow the local economies and generate more jobs. KBR is working with clients in China, India, Thailand, Indonesia and other countries to offer our technologies and best practices to enable local producers to reliably and economically produce the products needed to fuel this growth.

40 • July 2016

CEW/CPF Spotlight

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Latest Developments in Innovation and Technologies Future Trends of the Industry

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International Corporate News New Product Launches

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008

Features CEW Company Profile

KBR: A Global Technology Company

K

BR, Inc. is a global technology, engineering, procurement and construction company serving the hydrocarbons and government services i n d u s t r i e s, e m p l oy i n g a p p r ox i m a t e l y 25,800 people worldwide with customers in more than 80 countries and operations in 40 countr ies across three distinct global businesses: • Technology & Consulting, including propr ietar y technology in offshore deepwater, refining, ethylene, ammonia a n d fe r t i l i s e r s , c o a l g a s i f i c a t i o n , evaporation and crystallisation, and acid treatment; and niche consulting and know-how through subsidiaries Granherne and Energo.

• Engineering & Construction, including Offshore Oil & Gas; Onshore Oil & Gas; LNG/GTL; Refining; Petrochemicals; Chemicals; differentiated EPC, and Industrial Services • Government Services, incorporating KBRwyle, includes capabilities that span the full spectrum of government mission requirements including research and development, testing, engineering, logistics, deployed operations, and lifecycle sustainment.

KBR Technology and Consulting KBR Technology & Consulting delivers proprietar y technology and consulting services throughout the hydrocarbons value chain, from offshore to specialty chemicals.

The business group is composed of eight distinct brands: KBR Technology KBR has been creating innovative technology for petroleum refining and petrochemical processing since 1919, and building plants based on those technologies for almost as long. From co-developing and commercialising the first FCC process unit in 1942, to revolutionising the fertiliser Chemical Engineering World

KBR believes in delivering flexible and proven technology solutions to clients to remain competitive and thrive above competition.

KBR’s engineering centers in India serve customers not only in India, but across the globe and help us to deliver our technology and solutions across different time zones.

John Derbyshire, President, KBR Technology and Consulting KBR has a long standing association with customers in the India region since 1974 delivering solutions for grassroots and revamp projects in the fertiliser, refining, petrochemical and chemicals sectors by providing cutting- edge technologies in niche areas.

Arup Ganguly, Director, Business Development, KBR Technology industry with the Kellogg ammonia process in the 1960s, to commercialising heavy oil and coal monetisation processes for a changing energy landscape, KBR has been a pioneer and an industry leader.

Our licensed technologies, whether full units or key equipment, can be found in thousands of installations around the wor ld. Our propr ietar y equipment is engineered to perform, underpinning our continued commitment to performance and quality for refining, coal gasification, petrochemicals, ammonia and syngas. In addition, our unique partnerships, joint ventures and alliances create a strong technology portfolio with industry leading technology providers such as Shell Global Solutions, BP, ExxonMobil Chemical, SK Innovation, Southern Company, and more.

Granherne Since our founding in 1984, Granherne has developed an enviable reputation as one of the world’s foremost design c o n s u l t a n c i e s fo c u s e d o n fe a s i b i l i t y, conceptual and front-end engineering for

the world’s upstream and downstream oil and gas industry.

With experience from more than 3,000 p r o j e c t s i n m o r e t h a n 4 0 c o u n t r i e s, Granher ne offers a range of ser vices that add value - throughout each stage of the asset lifecycle - for fixed and floating offshore production facilities, subsea p r o d u c t i o n fa c i l i t i e s, o f f s h o r e ex p o r t facilities, gas monetisation technologies and onshore reception, treatment, loading a n d s t o r a g e fa c i l i t i e s . G r a n h e r n e ’s consultancy also addresses other aspects of the oil and gas industry, including power, pipelines, insurance support, gasification, operations, risk and safety.

Energo Energo’s ser vices center on one goal: solving the most difficult and challenging structural problems for operators in the oil and gas industry around the world.

Through our two main ser vice areas, advanced str uctural engineer ing and integrity management, Energo ensures that clients’ onshore and offshore assets July 2016 • 41

CEW Features are high quality, structurally sound and tested to withstand long-term exposure to a variety of environmental and geographic conditions, as well as to prevent structural failures from catastrophic events.

GVA GVA has been a premier designer of licensed floating platforms and vessels for the global offshore industry since 1970.

Our offshore technologies date back to Alexander Keiller & Co., a mechanical workshop in Gothenburg, Sweden in 1841 that delivered its first small steam tug in 1847. After producing some 1000 ships, the shipyard closed in 1989 and GVA Consultants AB emerged as an industry leader in innovative offshore technologies and continues as a world-leading designer and technology provider.

KBR Integrity Management KBR Integrity Management brings together KBR’s experience and capabilities in asset i n t e gr i t y m a n a g e m e n t a n d a d va n c e d structural, process, and subsea engineering to offer a full suite of integrity management solutions. We help our clients assess the integrity of offshore facilities, pipelines, and subsea systems and well assets to choose the safest, most cost-effective strategy to maximise asset life.

Acid treatment and concentration, PLINKE provides individual solutions for clients’ specific needs.

Ecoplanning KBR Ecoplanning Oy, a technology and engineering company, provides evaporation and crystallisation technologies to industrial clients in the fertiliser, chemicals, chlor-alkali and other markets. Ecoplanning specialises in regeneration of acids, evaporation, crystallisation and complete plant design.

Ecoplanning’s process knowledge is based on more than 40 years of experience a n d m o r e t h a n 2 0 0 eva p o r a t i o n a n d crystallisation plants, e.g. caustic soda concentration in chlor-alkali industry and various salts crystallisation in chemical industr y. Ecoplanning also has broad ex p e r i e n c e i n t h e r e c ove r y o f a c i d s containing different kind of impurities, especially of sulfuric acid from the production of titanium dioxide or of the bleed acid from copper refineries.

Weatherly Weatherly designs a wide range of processes for fer tilisers, including ammonia, nitric acid, ammonium nitrate and integrated urea-ammonium nitrate.

PLINKE PLINKE GmbH offers state-of-the-ar t process technologies for the treatment, concentration and recycling of Sulfuric, Nitric and Hydrochloric Acids. We also offer process technologies for NOx treatment of effluent gases, effluent water treatment downstream of the plant, and adiabatic nitration for the production of nitrobenzene.

Since its inception in 1954, Weatherly has been actively engaged in developing a n d apply ing proc es s tec hnology for t h e c h e m i c a l i n d u s t r y. I n a d d i t i o n t o process work, Weatherly offers full-service engineering services including basic and detail engineering, procurement, project management and construction services on a world-wide basis.

PLINKE designs and constructs tailor-made plants worldwide. With more than 65 years of experience in the field of acid treatment and more than 500 plants in the areas of Sulfuric Acid treatment and concentration, Nitric Acid treatment and concentration, Hydrochloric

KBR in India KBR has operated in India since 1974 delivering key grassroots and revamp projects in ammonia, refining and petrochemicals, and opened permanent KBR office in India in 2008.

Ecoplanning’s process knowledge is based on more than 40 years of experience and more than 200 evaporation and crystallisation plants, e.g. caustic soda concentration in chlor-alkali industry and various salts crystallisation in chemical industry.

42 • July 2016

KBR now has multiple offices in India operating through its 100% owned s u b s i d i a r y, Ke l l o g g B r ow n a n d R o o t Engineering & Construction India Pvt Ltd (KBRECIPL). KBRECIPL offices in Gurgaon and Pune are global engineering centers for KBR Technology & Consulting.

The Gurgaon office has technology exper ts in Syngas, Refining, Olefins & Chemicals, Mechanical, Plant Engg, CSE, PEQ, and Commissioning. The Pune office is dedicated to Automation and Process Technologies (APT). KBR also has an office in Chennai, which is the global engineering center for KBR Engineering & Construction.

KBR serves its clients all across the length and breadth of the fer tiliser, refining, petrochemical and chemical sectors in India region.

Some of the clients KBR have served in the past are: Matix Fertilizers, National Fer tilizers Ltd (Nangal), Chambal Fer tilisers, Jaiprakash Associates Ltd (JAL), KRIBHCO, Deepak Nitr ite, Reliance Industries Ltd, IndianOil, HPCL, Bangladesh Chemical Industries Corporation (BCIC), etc.

Chemical Engineering World

Features CEW Case Study

Recheck Your Heat Integration Project – Is It Really Energy Efficient?

In today’s process industry, energy optimisation is one of the keys to survival. New plants are being constructed with the latest technologies, having an in-built lower operating cost. To compete with new generation plants, operators of existing plants are trying to explore all the possibilities to make their existing plant more energy efficient. Heating utilities, like steam and fuel oil, are the most expensive in the plant. Hence, the possibility of utilising the hot streams available in the plant to preheat the process is being evaluated. This is to reduce plant heating utility consumptions and to make the plant more energy efficient. Often, the field operator uses their operating plant experience and intuition to select the heat integration proposals. However, modifications done without the basis of a detailed analysis may not be beneficial. If the modification involves the addition of a new heat exchanger in the heat exchanger train, a detailed analysis of the complete exchanger network is crucial to establish the overall gain from the proposed modification.

T

he following case study highlights the probable issues associated with modifications to heat exchanger networks. It is emphasised that a detailed analysis of whole system is warranted to establish overall energy gain from the modification, rather than solely relying on the thermal duty of the new exchanger.

overall exchanger train in the existing plant is summarised in Table 1.

Proposed Modification: To reduce fuel oil consumption in the final fired heater, it

was proposed to flash steam condensate available elsewhere in the plant to generate very low pressure flash steam at 2.5 barg. This steam was proposed to be used in a new heat exchanger, which would

Case Study: Addition of New Waste Heat Exchanger in Exchanger Train Existing Plant Scenario: Figure 1A indicates an existing plant heat exchanger train, wherein the process stream was being heated from 90˚C to the maximum possible temperature using the different levels of process flash steam available in the plant. The objective of the exchanger train was to pre-heat the process stream and thus minimise fuel oil consumption in the final fired heater before the feed entered the reactor.

Exchanger ‘HX1’ was being operated using 5 barg flash steam generated from the last flash vessel, ‘HX2’ was being operated using 10 barg flash steam generated from the intermediate flash vessel and ‘HX3’ was being operated using 25 barg flash steam generated from the first flash vessel. The performance of individual operating exchangers and Chemical Engineering World

Figure 1: existing process pre-heat train with proposed modification

July 2016 • 43

CEW Features Existing Plant operation

Expected Performance post modification

Tin ( C ) Tout ( C ) Duty (KW)

----

Tin ( C ) Tout ( C ) Duty (KW)

Heat Exchanger

Actual Performance post modification Clean

Fouled

90 102 1501.6

90 102 1501.6

90 102 1501.6

90 112.77 3479

102 124 3479

102 124 3479

102 124 3479

Tin ( C ) Tout ( C ) Duty (KW)

112.77 172.32 9728

124 183 9728

124 183 9728

124 178.55 9034

Tin ( C ) Tout ( C ) Duty (KW)

172.3 212.4 7122

183 223.7 7122

183 220 6662

178.55 214.7 6505

20329

21830.6

21370.6

20519.6

7.4

5.1

0.9

New HX

HX1

HX2

HX3

Total HX Train Duty % HX Train duty increase

Table 1: Exchanger train performance for existing and modified condition

be located upstream of existing ‘HX1’.

The flash steam pressure was selected such that the condensate pressure shall be sufficient to transfer it to the utility block. About 2.5 T/hr of flash steam at 2.5 barg was estimated to be generated. The modification was considered to be simple as it includes only a new flash vessel and steam exchanger, along with associated piping and instrumentations. The expected revised exchanger train temperature profile and duties was as tabulated in Table-1. The basis of the modification was that, post the modification, the fuel oil consumption would drop by an equivalent amount to that of the duty of the newly added exchanger.

However, though the new exchanger performance was as per design intent, the heat exchanger train as a unit failed to perform as per expectation. There was some gain during the initial period of operation (when exchangers were clean) which eventually dropped to practically nil. The post modification heat exchanger train performances, during the initial period of operation (clean condition) and after a few days of operation (fouled condition), are also tabulated in Table 1.

44 • July 2016

What Went Wrong?

The modification was implemented without the detailed study of the existing heat exchangers for the revised temperature profile. While making the modification, it was assumed that the duty of all the existing heat exchangers will remain the same as in the existing plant and hence the HX3 process outlet temperature will increase by an amount equivalent to the duty of the new exchanger. The author was contacted to identify the reason of the exchanger train underperformance.

Existing exchanger train was analysed in detail. All the exchangers were simulated to predict the performance of existing exchangers for different tube side inlet temperatures, maintaining all the other conditions same.

HX1 was simulated and it was found to be about 60 per cent overdesign in the original operating conditions (existing plant scenario) and about 29 per cent overdesign for the revised tube side inlet temperature (modified exchanger train scenario). The exchanger overdesign had reduced due to reduction in the Effective

Mean Temperature Difference (EMTD) from 56.7 0C to 44.8 0C. Due to excessive overdesign of the installed hardware, the exchanger was found to be adequate for the revised operating conditions.

