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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
Maulik Jasubhai Shah Hemant K. Shetty Hemant K. Shetty
Sub Editor Feature Writer Design Team
Mittravinda Ranjan (mittra_ranjan@jasubhai.com) D P Misra, N G Ashar, Prof. M C Dwivedi P V Satyanarayana, Dr S R Srinivasan, R B Darji, R P Sharma Bernard Rapose (bernard_rapose@jasubhai.com) Mahesh Kallayil Arun Parab, Shankar Joshi
Subscription Team Marketing Co-ordinator Production Team
Dilip Parab Brenda Fernandes V Raj Misquitta (Head), Arun Madye
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Technology News
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FEATURE Hygienic Drying in a Vacuum- Spherical Dryer for API Production - by Lars Voges, Sales Director, Business Line Filtration & Drying Europe Use of Centrifugal Pumps with Difficult Pumping Media
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- by Frank Bungartz, Director, Paul Bungartz Gmbh & Co. Kg The Right Formula for Emission Reductions
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- by Arne Berndt, President, SoundPLAN GmbH and SoundPLAN International LLC. Technology Selection for a Chemical Process - by Abhijit Kharote, AGM – Process Engineering and Shardul Shindadkar Sr. Executive-Sales, Marketing &Business Development,
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Ingenero Technologies (I) Pvt Ltd. Understanding your company’s stages of maturity
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- by Sharad Mittal, Business Partner, Competitive Capabilities International
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210, Taj Building, 3rd Floor, Dr. D. N. Road, Fort, Mumbai 400 001, Tel: +91-22-4037 3636, Fax: +91-22-4037 3635
SALES
Industry News
CASE STUDY Cooling Water Network Analysis, -by Dr. Anil Khadse, Process Manager, Sunil Hadkar, AGM- Project Development and Mr Manoj Tiwari, Process Engineer. Ingenero Technologies (I) Pvt Ltd
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MARKETING INITIATIVE From simulation to operation with a click of the mouse Industrial IoT solutions at Automation Expo
PRODUCTS EVENTS PROJECT UPDATE BOOK SHELF AD INDEX INTERVIEW
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All Set to Revamp and Modernise Overall Operations -A.M. Tiwari (IAS), Chairman & Managing Director, GSFC Growth of Caustic Soda Industry can Become One of the Major Factors in Fulfilment of the Dream “Make in India” - P.K. Gera, IAS, Managing Director, Gujarat Alkalies and Chemicals Limited. Exciting Times Ahead for Indian Pigments Industry - Ravi Kapoor, Managing Director, Heubach Colour Limited. Understanding Market Demands and Envisioning Future Requirements Constantly Drives Koch-Glitsch, -Jatin Parikh, CEO, Koch- Glitsch Not a Rosy Road ahead for Indian Manufacturers Competing in the Global in the Global Markets, - Nishit Dand , Managing Director, Sure Safety
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Disclaimer: The Editorial/Content team at Jasubhai Media Pvt Ltd has not contributed to writing or editing “Marketing Initiative.” Readers would do well to treat it as an advertisement.
Printed and published by Mr Hemant K. Shetty on behalf of Jasubhai Media Pvt. Ltd., 26, Maker Chamber VI, Nariman Point, Mumbai 400 021 and printed at The Great Art Printers, 25, S A Brelvi Road, Fort, Mumbai 400 001 and published from 3rd Floor, Taj Building, 210, Dr. D N Road, Fort, Mumbai 400 001. Editor: Ms. Mittravinda Ranjan, 3rd Floor, Taj Building, 210, Dr. D N Road, Fort, Mumbai 400 001.