Following eq. 1 is a basic equation for the exchanger duty. …..(1) Q = UA (EMTD) = m Where, Q = Duty, KW U = Overall heat transfer coefficient, W/m 2C A = Heat transfer area, m 2 EMTD = Effective mean temperature difference = Ft x (LMTD), oC M = Mass flow rate, Kg/hr = Latent heat, KJ/kg The exchanger duty is therefore practically fixed by the amount of available steam (Q = m ). For the non-flooded existing heat exchanger, heat transfer area ‘A’ is constant. For constant tube side velocities and shell side steam condensation, the overall heat transfer coefficient ‘U’ can be assumed as constant. Thus the right side of Eq. 1 (UA (EMTD)) can be balanced with left side (m ) only by changing EMTD. This is because in actual plant operation, for an oversized exchanger, steam condenses at pressure lower than the supply pressure and thus at a lower temperature, resulting into lower EMTD. varies with the condensation Also pressure, and the exchanger operates with lower shell side condensation pressure to have Eq. 1 balance.

Thus, for non-flooded oversized exchangers, the exchanger steam side condensation pressure is lower than the steam supply pressure, which is achieved by the pressure drop across steam inlet control valve. When the existing heat exchanger (i.e. constant heat transfer area) is operated at steam condensation pressure which is the same as the steam supply pressure (represented by full open steam inlet control valve), it results in the highest possible EMTD for the given service.

This also represents the maximum possible duty from the existing exchanger hardware for the given service.

Chemical Engineering World

Features CEW side inlet temperature above 1190C, though outlet temperature continues to increase, the increase in outlet temperature is insignificant as compared to the rise in inlet temperature.

Above 1190C, the exchanger duty starts dropping significantly. This means that any heat addition upstream of HX2 resulting in a HX2 tube side inlet temperature higher than 119 0C will reduce the duty of HX2 and only part of the heat addition upstream of HX2 will get reflected at the HX2 outlet.

During start-up, as the exchanger was clean, an additional margin in terms of negligible fouling resistance was available as compared to the parameters considered for the design case. This resulted in higher HTC during startup, and the exchanger delivered the design duty even at lower EMTD. Thus, while adding any exchanger in the heat exchanger train, adequacy of all the downstream exchangers should be checked for the revised EMTD. Instead of assuming total energy gain equivalent to the duty of the new exchanger, the actual energy gain across the exchanger train should be estimated based on the revised temperature profile.

Figure 2: Tube side inlet temperature V/s outlet temperature

Now, let us analyse HX3. Though duty of both the exchangers HX2 and HX3 were decreased after the addition of HX1, there were two basic differences between these exchanger operations:-

Figure 3: Tube side inlet temperature V/s Exchanger duty

For simplicity of analysis, all the exchangers were simulated to predict the exchanger’s performance with the steam condensation pressure same as the respective steam supply pressure. HX2 was simulated to predict the exchanger performance with varying tube side inlet temperatures. The ‘tube side inlet temperature V/s outlet temperature’ and ‘tube side inlet temperature V/s exchanger duty’ was plotted (Figure 2 and Figure 3).

From the above two graphs, it can be observed that, up to a tube side process Chemical Engineering World

inlet temperature of 119 0C, the process outlet temperature increases proportionately and the exchanger duty remains constant i.e. the existing available heat transfer area is adequate to condense all the available flash steam with EMTD corresponding to a tube side inlet temperature up to 1190C. However, as the tube side inlet temperature increases above 1190C, the available heat transfer area becomes inadequate to condense all the available flash steam at reduced EMTD. Hence, uncondensed flash steam starts venting from the upstream vent valve PCV-2B. With an increase in tube

- HX2 delivered the design duty during start-up and failed to deliver the same eventually. However, HX3 failed to deliver the design duty right from start-up itself.

- With a drop in HX2 duty, uncondensed excess steam was being vented from the upstream vent valve PCV-2B. However, while attempting to get the maximum possible duty from HX3, the plant operator had noticed that this could be achieved only by keeping PCV3B closed and venting the uncondensed steam via exchanger vent valve HCV-3.

Why the Performance Characteristic of HX3 was Different from of HX2?

To establish the reason of the HX3 underperformance, plant operating data was analysed. It was observed that although inlet PCV-3A was fully open (HX3 operating at first flash vessel pressure), July 2016 • 45

CEW Features

Figure 4: First flash vessel steam condensation profile

the shell side condensate temperature was lower than the inlet steam temperature.

Hence, the steam composition of the first flash vessel was analysed and found to be contaminated with 0.5 %w/w of noncondensable inerts. Due to this, steam was not condensing completely at its dew point but condensed progressively with the temperature drop as shown in Figure 4.

Figure 5: Tube side inlet temperature V/s tube side outlet temperature and shell side condensate outlet temperature

Thus, even a small amount of noncondensable in the steam changes its condensation pattern, EMTD and the heat transfer coefficient significantly. HX3 was simulated to predict the exchanger performance with varying tube side inlet temperature. Figure 5 indicates the tube side inlet temperature V/s tube side outlet temperature and the shell side condensate outlet temperature. Figure 6 indicates the tube side inlet temperature V/s HX3 duty.

It can be observed that, in the existing plant operation, when HX3 tube side inlet temperature was about 172oC, the heat exchanger duty was highest, with shell side outlet temperature very close to tube side outlet temperature. With addition of the new heat exchanger upstream of exchanger train, HX3 inlet temperature was increased.

In addition to a decrease in exchanger EMTD, this also results in an increase in shell side condensation temperature.

Refer to Figure 4; vapour weight fraction i.e. uncondensed steam, increases with the increase in condensation temperature.

Thus, the increase in shell side condensation temperature results in a decrease in the amount of steam condensed. Hence, any increase in HX3 inlet temperature resulted in a decrease in HX3 duty.

While utilising the process steam, the quality of the steam should be investigated to determine the non-condensable gases, 46 • July 2016

Figure 6: Tube side inlet temperature V/s HX3 duty

if any. Even a small amount of noncondensable gas can change the steam condensation phenomenon significantly, and the same should be factored-in during heat exchanger design and heat integration assignment.

Conclusion: Although the duty of the newly added heat exchanger was 1501.6 KW, the overall increase in heat exchanger train duty was only (20519.6 – 20329) = 190.6 KW due to reduction in duty of HX2 and HX3. This rise in duty is only 12.7 per cent of the new exchanger duty. Thus, before addition of the new exchanger upstream of the exchanger train, all the downstream exchangers should be analysed to ensure adequacy of the same

for the revised temperature profile. If the downstream exchangers become inadequate for the revised temperature profile, the overall duty gain from the modification will be lower than the duty of the newly added exchanger. The actual gain estimated across the exchanger train should be considered to estimate the Return of Investment (ROI) from the proposed modification instead of presuming that the gain shall be equal to the duty of new exchanger Author’s Details Ashish N Wanjari Deputy Chief Engineer Process Aker Solutions ashish.wanjari@akersolutionscom Chemical Engineering World

Features CEW Guest Column

Connecting IT with Operational & Engineering Technology for Asset Performance Modeling It is helpful to think of digital engineering information as the digital DNA for infrastructure assets – down to every nut, bolt and screw. Just as doctors can analyse human DNA to anticipate health issues and personalise healthcare for better health outcomes, companies can harness the digital DNA of their assets to personalise asset maintenance for better TOTEX, maximised uptime and more, write Bhupinder Singh, Chief Product Officer, Bentley Systems and Anne-Marie Walters, Global Marketing Director, Bentley Systems

A

s operations technology (OT) leverages the Industrial Internet of Things (IIoT) with sensors on operating equipment and assets producing an enormous volume of big data, there is a need for improved security, information sharing and data management. This, in turn, is driving an unprecedented convergence with IT. However, organisations are struggling to make use of the data from their OT and IT systems, causing them to miss opportunities to improve asset performance. This is due, in part, to the fact that the digital engineering models developed during the engineering phase of capital projects, are typically not playing a role in operations.

Anne-Marie Walters, Global Marketing Director, Bentley Systems

Bhupinder Singh, Chief Product Officer, Bentley Systems Chemical Engineering World

What if owner-operators could use these models in operations? Imagine how a digital engineering model— the engineering technology or ET of an asset—could help operations and maintenance people forecast problems, do better planning, and improve performance. It is now possible for companies to converge their IT, OT and ET – and seamlessly integrate process and information flows between them – to enable asset performance modeling to deliver actionable intelligence for decision support through an immersive environment for visual operations.

The Digital Engineering Model For many years, engineering departments have been using advanced modeling and simulation applications that focus on the process of design and construction of

an infrastructure asset – a plant, bridge, highway, railway or utility network – in a way that improves project delivery and asset performance. Better project delivery enables companies to optimise CAPEX – through both the depth of information modeling and the breadth of information mobility for collaboration during design and construction. There’s a staggering amount of information related to assets– detailed component specifications, precise geo-location, configuration management, fabrication details, cost information, predicted lifetimes, recommended maintenance and repair information.

Today’s engineering technology makes it possible to bring all of this information together within the federated digital engineering model, making it possible to track, access, and share with others collaborating on the project (see Figure 1).

The technology also enables engineers to model projects in a 3D virtual setting for design integration and construction work packaging, so that when the project is actually constructed in the real world, the project teams and stakeholders are able to minimise unforeseen situations and keep the project on track.

Ideally, all of this information flows between applications and project teams for better project delivery, which is the key to better CAPEX, and flows through to operations and maintenance systems across the entire asset lifecycle, which is key to reducing OPEX. For example, when companies can integrate the 3D models for each discipline involved in a project, it July 2016 • 47

CEW Features performance, enhanced understanding of interrelationships, and better decisionmaking and more accurate predictions of short- and long-term demand.

South Australia Water also integrated a demand optimisation tool that is used to optimise the availability and the movement of clean water around the network to demand areas quickly and efficiently. It calculates how to deliver the water by calculating costs and determining which pumping stations to use, which pumps are needed, and so on. Built-in analytics take the output of the demand forecasting tool to develop a live hydraulic model that determines water pressures and flows throughout the network. Using this digital engineering model, South Australia Water can actively optimise water supply and reliability to its customers. Customers enjoy improved water security, and response times to problems, such as broken water mains, have been reduced by 90 per cent.

Figure 1: Digital engineering models bring together critical information in a virtual 3D environment.

improves information mobility. Disciplines can more effectively communicate critical design details for operations, detect clashes earlier in the design phase and before construction starts, share updates during the engineering and construction phases, and hand over accurate and complete information to ensure successful start-up and ongoing operations.

The Beginning of IT/ET/OT Convergence The Industrial Internet of Things (IIoT) is driving a convergence between operational technology and information technology. Digital engineering models can accelerate this convergence and add the visual representation of the real world needed to aid decision making; this can have far-reaching impacts on the safety, productivity, efficiency and operations of industries worldwide.

For example, consider how South Australia Water is currently using predictive and 48 • July 2016

real-time operational analytics to forecast water demand and improve customer service while reducing operational costs.

To create a demand forecasting tool, they needed to pull information from both the operational and IT sides of the organisation in real time. Bentley’s predictive analytics software was chosen as the operational intelligence platform due to its real-time ability to connect and capture data from a wide variety of sources, ability to perform complicated calculations and analysis, and its impressive visualisation capabilities.

Real-time monitored sensor data is brought in from the reservoirs, water treatment plants, valves, flowmeters, and pumps spread across the extensive pipeline network. This operational data is combined in real time with climate, energy, cost, and population data and is displayed on dashboards. Bringing these data sources together has resulted in huge benefits, including improved

Tying together IT, OT, and ET also allows the company to take advantage of lower forward market pricing for electricity. They can use an energy portfolio management spot-market power price tool to determine the optimal timing for pump operations on five pipelines, as well as when to purchase power in highly volatile markets.

The impact on OPEX can be significant – a savings of AUD 3 million per year.

Making the Leap to Asset Performance Modeling Taking the convergence of IT, OT, and ET one step further, it’s now possible to enable real-time asset performance modeling, which ensures that assets are safe, reliable, and efficient over their operating life. For example, Bentley’s asset performance management software enables companies to develop both operational and asset strategies for improving reliability and maintaining asset performance and predictable production.

Using a Common Data Environment (CDE), companies can collect, consolidate, and analyse data and turn it into actionable intelligence. The software also helps ensure regulatory compliance and is aligned with asset management standards, Chemical Engineering World

Features CEW alerts, geo-coordinate to the exact positioning within the infrastructure asset, and drill down into the 3D digital engineering model to determine the cause of the alarm. Then they can refer to the manufacturer’s degradation data, access maintenance and repair data information, and take corrective action – all in seconds.

Figure 2: Asset performance monitoring brings together IT and OT with big data analytics

including PAS 55 and ISO 55001. At the same time, it applies leading information modeling and information management technologies to asset operations and maintenance, and when combined with information delivered at handover from projects, provides a complete lifecycle information management solution for owner-operators. This enables owneroperators to optimise processes for the day-to-day running of assets, balancing capital and operational costs and maximising production capability.

Many companies are already on their way to using these solutions, thanks to widespread adoption of condition monitoring technologies. As shown in Figure 3, monitoring assets requires integration of IT and OT systems, as well as big data analytics to discern patterns in data and automate or recommend optimal responses to them.

nut, bolt, and screw. Just as doctors can analyse human DNA to anticipate health issues and personalise healthcare for better health outcomes, companies can harness the digital DNA of their assets to personalise asset maintenance for better TOTEX, maximised uptime and more.

For example, companies can manage the performance of their assets far more effectively when they have digital engineering models that intelligently bring together all infrastructure data.

When IT and OT systems connect with this ET data, teams can view the asset performance history; see all failure

Harnessing the Power of Continuous Surveying Having an accurate frame of reference – for example, capturing precisely located photographs and videos and comparing these over time – allows companies to bring together OT, IT, and ET to support asset performance modeling. New, photogrammetric surveying methods allow systems to keep these frames of reference up to date. For example, Bentley’s ContextCapture software is being used to turn digital photography from UAVs and close up ground shots into accurate as-operated 3D models of infrastructure assets. Rather than producing a point cloud, the software generates a highly accurate 3D reality mesh that can be brought directly into a 3D engineering environment, and geo-coordinated for precise real-world location, to design in

To move to asset performance modeling, 3D digital engineering models across all disciplines are integrated with the IT and OT systems used for asset performance monitoring (see Figure 3). As the operating baseline for infrastructure assets, digital engineering models bring together schematics; engineering analyses; network models; 3D models; functional components, catalogs, and specifications, as shown in Figure 3.

It is helpful to think of digital engineering information as the digital DNA for infrastructure assets – down to every Chemical Engineering World

Figure 3: Asset performance modeling integrates 3D models with IT and OT systems used to model asset performance.

July 2016 • 49

CEW Features

Figure 4: Users can utilise 3D meshes as an immersive environment for visual operations.

context or compare the digital engineering model with the reality mesh — highlighting differences between the digital design and the actual conditions.

The 3D reality mesh can provide the digital frame of reference aligning all IT, OT, and ET data with the real world.

Specific components of the reality mesh can be hyperlinked to relevant documents and schematics, historical performance data, and real-time asset monitoring dashboards. When events occur or alerts are triggered, users can navigate their assets through the 3D mesh and then drill down to related maintenance and repair manuals and more (see Figure 4).

The entire experience is immersive, highly accurate, and based on the latest data.

Engineering in Context These same technologies also allow designers to engineer – and reengineer – in context. For example, when making

the decision to repair, replace or remove, rather than starting from scratch or using an existing design model, the engineer or designer can use the continuously surveyed model of the plant or asset as the accurate, 3D representation for the decision. They can walk through the model virtually and explore the options for adding or replacing with new equipment right in the context of the 3D reality mesh.

Once the engineering is approved and construction or replacement begins, the same continuous surveying technique can continuously generate a new 3D reality mesh to track progress and finally create the new point of reference for IT, OT, and ET. Everyone involved can instantly see conditions change as construction progresses – and once work is complete, owner-operators can continuously monitor and model assets to assess

Once the engineering is approved and construction or replacement begins, the same continuous surveying technique can continuously generate a new 3D reality mesh to track progress and finally create the new point of reference for IT, OT, and ET. 50 • July 2016

conditions, drill down into alerts and issues, take informed action, and optimise asset performance.

Seamless Integration of Processes and Information We are at an incredibly exciting convergence in the world of asset management. The ability to work in a comprehensive modeling environment, leveraging ContextCapture and 3D reality mesh technologies, and connecting with the Industrial Internet of Things through asset management and predictive analytics software, companies can converge their information technology, operational technology and engineering technology – and seamlessly integrate processes and information flows between them.

The next generation of engineers – digital natives – will no doubt find ways to exploit this convergence in unprecedented ways. We can realise immediate benefits today, by using these technologies to make more informed decisions regarding when to repair, retire, or replace assets so that they are safer, more reliable, and maximally efficient over their operating life.

Chemical Engineering World

Features CEW Technical Article

Asset Data Management & Integration Support - A Physiological Project Need Increasing levels of global competition and rapidly changing market conditions behooves chemical manufacturers to continually look at ways to maximise their asset utilisation and effectiveness, either through operational improvisations to increase throughput, yield and reduce costs or by expending additional capital. Resulting engineering projects tend to have tight deadlines and availability of ‘right’ engineering information from the plant has always been a bottleneck in most petrochemical, chemicals or refinery complex projects.

P

rojects in petrochemical, chemical or refinery manufacturing, whether large or small, inevitably require as well as generate enormous and complex sets of information. Effectively managing this bulk of information to ensure its timely availability and accuracy is an important managerial task. Poor quality of information or missing information can lead to project delays and suboptimal or even uneconomical decisions. Even when the information is available, it is not uncommon to have challenges. See the Figure 1.

These discrepancies results in lack of confidence in the data to use and the

one cannot rely on the set of information available resulting in extra effort and hence project delays or if the extra effort is not taken, it could result in suboptimal or uneconomical decisions, operational issues or even the project failure.

of information may generate compatibility issues between client and contractor, if the system is not unified into an integrated database. It is challenging to collect data from different systems and maintain consistency.

In old plants, data (vendor or contractor documents and drawings) is available and stored in the form of hard copies, making mining of data a time consuming task as well as putting a question mark on reliability, consistency and completeness of the data. With advancement in technology and introduction of sophisticated software and applications, generation and management

A survey conducted by Gartner indicates that an average organisation loses USD 8.2 million annually on account of poor data quality. Further, of the 140 companies surveyed, 22 per cent estimated their annual losses resulting from bad data at USD 20 million. Four per cent put that figure as high as USD 100 million.

Data needs typically arise on projects done at various stages of the lifecycle of a chemical plant: • Design • Engineering • Commissioning • Operations • Expansions • Modifications • Statutory or Regulatory Requirements Both engineering design projects and operational improvement analytics projects are crucially dependent upon accurate and timely information availability as well as the ability to use this information effectively.

At the same time unnecessary information presented to managers can result in confusion and decision-making paralysis.

Figure 1: Major hurdles during project execution:

Chemical Engineering World

Having the right information available at the right time, in the right form and the right amount is key to evaluating and making July 2016 • 51

CEW Features

Knowledge

Information

Data Figure 2: Involvement of multi-disciplinary subject matter experts is extremely important

decisions on Capex and Opex projects to reduce production costs, increase capacity or throughput, enhancing safety measures or even setting up a new or revamped plant. There is a significant hidden cost on both ongoing operations as well as projects, where the systems to store and retrieve quality data which can be readily converted to usable information and knowledge have not been properly established.

There have been examples of companies who have acquired older or underperforming assets at an ‘attractive’ price, realising later that there is a pricetag to be associated with the existence of well maintained data and information structures, which may have been overlooked at the time of due diligence and price negotiation. Missing data or poor quality data can increase cost and timelines on projects, whether for efficiency improvement, compliance, revamps or expansions. In case of the examples of companies mentioned above, 52 • July 2016

the document control room in the plants comprised of several files of engineering data and documents without any proper identification of final or the as-built version, making it difficult for a contractor appointed to perform revamp work, increasing costs and timelines. In this case, there were occasions where it was observed that certain engineering documents which were critical input documents for the project, were not even in a legible format, which translated into delayed work, resulting delay in plant start-up and finally loss of revenue.

Ingenero has supported some of their Process Manufacturing clients address such shortfalls in this area, with their Asset Data Management and Integration Support Services (ADMISS). ADMISS provides a scientific and proven approach to create a centralised repository with structured and consistent data along with as-built information plugged-in which becomes easy for use or retrieval. Additional levels of analytics or Business Intelligence

interfaces are typically added on, once the data foundation is set, which can then be accessed from remote locations using the Industrial Internet of Things (I-IoT) concepts, for operational improvement use or engineering project inputs.

ADMISS entails the involvement of subject matter expertise and technology to manage asset data and convert it into decision quality knowledge. The involvement of multi-disciplinary subject matter experts is extremely important in this process, absence of which will create a dilemma in the selection of the right set of information, thereby hampering the ability to make optimal or sometimes even the correct decision.

This solution consists of some key steps, starting with data collection through consolidation of necessary data/ information into a readily accessible database, which helps convert raw data into knowledge, enabling correct decision making. The key steps are: Chemical Engineering World

Features CEW

c. Reconciliation becomes a crucial part of the step wherein information may be available in bits and pieces as well as at times from multiple sources such as engineering drawing, operations data, etc. but not consistent with each other.

It becomes essential to reconcile this information to avoid duplication, gaps and inconsistencies.

This is a common scenario in most plants undergoing frequent modifications and where these details are not updated in the engineering documents. This acts as a major hurdle in carrying out further studies.

Chemical Engineering World

Authors’ Details Mayuresh Mokal AM-Sales & Marketing Ingenero E: mmokal@ingenero.com Dr Pratap Nair President & CEO Ingenero E: pnair@ingenero.com

Pumps & Valves Special August 2016

Single repository with ease access, transfer of quality information, Structured and consistent information, Assurance of data with improved decision ability, Shorter times to initiate and execute engineering for expansion/ revamp and operations improvement projects are some of the benefits of this ADMISS solution.

The main purpose is to extract information from collected data and transform it into an understandable structure for further usage.

For example, Piping Isometrics may indicate existing pipeline from reactor to column of size 8 inch but after walkdown it is identified to be 10 inch.

Valves Pumps & Special 16 August 20

b. Data Mining is carried out using advanced analytics and other stateof-art tools and techniques such as artificial intelligence or statistical programs, from a pool of collected data.

e. Data Consolidation enables the user to have a single repository access to information instead of indexing it across multiple locations.

Contact our representative to book your advertisement in Pumps and Valves special issue of Chemical Engineering World magazine.

Experts have observed that improper screening of data has led to project loss worth millions of dollars hence involvement of Subject Matter Expert (SME) in the data collection team is of utmost importance. The process involves field walk-down by data collection team led by SME to prevent the hurdles that can be faced during later stages.

d. Validation of Collected Data needs to be carried out in conjunction with reconciliation and requires presence of domain experts for cross checking calculations and for verifications. The outcome will result in omission of obsolete information.

2017 Mumbai

a. Data Collection is the most critical portion of the data integration program wherein the domain experts screen the right information before it lands up in user’s hand thereby saving on precious time later.

ry 2017 14-17, FebruaIndia Mumbai,

Validation of Collected Data needs to be carried out in conjunction with reconciliation and requires presence of domain experts for cross checking calculations and for verifications.

July 2016 • 53

CEW Features Technical Article

Stage- gate Process and Criticality of Front End Loading Modern day chemical projects are becoming more complex and with the competitive market it is very essential that each project gets completed with the three key parameters of Quality, Schedule and Cost under control. It is very common to hear of projects getting delayed and going over budget.

I

ntroduction to Stage Gate approach

To streamline the execution of projects, one of the most effective tools is the implementation of the Stage Gate process while executing projects. This methodology involves dividing the project into multiple stages and having a check (GATE) at the completion of each stage. This enables the management to gauge whether the project is on track and also provides them with opportunities to decide whether to proceed and release further funds to the project or to discontinue the project.

A typical project is always split into 5 distinct stages and corresponding 4 gates as can be seen in the figure 1 below.

The main idea of the Stage Gate Process is that the Project team has to go to the management at the completion of each stage and get an approval from them to move ahead to the next stage. So each gate acts as a checkpoint for the project wherein all Key stakeholders in the form of a Steering committee or company board are involved in the decision making process.

Project Development Fel 1 Gate 1: Approval of feasibility report

FEL or Front End Loading is a standard defined by IPA (Independent Project Analysis) for the initial phases of the project.

The first three gates are very critical as it is only at the third gate FEL3 the main project funding is approved by the management and the actual purchase of hardware like equipment, piping, instruments etc is done only after FEL3.

So, not only does the first three stages give an opportunity to scrap the project if not found feasible but also any item missed out at this stage will get amplified in terms of cost and schedule impact.

To understand the importance of the FEL3 gate, 80 per cent of the project finances are allocated at this gate. So, the accuracy of the FEL3 package can make or break the project.

FEL2 and FEL3 Content FEL1 is normally applicable for New product application i.e. if a new product has been implemented in R&D and needs to be scaled up or if a new process is developed for an existing product.

Basic Design/ FeeD Fel3

Concept Design Fel2 Gate 2: Approval of Concept and ±20 % Cost estimate

Gate 3: Approval of FeeD and allocation of funds based on ± 10% cost estimate

In this article we shall focus on the implementation of project for existing product for which the basic commercial scale feasibility is established.

In such a case the FEL2 and FEL3 stages become most critical. The primary check to be done is to ensure that all relevant information/ documents required for clearing the gate are available. Given below is a summary of the documents required on the completion of FEL2 and FEL 3 stages to clear the respective gates.

While going in for the management clearance for the FEL2 or FEL3 gate it is always advisable that check list with complete list of documents be always used. The documents which are not relevant for a specific project should be accordingly indicated in the list so that it is ensured that no aspects of the project are missed out.