Chemical Engineering World
CEW Industry News Simmons Edeco Expands European Headquarters GREAT YARMOUTH, England- SIMMONS EDECO, a leading supplier of wellhead and valve maintenance, asset integrity solutions and onshore drilling services to the global oil and gas industry, announced that it has dramatically expanded and enhanced its European operations base in Great Yarmouth, England. “This first-class facility reflects the quality of service and innovation that have become synonymous with SIMMONS EDECO during the past 55 years,” said Brian Kelly, Valve and Well Services Manager for SIMMONS EDECO Europe Limited. “By combining our engineering services, service center, operations and training functions in one central location, we are truly harnessing the full potential of our experienced workforce and field-proven technologies. And our customers around the world benefit.” Expansion benefits customers and staff To better serve its growing customer base, SIMMONS EDECO has taken a number of significant steps during recent months. The 100,000 square foot base has more than doubled in size. The new complex offers significant benefits to customers and staff. For example, the company delivers its recently launched Well Life Cycle & Well Integrity Awareness Programme to train employees and customers in valve and wellhead maintenance. Training takes place in the dedicated training facility, where delegates work with an actual pressurized training surface Christmas tree. The expanded state-of-the-art maintenance centre and bigger warehouse also mean that SIMMONS EDECO can store, service and deploy equipment more efficiently. Space dedicated to office and administration has also been enlarged to house the 84-plus staff that supports operations around the world. This translates to greater hands-on project management and rapid response, ultimately reducing costs for customers. European base supporting recent contract awards The expanded multi-million pound facility comes as good news to SIMMONS EDECO customers. During recent months, EDF Energy, SSE and a major operator in the Southern North Sea have awarded valve and wellhead maintenance service contracts to the company, which are being supported from Great Yarmouth. In addition to serving as a European hub for valve, wellhead and asset integrity maintenance, the facility showcases SIMMONS EDECO systems, including single- and dual-completion training Christmas trees, and specialist treatment products, as well as asset integrity solutions, onshore drilling and workover services.
Nuberg to Execute 228 TPD Caustic Soda Plant Project in Egypt New Delhi, India, Egypt- Nuberg, a leading global EPC & LSTK company for specialty chemicals has been chosen by Egyptian Petrochemicals Company (EPC) as a single-point solution company, 8 • July 2017
from concept to commissioning, for caustic soda-chlorine plant in Alexandria, Egypt. The project envisions setting up a turnkey project having production capacity of 228 TPD with a provision to expand it to 342 TPD in future. The plant will be based on new generation state-of-the-ar t bipolar membrane cell technology (Bi-Chlor) from INEOS Technologies, UK which is widely sought out by caustic soda manufacturers for its best in class power consumption, longevity, low capex/opex and environmental considerations. The plant will produce caustic soda, chlorine, hydrogen and other chlorine derivatives. Chlorine produced shall be used as a raw material in existing EDC/VCM plant for PVC production. The contract signing ceremony took place at hotel Hilton Green Plaza in Alexandria, Egypt in the presence of the dignitaries from both the companies. The contract was signed by Mr. AK Tyagi, MD, Nuberg and Chemist Gaber A. Hassan, Chairman, EPC. Sharing his happiness on winning the contract, Mr. A K Tyagi, MD, Nuberg said, "We are thankful to Egyptian Petrochemicals Company for entrusting our turnkey project engineering capabilities and our EPC services and solutions for its caustic soda plant. We are excited to partner with INEOS Technologies once again, strengthening our relationship with them even further." Chemist Gaber A. Hassan, Chairman, EPC said, "The caustic soda plant is of great importance to our company in specific and to the petrochemical sector in general. I would like to highlight that this project is among the chain of projects that will be executed by our company in near and far future to promote the petrochemical field in Egypt. I would like to congratulate Nuberg on being awarded this order and I am confident that Nuberg has the experience and the expertise to execute an excellent plant in cooperation with the licensor INEOS Technologies." Role of INEOS Technologies will be of process licensor and will supply technology know-how and state-of-the-art electrolyser commissioning services. Caustic soda produced in the plant will be supplied mostly to the markets of Europe, Asia and Africa. Caustic Soda has applications in various industries such as hydrocarbons, paper, chemicals and soaps & detergents industry. Nuberg's scope of services includes basic & detailed engineering, supply, civil and equipment installation, commissioning of plant and start-up for new bipolar electrolyser as a turnkey project. Nuberg, which is the biggest EPC Company for chlor-alkali industry in the UAE, is among world's leading EPC companies for caustic soda-chlorine plants, offering a comprehensive singlepoint solution to caustic soda manufacturers across the world. Nuberg has successfully executed turnkey projects not only for chlor-alkali industry but also for other chemicals and speciality chemicals such as sulfonate, anisole, sulphur bentonite, sulfuric acid, hydrogen peroxide, calcium chloride among many others. Chemical Engineering World
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Delivering Reliability. For Life. © 2017 The Lubrizol Corporation, all rights reserved. All marks are the property of The Lubrizol Corporation. The Lubrizol Corporation is a Berkshire Hathaway company. 17-78489
CEW Industry News Industrial Scientific Meets Restriction of Hazardous Substances Standard PITTSBURGH, PA – Industrial Scientific, the global leader in gas detection, is pleased to announce that effective immediately, all products will be manufactured according to European Union Directive 2011/65/EU Restriction of Hazardous Substances (RoHS) Standard. All products shipped from Industrial Scientific manufacturing facilities to European customers will meet RoHS compliance standards. RoHS Directive 2011/65/EU prohibit the sale of electronics with cer tain hazardous materials to member countries. The substances include lead, cadmium, mercury, hexavalent chromium, polybrominated biphenyls, and polybrominated diphenyl ethers. The goal of RoHS is to reduce the impact of global consumer electronic waste. Each of the prohibited chemicals has been shown to have negative health effects on humans through direct contact, even at low exposure levels, and when electronics containing the chemicals are discarded. “Industrial Scientific is dedicated to preserving human life, so it only makes sense that we are also fully committed to protecting the environment and reducing exposure to hazardous chemicals,” said Justin McElhattan, president and CEO of Industrial Scientific. “By eliminating the restricted materials from our products, Industrial Scientific is protecting our employees from any potential exposure while reducing the environmental impact our products have on our communities.”