In addition to the documentation requirements it is essential that certain cross-functional reviews are conducted in these stages.

Project execution (ePC)

Plant commissioning and Start up Gate 4: Acceptance of Mechanical Completion and prestart up review

Figure 1: A typical project is always split into 5 distinct stages and corresponding 4 gates

54 • July 2016

Chemical Engineering World

Features CEW Stage

Concept Design

Basic Design

Discipline

Document

Process Engineering

Project description, Preliminary process flow diagrams, Equipment list and load list, Control Philosophy

Project Engineering

Organisation chart, Execution strategy, Cost Estimate ± 20% preliminary estimation of ROI

Layout

Plant layout, logistic concept

Civil and Structural

Site master plan, Soil Investigation studies, Building/ Structure outline drawings

Process Engineering

Specifications and Standards, P&ID`s (AFD) for process and utility, Tie-In drawing, Equipment datasheet (for purchase) Laboratory description

Project Engineering

Cost estimation +/-10%, Time Schedule

Instrumentation

Instrument specifications (DCS, PLC, Control Valves,), Control loop list

Civil and Structural

Architectural guide drawings, Steel structure calculations

Layout

Preliminary model( 3D model or 2D drawings)

Electrical and HVAC

HVAC Design, Electrical guide drawings for lighting, power systems, substation arrangement, IT and Telecom equipment

General

First MTO`s for Piping, Civil, Electrical and Instrumentation, etc

Table 1: Documents required on the completion of FEL2 and FEL 3 stages to clear the respective gates

For the FEL2 stage, the required review is an HAZID study which identifies the major hazards in the plant and identifies means to handle the hazards.

For FEL3 stage, it is essential that a HAZOP study and Constructability study be completed before the Gate.

For the HAZOP study all information especially vendor specific details might not be available, but at a minimum the extent of Instrumentation and Controls provided and the requirements of Safety Instrumented systems need to be evaluated. These have a major impact on cost and also on timelines due extended delivery dates for imported instruments.

Constructability review might throw up a major change in layout to ensure smooth installation of equipment and also additional area requirements for laydown and equipment installation.

Chemical Engineering World

Authority Approvals In addition to the above documents it is very critical that all the authority approvals required for the project be identified and a timeline for the same be prepared. Since local authority approvals are mandatory for the project, delays in getting them are a major cause of project delays and also can lead to project getting scrapped after proceeding ahead in the Execution i.e.

EPC phase.

Criticality in Project The implementation of the stage gate process is considered by some to be a tedious and time consuming process which leads to extended project timelines, but the reality is far from this.

Implementing the Stage Gate process has its clear benefits: • Clarity of Project scope: With the detailing that is required and using check lists for the documentation,

there is a clear understanding of the inclusions and exclusions in the project.

• Traceability: Any modifications done to the project scope can be easily identified and the corresponding impact on Schedule and Cost can be easily estimated and tracked.

• Buying from key Stakeholders: Since the procedure requires passing through the Gate process at the end of each stage, it ensures that all key stakeholders are kept aware of the status of the project and there is a clear agreement between the project team and the key stakeholders on various assumptions and deviations.

• Judicious Use of Resources: With the use of the stage wise approach only limited spending of money and allocation of people resources is done in the initial stages with sufficient to limit the damages in case the project is found unviable at FEL2 or FEL3 stages.

Checks to Supplement the Stage-Gate Process So, does it mean that a simple implementation of the Stage Gate method would lead to projects getting completed on time and within cost?

Unfortunately that is not the case. Even after using the Stage Gate method there are cost and time overruns primarily due to 4 factors: • Projects are overdesigned/ over engineered • Unsubstantiated contingencies are considered • Project is prone to risks which are not anticipated • Improper Contractor selection To combat this it is essential that two tools i.e. Class of Facility Analysis and project risk register be used along with the Gate Process.

• Class of Facility analysis: This enables the project team what is most July 2016 • 55

CEW Features critical to management for the specific project. The analysis is done by a Cross functional team who rate the project on nine factors on a predetermined scale which includes Capacity, Product Quality, Reliability, Expandability, Lifetime, Automation, Maintainability, Turnaround and Schedule.

If we take the example of a Pharma project the rating of Product Quality and Capacity would come highest whereas items like Turnaround and Automation would be pretty low priority.

A clear rating from the assessing team gives a direction to the Project team while designing the project and ensures that the design is always aligned to the Management requirements.

• Project Risk Register: The project risk assessment has to be started right from the FEL2 stage and has to be continuously updated throughout the

The implementation of the stage gate process is considered by some to be a tedious and time consuming process which leads to extended project timelines, but the reality is far from this. project. Having a clearly documented Project risk register enables to provide for adequate contingencies in cost and timeline. Also the risks are continuously monitored and more importantly appropriate project team member can be assigned handle individual risks and the effects of the same can be mitigated.

• Contractor Evaluation: The approach taken by a lot of project teams is of one contractor fits all which is detrimental to the project. For effective execution the contractor evaluation has to be done based on the size, complexity and in some cases location of the project.

Conclusion A combination of the Stage-Gate Process with the three add-on points would go

a long way in implementing successful projects which would meet all three Key Success Factors of Quality, Cost and Schedule.

Author’s Details Shailesh Dhume Principal Consultant Infuse Consulting E: shailesh.dhume@ infuseconsult.com

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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 56 • July 2016

Chemical Engineering World

Features CEW Technical Article

Mapping the Way to Controlling Nuisance Noise Taking steps to reduce noise levels in the workplace can be expensive, but there are many benefits, both in terms of worker safety and cost reductions. However, for any mitigation activity to be appropriate and effective, an accurate assessment of noise sources is required, along with details of how noise travels around the site.

I

n the wide-field of chemical engineering, nuisance noise can come from a variety of sources and have a range of impacts. For example, the heat and noise generated by the distilling processes in refineries and the seemingly endless racks of pipes transporting sound across the premises can seem both deafening and disorientating. Spray-on foam is one way to help dampen the noise and reduce heat loss, but how much should be used and where will it be most effective? What other measures could be implemented to make the biggest difference?

considered: type of noise; noise levels and temporal pattern frequency distribution; noise sources (location, power, directivity); noise propagation pathways, through air or through structure; room acoustics (reverberation). In addition, other factors have to be considered; for example, number of exposed workers, type of work, etc.”

Getting to the Source Noise emissions on occupational sites vary widely in sound power, frequency spectra, directivity and also in their

timings. Their regularity in different work situations also varies between irregularly distributed noise impulses and almost continuous noise.

The danger of hearing loss is a given if people are exposed to a noise level of more than 85 decibels (dB). The risk of hearing loss increases with the magnitude and exposure time and the frequency of the noise; with higher frequencies doing more damage. Hearing loss makes up between 30 per cent and 40 per cent of occupation-related illnesses.

Whether designing processes and equipment for large-scale manufacturing, test production methods and by-products treatment, or direct facility operations, chemical engineers need to be protected from excessive noise, and plan the protection of those who will work in the situations being designed.

In the arena of noise control the saying ‘scientia potentia est’ (‘knowledge is power’) is very apt. It is not hard to recognise nuisance noise, but identifying its exact source and field of propagation can be a very different matter. If you are going to reduce noise and mitigate its harmful effects, then you need to know as much about it as possible. To be truly effective, any attempts at noise control must be based on an accurate analysis rather than guesswork or reference to previously recorded levels.

The World Health Organisation, in its paper ‘Engineering Noise Control’ says: “To adequately define the noise problem and set a good basis for the control strategy, the following factors should be Chemical Engineering World

Figure 1: SoundPLAN - External Noise

July 2016 • 57

CEW Features In noisy locations, when considering how to control the sound, the primary requirement is to locate and document the areas where the noise reaches 85 dB or above. This is known as the ‘noise contour line’. In areas where noise levels exceed 85 dB, workers should wear hearing protection. Failure to clearly mark the noise contour line could leave companies open to fines and litigation. There must always be signs showing employees and visitors where hearing protection is required and it is the supervisor’s responsibility to ensure it is always worn.

The contour line applies both inside the building and outside.

If a workplace has areas that may be close to or above 85 dB, then a noise study should be carried out to define all areas where hearing protection is required. Workers can also be provided with noise dosimeters to keep track of their daily dosage of noise. A well-studied and documented noise policy is better than paying for lawsuits from workers with hearing problems and paying for disability because of tinnitus and hearing loss.

Mapping the Noise Using the data from the study, and other relevant sources, with sound mapping software means that realistic noise simulations can be developed. These can show the sources of the loudest noise and the propagation across the site. Measurement alone shows only one noise level and it is not possible to assess how much noise came from any source.

However, computer-devised simulations mean you can now isolate and address problem areas.

Equipment (PPE) required. Removing, or reducing the need to wear PPE can also improve working conditions and communication between workers. This can help improve productivity levels and reduce accidents.

Figure 2: SoundPLAN - Noise in A Building

size, geography, objective, and most significantly, the available data which can be imported and used.

Noise Reduction Pays There are a number of benefits to controlling noise in industrial situations.

The protection of workers’ health should be a priority, but there are considerable financial incentives too.

Health and Safety: As well as the more obvious concerns around damage to hearing, there are a number of other potential health implications of longterm exposure to excessive noise.

These include sleep disturbance and cardiovascular disease as well as other physical disturbances. It can also affect workers’ psychological well-being, leading to communication issues, nervousness and reduced reactions.

Potential Cost Savings: Although there will be an initial outlay for noise audits, new quieter equipment and mitigation factors, properly managing noise should show a positive return on your balance sheets.

Noise mapping also means you can predict future levels of noise and take steps to control it, whereas measurements cannot occur until the entity making the noise is physically there. This means you can work with ‘what-if scenarios’ prior to building a facility and to also assess how effective new quieter equipment or noise mitigation techniques would be.

Not taking action can be expensive.

If excessive noise is left untreated, businesses can face legal action from workers whose health has been affected.

This in turn can increase insurance premiums. There is also the cost of lost man hours when workers take time off sick and the management time to deal with both sick leave and litigation. Those costs can soon mount up, so investing in noise control can quickly pay for itself.

No two noise maps will be the same as their make-up is dependent on the project

Further, direct cost savings can be seen with the reduction of Personal Protective

58 • July 2016

Legal Requirements Simply ignoring nuisance noise is not an option. Most industrial nations have specific noise rules that sit alongside health and safety regulations. These include the Noise Control Act (USA), Occupational Exposure Limits (Canada), the Environmental Noise Directive (EU) and Control of Noise at Work Regulations 2005 (UK) and the Noise Pollution (Regulation and Control) Rules, 2000 (India). This national legislation requires noise control measures to be implemented so that the lowest reasonable levels of noise emission and noise exposure can be achieved. All employers should make themselves aware of the rules affecting their employees, especially if they are working across international boundaries where legislation may not be consistent.

Hearing the Message Loud and Clear Once you’ve created a noise map and developed your noise policy you can introduce controls to start defending workers against the problem noise. By reducing the noise by just a few decibels the risk of hearing loss and other harmful effects is considerably lessened.

Using low-noise and well-maintained equipment or placing a barrier between the worker and noise source are relatively simple steps, but they can have a huge impact on people’s lives. Using noise mapping software gives you the knowledge to accurately identify the most appropriate changes and safeguard your workers and your business.

Author’s Details Arne Berndt Owner & Adviser at SoundPLAN GmbH and SoundPLAN International LLC E: arne@soundplan.com Chemical Engineering World

Market Insights CEW

“Collaboration is the Key”- Resil Chemicals

R

esil Chemicals has recently won prestigious National Award - 2016 by Technology Development Board for the commercialisation of an indigenous technology, N9 Pure Silver. N9 Pure SilverTM, along with its variants N9 Plastix and N9 Claro CT, is a family of silver-based antibacterial and hygiene solutions. It is a revolutionary Silverbased technology that, on contact, neutralises odour-causing bacteria, keeping the treated product fresher for longer, says Ganesh Srinivasan, Executive Director - Innovation at Resil Chemicals Private Limited. In an email interaction with CEW, Srinivasan further says that the breakthrough technology delivers outstanding odour control performance, combined with impeccable environmental credentials and safety profile.

“The potential presented by N9 Pure Silver is immense. From articles of daily use, such as clothing, and bed linen, to food packaging and hair care - the opportunities are vast, making it an ideal solution for several industries,” he adds.

Resil Chemicals is an innovation-driven and diversified specialty chemicals and high-performance materials manufacturer for industries ranging from textiles to pharmaceuticals and agriculture. Srinivasan believes that the success has been ensured by organisation’s continuous technological upgrations and its ability to customise products for individual customers.

Resil was a pioneer for silicones in textiles; the company was among the first to supply the full range of textile finishing and auxiliary chemicals and manufacture customised silicones for textiles.

“Today, we are also one of Asia’s largest formulators of customised silicones. Thus, Resil has developed significant in-house polymer formulation technology, giving us in depth understanding of the dynamics of chemical-tosubstrate interaction, and a thorough comprehension of the requirements of its customers,” he further states.

While commenting on Performance Chemical Business, he reveals, “It caters to the silicones requirements for various industrial uses like personal care, pharmaceuticals, agriculture etc. This ability to customise helps us differentiate from other suppliers; while our competitors provide standard products, we provide customised solutions to our customers’ problems.”

Srinivasan says that silicones are crucial for rubber, leather, pharmaceuticals and personal care segments. “Silicone as a chemistry has a wide variety of applications due to its chemical

From a small manufacturing unit in 1994 with just 5 employees, today, Resil is a 300+ member organisation with 4 internationally certified manufacturing facilities with over 20,000 metric tons of specialty chemical production per year.

Resil now exports to more than 10 countries and has diversified into emerging technology based products such as hand sanitisers, disinfectants and car care products.

The chemical industry in India is the largest consumer of its own products. “Firstly, with the government’s focus on “Make in India”, we feel industrial production in India will increase, thereby increasing demand of downstream products.

Chemical Engineering World

M S Vijayan, Joint Managing Director, Resil Chemicals Pvt Ltd receives the award on Technology Day at Vigyan Bhavan, New Delhi.

July 2016 • 59

CEW Market Insights

Applications of N9 Pure Silver Plastics: N9 Plastix is used for plastics such as LDPE, PP, HDPE, PES and PVC. They can be incorporated either directly or during the master batch stage for applications ranging from food packaging to water tanks. Plastics are prone to the development of bacteria and algae which causes odour, degradation, discolouration, and staining. This leads to crosscontamination. With the advantage of Silver, N9 Plastix additive provides malodour-control and long-lasting freshness, making it a must-have for all plastic articles.

Personal Care: N9 Claro CT is a colourless product that can be added to a variety of personal care and cosmetic formulations for skin care, hair care, body care and home care applications.N9 Claro CT is a silver ion-based antimicrobial technology that can be incorporated into cosmetics and personal care products as a preservative. It is a highly effective product of natural origin, making it completely safe.

It is recommended for use in deodorants, antiperspirants, hand creams, anti-acne face washes, hand washes, foot creams, body lotions, body washes, and shampoos as a safe alternative to carcinogenic preservatives like Triclosan. nature, ranging from antifoams, textile softeners, lubricants, silicone rubber… the possibilities are endless! While in the past manufacturers used silicones in lower quantities due to its relatively ‘high price’, today silicones are widely accepted and are seen as indispensable, especially to rubber, leather, pharmaceuticals and personal care industries.”

Resil’s smart partnerships with various silicone industries and research institutes in the area of silicones help discover new molecules and materials. Srinivasan is of the opinion that in the specialty chemical industry, collaboration is the key.

“Ours has always been a collaborative approach- We work with top international silicone manufacturers and chemical majors to ensure that we can make differentiated products. We also collaborate with leading research institutes like IIT Delhi to develop new technologies to solve consumer problems and pain points,” he explains.

The company has 33 members and operates out of state-of-the-art-laboratories which are recognised by the 60 • July 2016

Department of Scientific and Industrial Research (DSIR), Government of India. Its R&D team is driven by its ‘Tenets of Innovation’ which simply put, places emphasis on Customer, Creativity, Collaboration, Communication and Community.

This ethos is imbibed by all our team members.

Resil has just opened its fourth and largest state of the art unit at Malur, Karnataka. It is looking to expand into new international markets; it has a full-fledged sales operation in Bangladesh and has made inroads into Sri Lanka, Turkey, Philippines and Thailand.

Scope of Chemical Industry in India Srinivasan believes that the contribution of chemical industry in overall GDP can certainly grow in future. He says, The chemical industry in India is the largest consumer of its own products.

“Firstly, with the government’s focus on “Make in India”, we feel industrial production in India will increase, thereby increasing demand of downstream products. Secondly, India is one of the few growing major global economies. Global chemical majors will be looking to invest more in India, especially as there is a looming downturn in China. Things are looking bright for chemicals in India and there is no reason why the industry’s share of the GDP should not increase,” he justifies.

He also comments on Ministry of Chemicals and Fertilizer’s plan to create chemical hubs in the country and calls it a “a great initiative.” “There are about 22 refineries in India and the move to set up clusters around them will definitely result in cost savings for downstream chemical players. Creating chemical clusters will help in reducing many investment burdens, especially on effluent treatment, chemical storage and testing facility infrastructure which can now be shared.”

However, he also opines that government needs to undertake import tariffs to ensure that it is chemical inputs into the country from competitors in China.

one focused effort the is the rationalisation of cheaper to import critical and not the final product

Srinivasan expresses, “A lot of work is going on to rationalise basic chemicals, but a lot remains to be done. Another major effort that we desperately need is a speeding up of all initiatives like the chemical cluster hubs and the GST. While we see a lot of progress and initiative by the government, the machinery needs to move faster.”

- Harshal Y Desai Chemical Engineering World

Marketing Initiatives

Bhastrik Mechanical Labs: Contribute to the Success of Customers around the Globe

B

hastrik Mechanical Labs Pvt. Ltd. is promoted by pioneers with 30 years of hands on experience in the field of manufacturing Metal Bellows, Edge Welded Bellows & Membrane Compensators.

Bhastirk Mechanical Labs was started in January 2004, with the sole objective of manufacturing high quality specialty Bellows and other allied products with improved, well designed special purpose machines.

Our mission is to contribute to the success of our customers around the globe by providing versatile unmatched combination of our terms Technical Excellence, practical experience and responsiveness.

Our vision is to be recognized by our customers, employees and competitors as being “The Best” Engineering firm.

CONVOLUTED BELLOWS: Bhastrik Mechanical Labs manufactures Convoluted Metal Bellows in Stainless

Steel 304, 304L, 316, 316L, 316Ti, 321& AM 350 and Exotic metals including Hastelloy C-276, Inconel 600 & 625/625 LCF, and Phosphor Bronze.

The precision-formed diaphragms are edge welded by Micro plasma/ Laser welding using special fixtures to prevent uneven stress build up.

Bellows sizes ranging from Internal Dia. 10mm to 600mm, wall Thickness ranges from 0.10mm to 1.0mm with single ply or multiple number of Plies.

MEMBRANE COMPENSATORS: Bhastrik Mechanical Labs Manufacture Membrane Compensators which are used for the absorption of changes in volume due to temperature difference (Insulation Oil in High-Voltage)

We have Manufacture Metal Bellows in U shape & Toroidal shape by HydroForming, Expanding Mandrel forming and Elastomeric forming Methods.

EDGE WELDED (DIAPHRAGM) BELLOWS: Bhastrik Mechanical Labs possess the capability to manufacture Nested Ripple type Edge Welded Bellows in Stainless steel and Exotic metals like Hastelloy C276, Inconel 600, 625 and AM 350 of size ranging Min. of 12mm ID to 175mm OD. Thickness of Diaphragm varies between 0.1mm and 0.3mm. In some special cases, we have welded Diaphragms as thin as 0.03mm (30μm) with ‘0’ wrinkles & distortion.

Stainless Steel Diaphragms are pressed with a Special profile. They are welded together on their exterior diameter with ‘0’ wrinkles & distortion.

BHASTRIK MECHANICAL LABS PVT. LTD. Contact us: Plot No. 95 & 96, 1st Main Road, Nehru Nagar Industrial Estate, Kottivakkam, Chennai – 41.

Tamil Nadu, INDIA. Tel: +91 44 – 4359 3702 / 03.

Fax: +91 44 – 2454 0353 Email: admin@bhastrikbellows.com sales@bhastrikbellows.com Web: www.bhastrikbellows.com Chemical Engineering World

July 2016 • 61

Marketing Initiatives

Applying Vacuum in the Process Industries Solution from the Experts

V

acuum generation technology plays a significant role in many l a b o r a t o r y a n d m a n u fa c t u r i n g environments and lays the heart of many production processes. The crucial needs are offered from Toshniwal’s outstanding vacuum resources ranging from pressure measurement equipment to complete systems, so you always get the perfect results you need.

Requirements from the Process Industry In the chemical industr y, a vacuum is almost solely used to run the thermal base operations (like drying, distillation etc.) at lower temperatures to protect the products. The main function of the whole vacuum system is, therefore, to lower the pressure and with that to reduce the boiling temperature. For this the vapor must be pumped and condensed. The best vacuum pump for the condensable vapors is the condenser. For this Toshniwal offers a variety of solutions from its experience over 3 decades in this line.

The main task of the vacuum pump is to pump the leakage air and control the base pressure. This principal setup is shown in Fig. 1. As can be seen in the figure, the main job of the vacuum pump is to evacuate the iner t gases, loaded with some vapors. The main part of the vapour is pumped by the condenser.

Therefore, the actual amount of c o n d e n s a bl e pu m p e d by t h e va cu u m pump strongly varies with the operating conditions. Also adjustment between condenser and pump influence the vapor concentration in the pump. The deviations in real operation often result in a much higher vapor concentration than expected in the selection.

62 • July 2016

That is an essential difference between vacuum pumps in chemical process and the usage in other applications, because the selection of the pumps is dominated by the pumping of vapors’ and vapor m i x t u r e s . A l s o t h e r e q u i r e m e n t s fo r vacuum systems in these applications are mainly guided by explosion hazards, condensation and corrosion problems. Dry running vacuum pumps are today mainly used in pharmacy and fine chemistry. In these industries multipurpose plants are widely used. These are plants designed for the production of a wide range of d i f fe r e n t p r o d u c t s . T h i s a l s o m e a n s for the requirements of the connected vacuum system, covering a wide range of operating and process conditions.

Additionally an easy product change is necessar y, which requires that the vacuum system is independent from the pumped chemicals.

The increasing application of dry running vacuum pumps is not just to avoid contamination with service liquids; it is als o to improve p e r fo r ma n c e a t multipurpose plants.

The vacuum level in a process plant is mainly driven by the temperature in the condenser and the performance curve of the vacuum pump. The required temperature in the reactor to run the processes in a reasonable time results from the working pressure. The increasing requirements on product quality lead to lower pressures as a precondition for lower temperatures in the reactor. This influences not only the selection of the condensers, but also on the attainable working pressures of the vacuum pumps. The normal working pressures at the pump flange of typically 1 to 10 mbar and the increasing costs for contamination and disposal of service

Over three decades of expertise in Vacuum Technology, we offer tailored solutions ranging from individual products to a complete system Toshniwal’s Vacuum product play a vital role in a vast range of technologies. We are manufacturer and supplier of vacuum pumps, vacuum systems and roots pumping system for specific segments in the industry. We owe our recognition competence as service providers with our own manufacturing facilities and as partners of high-tech manufacturers all over the world to the innovative methods with which we satisfy the very highest precision and quality demands.

Chemical Engineering World

Marketing Initiatives liquids makes dry vacuum pumps the first choice in the pharmaceutical and fine chemistry industries.

In the mechanical and thermodynamic design of such a pump, as well as its operation, the handling of condensable vapors is a major concern. Due to the multipurpose characteristic of he plants you will find the whole range of chemicals, from water vapor, highly flammable solvents right up to high corrosives and deposit building vapors. The low operating pressures mean pressure ratios of 100 to 1000 with very low mass flows even at high volume flows.

These high-pressure ratios result physically in high compression temperatures, which have to be controlled in respect of explosion hazards and to avoid carbonization in the pump chamber. On the other hand, these thermal conditions, with the correct selection, open up the chance to avoid the condensation of corrosive vapors, which is the most efficient and cost effective method to prevent corrosion.

Summarized here are the requirements important for dry running vacuum pumps a n d s y s t e m s w h e n t h ey a r e u s e d i n chemical processes:

of any Project, especially at the conceptual stage. The services provided

by To s h n i wa l m e e t a l l t h e s e c r i t e r i a to produce practicable, operable and cost effective engineering solution. Our design combine cost saving and low m a i n t e n a n c e s c h e d u l e s t o m a x i m i ze b e n e f i t s t o o u r c l i e n t s. B y r e d u c i n g the cycle time in the process we add value to the customer’s process.

We understand the impor tance o f e s t a bl i s h i n g a n d a g r e e i n g t o t h e objectives of the customer before we begin to operate or suggest a solution.

That is why we always work very closely with our customers.

Contact: Toshniwal Instruments (Madras) Pvt Ltd 267 Kilpauk Gardens Road, Chennai, 600 010 Email: sales@toshniwal.net Website: www.toshniwal.net

• • • • • •

Safe pumping of ignitable vapors Resistant against corrosive Medias Handling of thermal sensitive chemicals No contamination of service liquids Optimal adaptation to the process Monitoring of important process data for early failure detection Easy integration in existing process control systems • Interface for remote diagnosis Expert, efficient and effective engineering study work is fundamental to success

Figure 1: Vacuum Processes in Chemical Industries

Chemical Engineering World

July 2016 • 63

Marketing Initiatives

High Quality Rubber Components with Modern Vacuum Technology

T

he main products of Datwyler Phar ma Packaging Italy Sr l. are small rubber components for medical equipment. The output of t h e c o m p a ny ’s p r o d u c t i o n fa c i l i t y i n Montegaldella (VI) is primarily rubber par ts for syringe plungers and sealing c a p s fo r s t e r i l e p r o d u c t s. D a t w y l e r ’s thermoforming machines rely on screw vacuum technology by Busch. A vacuum system with four COBRA screw vacuum pumps ensures high product quality, as air and gas bubbles are removed from the rubber during the moulding process.