LANXESS expands range of membranes for reverse osmosis Specialty chemicals company LANXESS is expanding its range of membrane elements for reverse osmosis (RO). The new Lewabrane RO ULP line has three product grades available immediately for water treatment. They display higher water permeability than the standard elements, while offering the similar high level of rejection of critical substances. The operating pressure required in the pressure vessel is 40 percent lower, which reduces operating costs. Furthermore, the new membranes are a good option for removing trace elements from wastewater and drinking water. “The new ULP products are recommended for applications in which a high flow rate, moderate salt rejection and low power consumption are the primar y design parameters. Fields of application therefore are the cost-efficient filtration of drinking water and high-tech wastewater treatment,” says Alexander Scheffler, director membrane business in the LANXESS Liquid Purification Technologies business unit (LPT). “Our customers are so impressed with the performance profile that we already have received numerous pre-orders,” he adds. Eliminating trace elements cost-efficiently at low operating pressures Synthetic organic substances, known as trace elements, can be found in bodies of water in concentrations of a few nanograms to 10 • July 2017
a maximum of a few micrograms per liter. Originating for instance from drugs, household chemicals, industrial chemicals, cosmetic products and crop protection agents, they are introduced into the water system by household and industrial wastewater. The product designation “ULP” stands for “Ultra Low Pressure,” because the advantage of these membranes is their ability to remove such organic compounds almost entirely even at low operating pressures. “Drinking water systems process tremendous volumes of surface water often on a daily basis. Therefore, to minimize investment costs, it is desirable to have a membrane that displays high water permeability and thus a high flow rate, like those in our Lewabrane RO ULP line,” explains Scheffler. To reduce the formation of organic deposits – i.e. typical biofouling – in wastewater, the ULP membrane uniquely has the most hydrophilic surface of all the Lewabrane product grades. Thanks to this hydrophilic behavior, a thin, protective film of water forms on the membrane surface, which reduces the adsorption of organic substances. The ASD feed spacers, which are inserted in the membrane elements to create space between their surfaces for flowing water, also reduce fouling. They have an alternating strand design (ASD), comprising filaments of different thickness, which cause uniform overflow and thus counteract biofouling. This lowers operating costs because fewer cleaning chemicals are required and the interval between cleanings can be extended. Multi-ReUse Project: Lewabrane in end-of-pipe solutions The research project on “Modular Treatment and Monitoring in Wastewater Recycling (Multi-ReUse)” was launched in 2016 with funding from the German Federal Ministry of Education and Research (BMBF). This project aims to develop and improve processes for the economical use of wastewater. Against this backdrop, the Oldenburgisch-Ostfriesische Wasser verband (OOWV Water Management Association) joined forces with research partners – IWW Zentrum Wasser GmbH and the Biofilm Center at Duisburg-Essen University (UDE) – and equipment companies – inge GmbH, IAB Ionenaustauscher GmbH Bitterfeld (a wholly owned LANXESS subsidiary) and De.EnCon GmbH – to develop flexible processes for producing defined water qualities and volumes. To achieve its goals, the consor tium is using innovative processing combinations and new developments in the field of membrane technology. At the same time, fast and reliable methods are being developed for process control and for monitoring the quality of hygiene-relevant parameters. The results are being implemented at the Nordenham water treatment plant in Lower Saxony in collaboration with the OOWV. This pilot facility is due to go into operation in July 2017. It incorporates membrane elements from LANXESS, including the new ULP products. “We are studying the fouling and rejection behaviour of our membrane elements in long-term practical trials,” explains Scheffler. Chemical Engineering World