Datwyler Phar ma Packaging Italy Srl. is par t of the international Datwyler Sealing Solution Group, which is owned by the Datwyler cor poration. Datwyler Phar ma Packaging Italy Srl. operates t w o p r o d u c t i o n s i t e s i n I t a l y. A t t h e Montegaldella (VI) facility, components such as stoppers for blood collection tubes and parts for single-use syringes a r e m a nu fa c t u r e d . T h e s i t e e m p l oy s 140 staff and operates around the clock in a 3-shift system. The manufacturing

process includes all stages of production, from mixing of raw materials to preparing the finished sterile rubber components for shipment. Datwyler’s customers are medical technology companies throughout the world.

The first production stage is the mixing of rubber with additives and chemicals to form strips of base material, which are then coiled. The composition of this base material is dependent on its later application, and is prepared to customer specifications. Two production lines of twelve ther mofor ming machines each c u t t h e b a s e m a t e r i a l s t r i p s t o s i ze automatically. The trimmed sections are then pressed into a mould under vacuum, after which the individual components are stamped, vulcanised, tested, washed and packed.

The moulding process takes place under high mechanical pressure, at temperatures between 175 0C and 180 0C, and in a vacuum of 1 mbar (-999 mbar). This vacuum level is necessary to exclude air bubbles from

Figure 1: Centralised vacuum generation outside of the production rooms

64 • July 2016

the finished component, and to remove vapour generated by the high temperature and pressure of the process. The moulding machines were originally equipped with oil-lubricated rotary vane vacuum pumps, which soon developed a serious problem: the vacuum pump oil reacted with the process vapour, causing emulsions and greasy deposits to accumulate in the vacuum pumps. These deposits reduced the vacuum output, so the required level and pumping speed could no longer be achieved. Costly measures to keep these vacuum pumps running were attempted, including changing the oil every two weeks.

In 2009 Datwyler signed a maintenance agreement with Busch, in which Busch agreed to carry out third-party servicing of the vacuum equipment.

After Busch vacuum specialists had studied the problem in depth, they presented their recommendations to Alessandro Piccoli, the maintenance manager of the Montegaldella (VI) site. Their solution: replace the oil-lubricated rotar y vane vacuum pumps with Busch dr y screw technology. Consequently, a COBRA screw vacuum pump was subjected to extensive testing. These vacuum pumps operate without compression chamber fluids, which means there is no contact between t h e ex t r a c t e d va p o u r a n d a ny o t h e r medium in the vacuum pump. In addition, COBRA vacuum pumps run at a working temperature which allows vapour to pass through the pump without condensing.

The COBRA test system proved to be highly satisfactory, so Alessandro Piccoli ordered two COBRA vacuum pumps to supply a line of six moulding machines.

Both vacuum pumps incorporated Panda Roots vacuum pumps as boosters. This a r r a n g e m e n t p e r m i t t e d t h e va c u u m system to be installed away from the Chemical Engineering World

Marketing Initiatives of COBRA dry screw technology and the centralisation of the vacuum supply. Plans to extend the vacuum system to supply all 24 moulding machines have been made, and will be implemented shortly.

Figure 2: Screw vacuum pump COBRA NC

Figure 3: Blood collection tubes

Figure 4: Rubber plugs

production buildings, with vacuum for the thermoforming machines supplied by a pipework system. An upstream vacuum reservoir ensures that the required vacuum level and pumping speed are constantly available. In 2012 two additional vacuum units were ordered and installed – also with COBRA fore pumps and Panda Roots booster pumps – to supply a complete line of twelve thermoforming machines.

All the vacuum units are equipped with a fully automatic control system, which monitors the vacuum level and activates the minimum number of vacuum pumps required to meet the current demand from the twelve thermoforming machines. This means that all the vacuum pumps run only when the entire line is operating at maximum capacity. In everyday use, only three COBRA/Panda combinations are required. For Alessandro Piccoli, whose goal is maximum energy efficiency, this is another important argument in favour Chemical Engineering World

For Alessandro Piccoli, the Busch solution has brought the following advantages: • No reaction between extracted vapour and operating fluids, due to dry screw vacuum technology • No accumulation of condensates in the vacuum pumps, due to the even temperature distribution throughout COBRA units • Considerable energy savings, due to vacuum supply centralisation and automatic demand-driven control • An extremely reliable vacuum supply • Significantly reduced maintenance effor t and consequently lower costs for servicing, replacement parts and production downtime • Easy access to the vacuum system even if thermoforming machines are operating, maintenance possible during production • No noise emissions in the production building or at workstations, due to external location of centralised vacuum system Contact: www.buschvacuum.com

Author’s Details Uli Merkle Head of Marketing Services Busch Dienste GmbH uli.merkle@busch.de

July 2016 • 65

CEW Products Liquid Polymer Systems

Vision Inspection

Fluid Dynamics is a global leader in polymerblending systems for the water and wastewater industries, specializing in non-mechanical polymer-blending equipment.

Fluid Dynamics offers dynaBLEND Liquid Polymer Dilution/Feed System. The patented dynaBLEND technology eases the task of blending liquid polymers for wastewater processes because it has been designed to effectively activate all types of liquid polymers. The dynaBLEND’s non-mechanical mixing chamber also delivers an unequalled degree of reliability when compared to other technologies. The system also features an injection check valve designed with easy disassembly and inspection in mind, which eliminates many of the maintenance concerns that affect other systems.

For details contact: Dover India Pvt Ltd – PSG 40 Poonamallee By-pass, Sanneerkuppam Chennai 600 056 Tel: 044-26271020, 25271023 E-mail: sales.psgindia@psgdover.com

Mettler Toledo CI-Vision offers the V2622 Flex-Lite, a compact smart camerabased vision solution. The V2622 offers manufacturers the ability to only take the software and cameras they need, and allows for in-house setup of the system. These smart cameras have delivered quality results to the pharma industry and are now being brought to other industries for similar applications in package quality, code reading and graphical identification. Some camera models include liquid lens technology, allowing for adjustments in camera focus to be made with no moving parts.The system comes in multiple configurations ranging from a single smart camera and patch panel all the way to a two camera system with a dedicated control box and touch screen PC running Inspection Manager, a software allowing control of multiple smart cameras from a centralized interface. Manufacturers can decide which configuration works best for them, or have the vision experts at Mettler Toledo tailor a solution for them.

For details contact: Mettler Toledo India Pvt Ltd Process Analytics Solutions Amar Hill, Saki Vihar Road Powai, Mumbai 400 072

or Circle Readers’ Service Card 1

or Circle Readers’ Service Card 2

Metering and Peristaltic Pumps Neptune offers its new Series MP7100 mechanically actuated diaphragm metering pump. The MP7100 pump incorporates the ruggedness of a hydraulic diaphragm metering pump, eliminates the need for intermediate fluid or hydraulic oil to actuate the diaphragm and reduces the potential for gearbox oil to contaminate the process. The result is a pump design that provides reliable and accurate dosing of a wide range of mild to aggressive chemicals, including those used in municipal water and wastewater treatment. The gears of the Series MP7100 pump operate in an oil bath for longer life while its finned gearbox design dissipates heat more efficiently than other designs. This pump has a max capacity range up to 275 gph (1,041 L/h) pressures to 235 psi (16 bar), and a suction-lift exceeding 20 ft (6 m) on water-like chemicals.

Neptune’s new models of its Abaque Series peristaltic (hose) pumps for the North American incorporate a stronger and more durable rotor design and an innovative hose holding system. Abaque pumps meet the challenging requirements of the water industry thanks to their seal-free design that eliminates leaks and product contamination, while offering suction-lift capabilities to 25.5 ft (9 meters). Abaque pumps are available in ductile iron and SS construction, allowing higher discharge pressure up to 217 psi (15 bar). Abaque hoses are available in natural rubber (highly resilient with excellent abrasion resistance and strength), Nitrile Buna Rubber (highly wear resistant to oily products), Nitrile Buna Rubber with FDA Liner (used in hygienic applications), EPDM (high chemical resistance when handling concentrated acids, alcohols and ketones) and Hypalon (resistant to chemicals, temperature extremes and ultraviolet light). Abaque pumps are available in 9 sizes, with flow rates ranging from 0.59 to 80.1 gpm (0.13 to 18.2 m3/h).

For details contact: Dover India Pvt Ltd – PSG 40 Poonamallee By-pass, Sanneerkuppam, Chennai 600 056 Tel: 044-26271020, 25271023 E-mail: sales.psgindia@psgdover.com or Circle Readers’ Service Card 3

66 • July 2016

Chemical Engineering World

Products CEW Loop Reactor The HLE loop reactor is an advanced version of a traditional gas liquid induction reactor (hydrogenator) wherein a concept of external heat exchanger is incorporated to reduce the reaction time. The HLE loop reactor consists of a reactor – heat exchanger – external/internal pump and sequencing automation for sensing and control. The hydrogenation reactions are generally very exothermic in nature. The internal coils/double coils in hydrogenators conventionally used, have limited heat transfer area to remove the heat of reactions. In HLE loop reactor, due to incorporation of external arrangement to remove heat, via the heat exchanger, there is no limitation in the heat transfer area. The reaction can be continued without interruption, resulting in significantly faster and shorter reaction time. The reaction rate is further enhanced by the extremely high mass transfer, which becomes possible due to high flow rates and specifically designed nozzle for gas induction.

HLE has a pilot loop reactor with a working capacity of 120 litres designed to operate at 40 kg/ cm2. Customers can avail benefit of their pilot facility by undertaking a suitability check prior to adopting the loop reactor.

For details contact: HLE Engineers Pvt Ltd A-6 Maroli Udyognagar, Post: Maroli Bazar, Dist: Navsari Gujarat 396 436, Tel: 02637-270150 E-mail: info@hlengineers.com or Circle Readers’ Service Card 4

FRP Storage Tanks EPP storage tanks, reaction vessels, pressure vessels and vacuum receivers are manufactured by the contact moulding (hand layup) or by filament winding (on CNC machines) methods for the storage of highly corrosive chemicals, acids and wastes. These tanks and vessels are offered as per customers’ requirement complete with all the relevant accessories.

EPP offers storage tanks and vessels in various shapes like square, round, rectangular, vertical and horizontal with flat bottom or conical bottom.

These storage tanks find application in storage and transportation of chemicals, water, acidic and alkaline chemical slurries, reaction vessels, pressure vessels and vacuum receivers for mixing, washing and filtration processes.

For details contact: EPP Composites Pvt Ltd Plot No: 2646 Kranti Gate Main Road GIDC Lodhika Kalawad Road, Metoda Rajkot, Gujarat 360 021 Tel: 02827-287059, 287060, 287061 Fax: 91-02827-287063 E-mail: kuwarjoshi@epp.co.in / bd@epp.co.in / vaishalijoshi@epp.co.in or Circle Readers’ Service Card 5

Chemical Engineering World

July 2016 • 67

CEW Products FRP Pipes

TPN Multivane Vacuum Pump

FRP pipes are made of fibre glass and resins.

It combines the extremely high ultimate strength of fibre glass with the corrosion and media resistance of the resin. They are being manufactured on fully automatic CNC filament winding machines. EPP pipes and fittings are designed for specific applications as per ASTM, BS, API and DIN Standards. They can be manufactured by hand layup and filament winding (CNC controlled machines) methods. It can also be offered in dual laminate structures. EPP pipes and fittings possess high mechanical properties hence can be operated in high pressure or vacuum conditions. It finds application in chemical process industries, pulp and paper mills, effluent and sewerage plants, steel pickling plants, water treatment plants and cooling water system.

For details contact: EPP Composites Pvt Ltd Plot No: 2646 Kranti Gate Main Road, GIDC Lodhika Kalawad Road, Metoda, Rajkot, Gujarat 360 021 Tel: 02827-287059, 287060, 287061 | Fax: 91-02827-287063 E-mail: kuwarjoshi@epp.co.in / bd@epp.co.in / vaishalijoshi@epp.co.in or Circle Readers’ Service Card 6

Toshniwal offers multivane vacuum pumps featuring solutions, the result of constant innovation through research and development.

Rotary multivane vacuum pumps are easy to install (no foundations needed). They are turnkey units for full automatic operation and represent the simplest and most economic system for vacuum plants.

The vacuum pump, complying with international and reliable standards, thanks to their safety, environmental protection, low noise level, compactness, high performances, reliability, efficiency and low life cycle cost.

The specific design of the rotary multivane principles grants excellent performance and leads to the best results in the category of air-cooled single-stage rotary vanes vacuum pumps.

For details contact: Toshniwal Instruments (Madras) Pvt Ltd 267 Kilpauk Garden Road, Chennai 600 010 Tel: 044-26448983, 26448558 E-mail: sales@toshniwal.net or Circle Readers’ Service Card 7

High Power Modular Drives Control Techniques, an Emerson business, has extended its range of high power modular drives. Both its Unidrive M and Powerdrive F300 variable speed drive ranges are now available in the larger frame size 11, providing a flexible method of building compact, reliable high-power solutions. Paralleled together, Unidrive M can control asynchronous and permanent magnet motors in systems up to 2.8 MW (4,200 HP). The new frame 11 is a 250 kW (400 HP) module that allows system builders to create high power solutions with the smallest number of components, keeping both footprint and costs to a minimum. Unidrive M differentiates itself on performance with extremely fast current control algorithms and high switching frequencies. Active Front End (AFE) solutions deliver unparalleled torque precision and power quality.

The Unidrive M modules can be paralleled into a wide range of flexible solutions to solve all system needs including Active Front End and multi-pulse rectifier configurations. They can be controlled by Control Techniques’ Unidrive M600, M700, M701 and M702 controllers. Control Techniques also offers a full range of high powered drive products tailor-made for fan, pump and compressor applications from 90 kW to 2.8 MW. The Powerdrive F300 Series also features a modular design and can control permanent magnet or standard AC induction motors. This modular approach to building high power systems also provides the flow industry with flexibility while keeping complexity low.

For details contact: Emerson Industrial Automation 117B Developed Plot Indl Estate Perungudi, Chennai 600 096 Tel: 044-66918400 E-mail: tr.sathishkumar@emerson.com or Circle Readers’ Service Card 8

68 • July 2016

Chemical Engineering World

Products CEW GRE Pipes EPP is the first Indian company to get API 15 LR certification for GRE pipes. EPP can manufacture 30 km GRE pipe per month considering average diameter of 300 mm. EPP glass reinforced epoxy (GRE) piping system offers complete solution to these and other offshore related problems. Even in highly corrosive fluids at various pressures, temperatures, adverse soil and weather conditions (especially in oil exploration, desalination, chemical plants, fire mains, dredging, portable water, etc). GRE pipes are used for range of applications, including: petrochemical and refineries – oil field application, crude oil transmission, salt water disposal, fire water and fire protection, sea water transmission, potable water transmission; offshore – cooling water, drainage, sewerage, column piping, fire water and fire protection, potable water; marine – cargo, crude oil slop line and wash line, effluent; fuel handling – fuel depots, jet fuel handling, service condition; industry – chemical processing, corrosive liquid transmission, desalination, fire water and fire protection, steam condensate return, general water service, brine transmission, etc.

For details contact: EPP Composites Pvt Ltd Plot No: 2646 Kranti Gate Main Road, GIDC Lodhika Kalawad Road, Metoda, Rajkot, Gujarat 360 021 Tel: 02827-287059, 287060, 287061 | Fax: 91-02827-287063 E-mail: kuwarjoshi@epp.co.in / bd@epp.co.in / vaishalijoshi@epp.co.in or Circle Readers’ Service Card 9

It is time to Migrate to an advanced Structural Analysis Software

Easy User Interface

Shaft Couplings

Conformancee to nuclear industry QA/QC - NRC

Essential components for torque measuring flanges in test benches are shaft couplings. Based on the tried and tested, backlash-free and torsionally rigid ROBADS construction series, mayr power transmission offers compensating couplings which are specially tailored to the high requirements placed on them in measuring flanges.

The misalignments cannot be completely eliminated due to the existing tolerances in the measurements of the components used and the external influences. Therefore torsionally rigid shaft misalignment compensation couplings are used together with the measuring flange. mayr power transmission offers ROBA-DS compensating couplings.

Integration with smartPlant 3D / Tekla / STAAD.Pro

The ROBA-DS disk pack couplings compensate for radial, axial and angular shaft misalignments. They also protect the bearings installed in the shaft train against unnecessary loads. On the ROBA-DS couplings, the nominal torques stated in the catalogue can be used without any restrictions. The couplings are compact, and simultaneously unite high performance density with completely backlash-free function.

Offshore structure analysis & deisgn

For details contact: National Engg Co (NENCO) J-225 MIDC Bhosari Pune, Maharashtra 411 026 Tel: 020-27474529 | Fax: 91-020-27470229 E-mail: nenco@nenco.org

5000+test problems Base plate modeling & analysis Linear and Non linear Static-Dynamic analysis Steel Frame & reinforced concreate design CIS/2 analysis data interface Comprehensive & detailed user documentation

Email: sales@iges.in

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Chemical Engineering World

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CEW Project Update

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

• CHEMICALS 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 ascertained.

According to MoEF sources, total land area is 100,400 sq m and built up area is 42,710 sq m. 33% 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 12,000-KVA will be available through Government Electricity Board.

Saras Plywood Products is planning a 60-TPM urea formaldehyde resin manufacturing plant in New GIDC Gundlav, district: Valsad, Gujarat. The existing land area is 1.5 acres.

The estimated cost of the project is ` 7.5-million. Kalyan Industries is the equipment supplier. The project is waiting for environmental clearance. Civil work will commence in 3 months.

The project is planned for completion in this year. According to SEIAA sources, the company has proposed primary treatment plant followed by evaporator for treatment of industrial effluent and has also proposed a multi-cyclone separator.

FMC India is planning an expansion of its chemical manufacturing unit at IDA Patancheru, district: Medak, Telangana. The estimated cost of the project is ` 17.5-million. As of September the project was waiting for the environmental clearance.

According to MoEF sources, the plot area is 4.027 acres. The company proposes to manufacture 50-TPM of products as part of the expansion. Green belt on 33 per cent of the land area will be developed and maintained. Power requirement will be made available through SPCPDCL. The project will be completed within 2 years.

Globex Laboratories (R&D) proposes a pigments manufacturing unit at village: Dabhasa, district: Vadodara, Gujarat. According to MoEF sources, the project will come up in the existing land on 9,312-sq m. Kadam Environmental Consultants, Vadodara is the environmental consultant. The project will entail manufacture of 40-TPM red pigments, 40-TPM yellow pigments and 450-TPM dilute phosphoric acid.

72 • July 2016

Environment clearance has been obtained for the products – red pigments and yellow pigments. Construction work has begun, as EC and NOC have been received. Effluents generated will be treated in effluent treatment plant having MEE. The company has applied for Amendment in Environmental Clearance dated 26 th September 2012 for change in fuel from LDO to agro waste briquettes and addition of one raw material, ie, phosphoric acid and generation of dilute phosphoric acid (25 per cent basis) as by-product.

Bohra Industries is implementing an expansion of its chemical and fertilizer manufacturing unit at Umarda, district: Udaipur, Rajasthan on 14,500-sq m of existing land. The project will entail expansion of single super phosphate capacity from 400-TPD to 600-TPD, granulated super phosphate from 200-TPD to 300-TPD and addition of new products namely 150-TPD triple super phosphate, 550-TPD synthetic gypsum, 30-TPD di-calcium phosphate, 160-TPD phosphoric acid, 0.3-TPD potassium fluoride, 150-TPD H 2SO 4 and 0.3-TPD sodium tri poly phosphate (STPP). Machinery has been ordered from China. Civil work is in progress. The project is scheduled for completion in 2018.

Ami Lifesciences proposes expansion of its s y n t h e t i c o r g a n i c c h e m i c a l s m a nu fa c t u r i n g u n i t ( v i z , p h a r m a c e u t i c a l bu l k d r u g s a n d d r u g i n t e r m e d i a t e s ) f r o m 6 5 . 7 0 - T P M t o 1 3 1 . 6 0 - T P M i n Pa d r a , d i s t r i c t : Vadodara, Gujarat. The estimated cost of the project is ` 87.046-million. Environmental Consultant to this project is Envisafe Environment Consultants. According to MoEF sources, total plot area is 23,760-sq m (existing 10,270-sq m and 13,490-sq m for expansion). The unit currently manufactures 2-TPM 1-Acetyl Naphthalene, 1-TPM 2-Acetyl Naphthalene, 6-TPM Itopide HCl, 1.20-TPM Loxapine Succinate, 0.30-TPM Amoxapine, 6-TPM Venlafaxine, 6-TPM Progunil HCl, 6-TPM CB-2-L-Valine, 0.60-TPM Nateglinide, 0.60-TPM Quetiapine, 24-TPM Carbomazepin and 12-TPM Oxacarbomazepin. The expansion will involve addition of new products. Water requirement from ground water source will be increased from 34.53-cu m/day to 181-cu m/day after expansion. Effluent generation will be increased from 9.35-cu m/day to 79.5-cu m/day after expansion. Highly concentrated effluent will be sent to captive incinerator for incineration. Remaining effluent (70-m 3 /day) will be treated in the ETP comprising primary, secondary and ter tiary treatment. Treated effluent will be sent to CETP for fur ther treatment. ETP sludge, inorganic residue and incineration ash will be sent to TSDF. Spent carbon, organic residue will be sent to incinerator.

Chemical Engineering World

Project Update CEW Adi Finechem is planning a 40-TPA specialty products manufacturing project on a 2-acre land at an estimated cost of ` 400-million in village: Chekhala, district: Ahmedabad, Gujarat.

The project is waiting for environmental clearance.

RSPL is planning a 1,500-TPD soda ash plant and 40-MW captive power project in village: Kuranga, district: Jamnagar, Gujarat. Land acquisition is in progress. 85 per cent of land has been acquired. The project is waiting for environmental clearance. The entire project is planned for completion in 5 years from zero date.

• MINING Metabluu Power, a sister concern of Minera Udyog India, is planning a 75,000-TPA iron ore mining project in village: Devikonda, district: Karimnagar, Telangana. The project is awaiting Government approval.

Aryan Ispat & Power is planning an expansion of its coal washer y in village: Bamoloi, district: Sambalpur, Odisha. The project will come up in the existing 204.

65-acre integrated steel plant premises. The capacity of the project is to be augmented from 0.70-MTPA to 5.70-MTPA. The cost of the project is ` 600.7 million. The project is awaiting environmental clearance and planned for completion in 1-year from zero date. According to MoEF sources, the expansion is based on heavy media cyclone (wet process) technology. The washery will produce washed coal of an average ash around 34% (GCV 4,350-Kcal/kg), middling (ash content about 58%) of GCV around 2,350-Kcal per kg useable as fuel in FBC boilers. The proposed expansion will be the state-of-the-ar t with close circuit water system, classifying cyclone, high frequency screens, thickener and multi-roll belt press filters. Power requirement of 5-MVA will be sourced from its own power plant connected with the Grid Corporation of Odisha.

NTPC is planning the Kudanali-Luburi coal mining project in district: Angul, Odisha. The company has signed an agreement on June 15, 2015 with Jammu and Kashmir State Power Development Corporation (JKSPDCL) for promoting a joint venture company with 67:33 equity par ticipation for under taking exploration, development and operation of jointly allocated Kudanali-Luburi Coal Block at Odisha by the Ministry of Coal.

DSP Associates is planning a 15,17,600-TPA sand (minor mineral) mining project in the mines of Tikola-1 Sand Unit at village: Tikola, district: Gurgaon, Haryana. Mining lease area is 42.50-hectare. The estimated cost of the project is ` 55-million. The project is waiting for environmental clearance. Mining work is expected to commence soon.

According to MoEF sources, out of the total area, 31.50-hectare area falls in the river bed and 11-hectare Chemical Engineering World

area falls in agricultural land (outside river bed). Method of mining will be opencast semi-mechanized without drilling and blasting. The mine will be excavated out in layers up to a depth of 3-m in riverbed and 9-m in agricultural field.

Letter of Intent (LoI) for mining contract has been granted for a period of 9 years.

• NON-CONVENTIONAL ENERGY Viaton Energy, promoted by the 3F Group and Creative Group, is planning a 10-MW power project in Punjab.

Discussion is in progress with the Government for allocation of site. The company is already operating a 10-MW biomassbased IPP at village: Khokhar Khurd, district: Mansa, Punjab from July 2013. The generated power is being sold to the Gover nment of Punjab.

Hubli Electricity Supply Company is planning solar RTPV grid connected power plants in district: Belagavi, Karnataka.

E-tenders have been floated to design, manufacture, supply, installation, testing and commissioning of solar RTPV grid connected power plants on roof-tops of 31 HESCOM office buildings in Belagavi Zone Jur isdiction for total load of 136-KWp including operation and maintenance for a period of five years. The approximate amount put to tender is ` 18.62-million.

• NON-CONVENTIONAL POWER BMS Starch, a part of the BMS Group, is implementing a 6-MW biomass-based co-gen power plant in village: Kurandi, district: Bastar, Chhattisgarh. The project is coming up along with a starch manufacturing unit on 26-acre of acquired land at a total estimated cost of ` 1,350-million. Equipment supplier is yet to be appointed. Civil work is in progress. The project is expected to be completed in this year.

• THERMAL POWER Surguja Power, a 100 per cent subsidiary of Adani Mining, proposes a 540/600-MW coal washery rejects based thermal power project spread over 47.5-hectare of land in villages: Parsa, Kete, district: Surguja, Chhattisgarh. The estimated cost of the project is ` 35-billion. According to MoEF sources, Greencindia Consulting is the environmental consultant. The project will comprise of a 4 x 135/150-MW power plant based on the coal washery rejects within the Parsa East and Kete Basan coal block at Udaypur Tehsil, district: Surguja. The Group has been assigned work by Rajasthan Rajya Vidyut Utpadan Nigam (RRVUNL) for mining, development and operation of Parsa East coal block and supply of beneficiated coal. Sizeable amount of rejected coal will be generated, which shall be utilized for power generation by setting up the power project within the coal block. The plant is proposed to have circulating fluidized bed combustion-based (CFBC) coal fired boilers.