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18/11/2016 10:20
CEW Industry News Topsoe to help HMEL meet BS-VI fuel specification on fast track Indian refinery company HPCL-Mittal Energy Ltd (HMEL) has chosen Topsoe’s diesel hydrotreater unit and hydrogen generation facilities to meet their upgrading requirements. The revamped refinery in Bathinda, Punjab will meet the BS VI (equivalent to Euro VI) fuel specifications, when completed in the last quarter of 2019. Topsoe’s bundled technology solution and the fast project implementation will make it possible for HMEL to meet the BS VI fuel specification deadline. This solution requires less investment than competing solutions along with shorter project implementation time, while providing optimal feed flexibility to meet processing objectives. The solution offers substantial project cost savings using a new diesel hydrotreater unit supplemented by revamp of the existing hydrogen generation facility with two of Topsoe’s proprietary heat exchange reformers (HTER). The compact HTERs are always individually customized for each plant to provide capacity increases up to 30% with a very small footprint. The diesel hydrotreater unit will be optimized to take full advantage of Topsoe’s HyBRIMTM TK-611 ultra-low sulfur diesel catalyst that deliver 25% improved activity for both nitrogen and sulfur removal and longer cycle lengths while processing complex feeds. “HMEL has chosen this solution based on Topsoe’s insight into processes, hardware, and catalysts for ultra-low sulfur diesel. We are very satisfied to be able to deliver such a highly effective integrated solution in a very short time,” says Morten Schaldemose, Executive Vice President, Refinery Business Unit, Haldor Topsoe. Engineers India Limited (EIL) is engaged to provide EPCM (Engineering, Procurement, Construction Management) services on the BS-VI Fuel Quality Project. EIL have considerable experience from the Indian hydrocarbon sector and carry vast experience in executing projects on a fast track basis.
BASF introduces first new class of public health insecticide for malaria prevention in more than 30 years LIMBURGERHOF, Germany- BASF has received a recommendation from the World Health Organization (WHO) for Interceptor® G2, a long-lasting insecticide-treated mosquito net (LN) based on Chlorfenapyr. Chlorfenapyr is a completely new insecticide class for combating mosquitoes for public health. This is the first WHO recommendation for a product based on a new insecticide class in more than 30 years. Working with the Innovative Vector Control Consortium (IVCC) and the London School of Hygiene & Tropical Medicine in a collaboration lasting over a decade, BASF’s scientists successfully 12 • July 2017
repurposed Chlorfenapyr to be effective on mosquito nets and meet stringent WHO performance thresholds for public health. Dave Malone, IVCC Technical Manager, said “The collaboration with BASF gave us access to an insecticide with a rare combination of attributes: New to public health, effective against resistant mosquitoes, and able to coat polyester netting with a long-lasting formulation.” A second Chlorfenapyr product, an indoor residual spray named Sylando® 240SC, is also in the final phases of WHO evaluation. Around the world, every two minutes a child dies from malaria and there are more than 200 million new cases every year. Malaria is also a major cause of global poverty and its burden is greatest among the most vulnerable. Long-lasting insecticide-treated mosquito nets (LN) and indoor residual sprays (IRS) are the cornerstones of malaria prevention, par ticularly in sub-Saharan Africa. But 60 countr ies have already reported resistance to at least one class of insecticide used in them. Part of the problem is that there were previously only four WHO-recommended insecticide classes for adult mosquito control: Only one of them, the pyrethroid class, was recommended for LNs. Continual use of the same insecticides enabled the highly-adaptable mosquito to develop significant levels of resistance. Independent trials in Benin, Burkina Faso, Tanzania and Ivory Coast have proven the efficacy of Interceptor G2 and Sylando 240SC against local insecticide-resistant mosquitoes. Medical entomologist Professor Hilary Ranson from the Liverpool School of Tropical Medicine has studied the problem for many years. “We’ve got to take insecticide resistance very