July 2016 • 73

CEW Book Shelf Alarm Management: A Comprehensive Guide Author/s: Price: Pages: Publisher:

Bill R. Hollifield, Eddie Habibi ` 10320.44 260 (Paperback) ISA

About the Book: In this second edition, Alarm Management: A Comprehensive Guide, various problems of alarm systems are covered with precise guidance on how they come about and how to effectively correct them. It is written by individuals with vast experience in the different plants, processes, and environments requiring effective alarm management. The second edition is filled with good examples and explanations of procedures, with practical lists and tips on how one should proceed. It is based on hundreds of successful projects.

Process Plant Design and Operation: Guidance to Safe Practicea Author/s:

Process Plants: A Handbook for Inherently Safer Design Author/s: Price: Pages: Publisher:

Trevor A. Kletz, Paul Amyotte ` 6345.75 224 (Hardcover) CRC Press

About the Book: This easy-to-read source provides a wealth of stimulating information on the design of inherently safer and user-friendly plants. It demonstrates how plants can withstand human error and equipment failure without serious effects on safety, output, or efficiency. Examples of user-friendly design and increased coverage on design procedures are implemented.

Materials of Chemical Plant Construction Chemical Author/s: Price: Pages: Publisher:

Hugh Griffiths 70 (Paperback) Forgotten Books

About the Book: It is a commonplace that in many chemical plants the costs of repairs and replacements may be a very serious proportion of manufacturing charges. Nevertheless in many works one finds that there is an extraordinary state of indefiniteness in respect of knowledge of materials of construction, and frequently breakdowns result which cause serious losses of production, time, and consequently of profits. In such works very frequently the designing engineer has but little knowledge of chemistry, and relies on the chemist for information as to how the various materials will stand up under the special influences to which they will be subjected.

If it should happen that the chemist is without plant experience, the results are disastrous.

Designing the Internet of Things Author/s: Price: Pages: Publisher:

Hakin Cassimally Adrian Mcewen ` 467 336 (Paperback) Wiley

About the Book: Designing the Internet of Things provides an overview of the steps required to take your idea for a connected device from concept through to production. This book is the ideal place to start. In addition to information about electronics and the variety of different platforms you can use to develop the hardware and software for your device, the book takes you through some of the product design possibilities and then ways to scale up production from a oneoff prototype through to mass production.

74 • July 2016

Price: Pages: Publisher:

Anton A. Kiss, Carlos A. Infante Ferreira 442 (Hardcover) CRC Press

About the Book: As the chemical process industry is among the most energy demanding sectors, chemical engineers are endeavouring to contribute towards sustainable future. Due to the limitation of fossil fuels, the need for energy independence, as well as the environmental problem of the greenhouse gas effect, there is a large increasing interest in the research and development of chemical processes that require less capital investment and reduced operating costs and lead to high eco-efficiency. The use of heat pumps is a hot topic due to many advantages, such as low energy requirements as well as an increasing number of industrial applications.

Therefore, in the current book, authors are focusing on use of heat pumps in the chemical industry, providing an overview of heat pump technology as applied in the chemical process industry, covering both theoretical and practical aspects: working principle, applied thermodynamics, theoretical background, numerical examples and case studies, as well as practical applications. The worked-out examples have been included to instruct students, engineers and process designers about how to design various heat pumps used in the industry. Reader friendly resources namely relevant equations, diagrams, figures and references that reflect the current and upcoming heat pump technologies, will be of great help to all readers from the chemical and petrochemical industry, biorefinery and other related areas.

Chemical Engineering World

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July 2016 • 75

CEW Interview

Getting Future Ready HPCL has rolled out investment plans worth over ` 30,000 crores over the next couple of years to upgrade and modernise Vizag & Mumbai refineries. The company is also a part of highly ambitious mega refinery & petrochemicals complex planned under the aegis of Ministry of Petroleum & Natural Gas, Government of India. B K Namdeo, Director - Refineries, HPCL, speaks about ongoing projects and investment plans of the company, in an exclusive interview with Mittravinda Ranjan.

76 • July 2016

Chemical Engineering World

Interview CEW What does the fall in crude prices mean for the refiners in the short term and long term?

Refinery profitability depends on Gross Refinery Margins (GRM) and Refining cost of crude per barrel. GRM is market driven based on supply-demand of products in international market. Therefore, there is no direct correlation of crude prices with profitability of Refinery. However, indirectly, impact of crude prices is on GRM as 8-10 per cent of product from crude is typically used in refining of the crude oil as fuel which in turn reduces the gross product worth (GPW) value of the crude in the GRM calculation. Hence, decrease/increase in crude prices impact GRM to the extent of the crude used as fuel in refinery; in other words keeping same cracks (product prices – crude price) GRM will be higher in lower crude price and vice versa. In 2015-16, we have seen the crude prices were significantly lower in comparison to previous years and cracks were also relatively low, yet the refineries have posted better GRMs & profitability.

Another major factor is reduction in working capital requirement while crude prices are low. This will result in lower interest burden which enhances profitability.

The steady long term low crude prices give sustainable high profitability which will facilitate higher investment in Oil & Gas sector.

India is planning its first Greenfield mega refinery project being planned by consortium of HPCL, BPCL & IOCL under the aegis of Ministry of Petroleum & Natural Gas (MoPNG).

How viable is the project in Indian context?

Let us take a look at the consumption pattern of petroleum products in the country which is one of the fastest growing sectors in India, projected to grow at 10-11 per cent per year. And if you look at, say, diesel/MS, they are growing at impressive rate of 8-15 per Chemical Engineering World

cent respectively on average. Total petroleum products consumption in India stood at about 183 MMT during 2015-16 while the overall refining capacity stood at 230 MMTPA which includes PSUs as well as private refiners.

So far, Indian refiners have carried out value addition and undertaken brownfield expansions of existing capacities and some of the grassroot refineries such as HMEL, BORL and Paradip refineries have come up in the recent past.

Assuming that the growth momentum remains the same over the next couple of years, by 2023-24 the refining capacity will get saturated and post that the demand will outstrip indigenous supplies.

This will create a situation of import dependency to meet the demand of MS and diesel.

Carrying out such projects is a herculean task which usually takes 6-8 years to commission.

What is the current status of integrated refinery & petrochemical project announced by HPCL in Rajasthan?

Integrated refinery and petrochemical projects bring significant value to the economics of business and the project cost is estimated to be ` 37,250 crores that would be spread over 5,000 acres of land in Rajasthan. There has been a delay in project due to unforeseen circumstances and currently we are in discussion with the Rajasthan Government to kick off the project but as of now there is no substantial information that we may be able to share.

The proposed project is India’s first Greenfield mega refinery and integrated petrochemical project with 60 MMTPA capacity by HPCL, IOCL & BPCL planned under the aegis of Ministry of Petroleum & Natural Gas, Government of India. Engineers India Ltd (EIL) has been roped in as the consultant for this forthcoming project and is working on the configuration of the refinery after understanding the demand supply of petrochemicals. Once the Front end engineering and design (FEED) is complete, we may look at having synergistic partner(s) who would bring significant value in terms of investment, raw materials or experience/expertise.

Please share HPCL’s plans on modernization & scaling up Mumbai and Vizag refineries.

If you take a look at the last year’s numbers, our total sales volume was more than total combined capacity of HPCL and HMEL which stood at 27 MMTPA. We sold around 34 MMT of petroleum products out of which 7 MMT was procured from MRPL and private refiners RIL and Essar. Owing to the strong product demand, HPCL has decided for modernisation and scaling up of the existing capacities at both Mumbai and Vizag facilities and earmarked around ` 25,000 crores for investment over the next 4-5 years.

These projects will also take care of the compliance to produce BS VI compliant fuels as mandated by the Government.

At present the project is in preliminary stage where we are scouting for the land of almost 15,000 acres on the west coast as one-third of the land will go into green belt. If you talk about the viability, the industry realises the value and economic benefits of such integrated projects of sizable capacities and looks at around 15 per cent ROI as the minimum threshold for refining projects. Suitable incentives are required from the Government as viability gap funding.

Current capacity of Mumbai refinery stands at 6.5 MMTPA which will be scaled up to 9.5 MMTPA with the investment of ` 4,100 crore in the first phase which will include upgradation to comply with BS VI standards targeted to be completed before 2020. Second phase of project will include bottom upgradation using slurry hydrocracking with investment of around ` 5,000 crores during the period 2018-2021, which will help us improve the GRMs. July 2016 • 77

CEW Interview The Vizag refinery project is one of the prestigious projects for HPCL and is one of the cornerstones of company’s growth strategy. Current capacity of Vizag refinery stands at 8.3 MMTPA. We plan to expand the refinery from current 8.3 MMTPA to 15 MMTPA, which will include replacing one old CDU with modern energy efficient 9 MMTPA unit along with upgradation to BS VI and bottom upgradation facility.

Additionally we are setting up hydrocracker to maximise the gains.

We have earmarked around ` 20,000 crores for Vizag refinery and targeting completion of this project in next four years. HPCL has already invested ` 2,000 crore to complete pre-project activity of setting up deep sea SPM terminal which will allow the very large crude carriers (VLCCs) to anchor to ensure crude supplies and also relocated storage terminals for black and white oil to ensure smooth execution of project.

Please talk about opting for slurry hydrocracking unit for bottom upgradation instead of setting up coker at Vizag.

Yes, HPCL is not taking the conventional route of setting up coker unit for bottom upgradation and opted to set up Hydrogen based resid upgradation. This is one of the advanced technologies for the refining industry and we are the first in India to adopt this trend which is giving a new direction to the bottom upgradation technology. Since Vizag refinery is very close to the airport, there is a restriction to install tall structures within certain air space. The height of coker unit is a major constraint for us because of the location.

Choosing hydrogen based resid upgradation such as SHCU has been a win-win situation for HPCL as this is the state-of-the-art technology which will enable us convert > 90 per cent resid as compared to 75 per cent in Coker unit plus completely eliminate production of heavy oils. There is a small amount of 78 • July 2016

In years to come, refiners will have to move from standalone models to highly complex integrated refinery and petrochemicals facilities to ensure profitability and requires massive capital investments and careful evaluation of integration opportunities. pitch that will be produced which can be used by the cement plants.

Moreover now there is greater awareness across the stakeholders and government has also become very particular about the environmental parameters compliance and we need to be prepared well to address such future challenges and move from conventional technologies to advanced ones.

What are the future challenges that you feel the refiners need to gear up for?

The first and the foremost is the environmental challenge as the government is becoming stricter towards compliance, take for example the decision to mandate implementing BS VI from BS IV by 2020. Hence, Refiners will have to be very selective about technologies which yield the desired margins as well as comply with the environmental norms.

Emission control is another critical area that the refiners have been addressing. Almost every refiner is using flue gas Desulphurisation and Sulfur recovery technologies to control sulphur emissions but over the period of time the authorities may introduce new parameters to control various other emissions. In my opinion, refiners need to be environmentally conscious and extremely selective regarding new technologies to sustain in the long run.

In years to come, refiners will have to move from standalone models to highly complex integrated refinery and petrochemicals facilities to ensure profitability and requires massive capital investments and careful evaluation of integration opportunities.

Alternative fuels like biodiesels, ethanol blending, etc are now gaining significant

attention because of lesser environment footprint and this is another area which refiners need to pay attention and be more assertive towards improving the fuel quality.

Talking about the fuel quality, vehicular pollution due to diesel has been under discussion for some time and there is a gradual advent of electric cars that is now catching the fancy in developed countries. How do you see these two trends impacting the refiners?

Typically in a refining set up, diesel forms around 40-50 per cent of processed crude oil quantity, approximately 15 per cent of processed crude is MS and rest is other petroleum products. Any situation which demands more than 15 per cent of MS would require the refiner to process very light crude oil which may not be a very profitable proposition. Shortfall in MS demand may be supplemented through LNG/CNG based fuels if the availability increases for automobile sector. In spite of all the efforts, diesel demand is going to remain stronger in heavy vehicles for goods transportation.

As far as demand of diesel is concerned, I think that is going to increase in the years to come, however the only area that I see which needs to be addressed is improving the quality of diesel which can be done through R&D by the refiners.

Coming to electric cars, though the numbers are expected to increase, dependence on diesel vehicles is expected to continue in future. There are very many challenges like electric cars inability to go over long distances due to the constant need of recharging batteries and lack of infrastructure etc which need to be addressed to make a dent in the automotive market.

Chemical Engineering World

R.N.I. No. 11403/1966 Date of Publication: 29 th of every month. Postal Registration No: MCS/095/2015-17 Posted at Patrika Channel Sorting Office, Mumbai 400001, on 29th & 30th of every month. Total Pages No.:80