seriously,” she said. “In some countries, the local mosquito population has increased its level of resistance 1,000-fold. It has been years since a new class of public health insecticide has appeared on the market. Alternatives are urgently needed.” Following the WHO recommendation, BASF will start preparations to launch Interceptor G2 for malaria prevention. Depending on local registration processes, the new mosquito net is expected to be available to health ministries and aid organizations starting towards the end of this year. “New resistance management products are desperately needed to prevent mosquito-borne diseases and save lives,” said Egon Weinmueller, Head of BASF’s public health business. “This development breakthrough strengthens my personal belief that we really can be the generation to end malaria for good.” Chemical Engineering World
CEW Industry News Shimadzu Japan Established in the year 1875 is celebrating 99th Year of Balance Division. Shimadzu & Amkette Analytics Ltd., the Weighing Balance Par tner SHI-AM Technologies India has made a successful release & launch of New AP Series Precision Weighing UniBloc Balances, STABLO-AP AC Discharge Static Remover Ionizer and LabSolutions DB Balance Network Data System. Models of AP series, which are new types of well reputed Super-Range, Dual Range Semi-Micro and Analytical Balances. The new models from the high-sensitivity AP-W series (with a minimum display value of 0.01 mg). These new Semi-Micro & analytical balances have achieved a minimum display value of 0.01 mg, and by improving the response time to only 2 seconds, while the previous model needs 10 seconds. As a result, work efficiency can be greatly enhanced. Moreover, in the same way as with the existing models in the AP-W series, the STABLO-AP ionizer is incor porated in the main unit of balance, which makes it easy to eliminate, in about 1 second, the static electr icity that can affect a measurement. Thus, the reliability of the measurement results is enhanced. The units also include a USB host, a buffer solution preparation mode function for users of HPLC system, and recipe function. S h i m a d z u 's a n a l y s i s n e t wo r k d a t a sy s t e m ( L a b So l u t io n s Balance) with the analytical balance makes possible the linkage of a variety of analytical instruments, and the centralized management of all measurement data within an environment that compliant with ER/ES (electronic records and electronic signatures) regulations. AP Series open all new opportunities to expand sales globally to customers who require the minimum value display of 0.01 mg in a great variety of industries, especially in the pharmaceutical, chemical, and food industries. Compliance with Various Regulations Suppor t for a variety of regulations such as ISO 17025 for inspection organizations, ISO 9001 and ISO 14001 for the manufacturing industries, and GLP/GMP and USP (United States Pharmacopeia) for the pharmaceutical industries is provided. In the interest of data integrity, a linkage with LabSolutions Balance can be created. An analytical balance can be connected to a PC and included as part of a Shimadzu network system. Once this has been set up, the management of data that complies with GLP/GMP, or other regulations, can be performed in a centralized way, which includes various types of analytical instruments. 16 • July 2017
Wide Variety of Functions for Stronger Coordination with HPLC Systems and Safe Data Manageme nt For HPLC (High-Performance Liquid Chromatograph) and other analytical instrument users, the AP-W series have advanced functions of navigating substances and masses to be weighed based on a registered solution recipe, and of automatically calculating the weigh values required for preparing solutions at specific concentrations. In particular, pre-registered common 13 buffer solutions recipes reduce the work involved in starting an analysis. Multi-Stand Convenient for Weighing Micro-tubes A multi-stand is now available, which is useful for accommodating medicine paper or rod- shaped samples that might easily roll off, and which can hold small containers or other objects in an upright position. This is particularly convenient for micro-tubes, which, while being held in an upright position, can be filled directly using a pipette. Also, it can allow direct fractionation without using medicine paper.
KSB in India receives Green Mark certification for its pumps! As a leading supplier of Pumps, Valves and related systems, KSB in India is committed to provide its customers high quality, energy efficient and safe products and services. In India, KSB manufacturers a large variety of centrifugal pumps for industrial applications. Under the environment labelling program by TUV India, KSB’s pumps series like Etanorm, Etabloc, Movitec B & Amarex IN are certified as “Green Mark Products”. "Green Mark" for a product indicates its contribution to reduction in the environment impacts associated with products, through the identification and achieving of specific criteria for the products for overall environmental profitability. Selected pumps are analyzed from cradle to grave, considering energy efficiency as primar y criteria i.e. from Product design →Raw materials → manufacturing process→ Product performance during use → Recycling & Disposal. These pumps are assessed according to the evaluation criteria of TUV India’s Environment Labelling Program with reference to Indian Standard - Environmental Labels & Declarations-Type I Environmental Labelling-Principles & Procedures (IS/ISO 14024:1999 -Reaffirmed 2004). With Green Marking its products, KSB will benefit demonstrating transparency, improving regulatory compliances, strengthening risk awareness, encouraging innovation, and its concern for environment apart from establishing competitive positioning and market differentiation. Chemical Engineering World
CEW Technology News Siemens India Wins First Cyber Security Contract for Power Plan Automation Siemens India has bagged its first order in the cyber security category for power plant automation from the Mumbai based completely owned CLP India Pvt.Ltd, subsidiary of CLP Holding Limited. Siemens will implement a Cyber Security Solution for their power plant automation at Paguthan, Gujarat. The Cyber Security Solution being implemented by Siemens Ltd. will support CLP India’s efforts to bolster cyber security at its power plant by detecting threats and minimising the risk of advanced cyber-attacks. The solution detects analyses and raises alarms of the threats that move laterally from Information Technology to Operations Technology network. Prashant Jain, head, power generation ser vices, Siemens Ltd, said, “In today’s digitalised world, power plant automation systems require robust and resilient delivery systems. Given the increasing frequency of cyber-attacks, it is very important to obtain a precise picture of the cyber security level of the plant and its associated instrumentation and control systems. Protective measures can then be implemented to remedy any deficiencies detected.” The complexities of power and modern energy are growing. Hence, a large number of power plant systems are connected through internet of things. When things are more on the internet, it is exposed to more security vulnerabilities due to meagre number of connected systems and lack of high level security available in simple devices. S i e m e n s i s a n e s t a bl i s h e d g l o b a l l e a d e r w h e n i t c o m e s to advancement of digitalisation across a wide var iety of industries. It has established a critical cyber security solution for power, infrastructure and industrial control system. These solutions provided by Siemens accords with the international standards such as NERC (Nor th American Electric Reliability Cor poration critical infrastructure protection) and VGB, the European technical association for power and heat generation.
HPCL, Mittal to invest $ 3 billion in setting petchem complex in Bhatinda . Lakshmi N Mittal and their state-owned par tner Hindustan Petroleum Corporation Limited (HPCL) are all set to invest $ 3 billion in setting up a petrochemical complex at their Bhatinda refinery in Punjab. .HPCL-Mittal Energy Ltd. (HMEL) a joint venture between HPCL and Mittal Energy Investments Pvt.Ltd., Singapore, plans to set up an up to 1.7-million tonne naphtha cracker unit to produce basic raw material that goes into making 18 • July 2017
of plastics. The plant which will initially start at 1.2 million tonne naphtha cracker will be expandable upto 1.7 million tonne later. This will be HPCL's first petrochemical plant in Northern India. The company has refineries in Mumbai and Visakhapatnam. HPCL and steel baron Mittal are equal partners in the Bhatinda refinery in Punjab. HPCL and Mittal Investment share hold 48.94 per cent stake each in HMEL while the balance is with financial institutions. HMEL had also plans to expand Bhatinda refiner y capacity fur ther to 10 mt, but Surana did not speak on the same. HPCL is investing Rs 45,000 crore by 2020 for expansion o f i t s M u m b a i a n d V i s a k h a p a t n a m r e f i n e r i e s a s we l l a s augmenting its marketing infrastructure. The investments will also help the company produce "products confir ming to Euro VI" emission specification, HPCL Chair man and Managing Director M K Surana said.
South Korean chemicals firm, Songwon, to open pilot plant in Gujarat Songwon, a South Korean speciality chemicals company has launched a new pilot plant in Panoli in Gujarat. The company attempts to strengthen the organisation’s overall speciality chemicals development capability. The new pilot plant is built on Songwon‘s Indian site with all the necessary main unit operations. It is equipped with the most up-to-date technologies and materials for producing wide range of chemicals for broad spectrum of applications. The new pilot plant will be immensely supported by the Songwon’s strong local R&D team in Panoli to reinforce the organisation’s position in the existing areas of business. The R&D team will be assisted by central technology innovations centre located in Maeam, Korea. “Technology and product innovation is at the core of Songwon’s b u s i n e s s s t r a t e g y. W i t h o u r h i g h - q u a l i t y m a n u fa c t u r i n g exper tise and strong R&D, we have already earned a solid reputation in the industry. This new facility will play an important role in ensuring that Songwon can continue developing new industrial technologies to meet evolving market needs and make it possible for us to reliably supply customers with innovative products for testing and approval,” said Giacomo Sasselli, leader operations, Songwon. Headquar tered in Ulsan (South Korea), Songwon Industrial Co is a leader in the development, production and supply of specialty chemicals. The second largest manufacturer of polymer stabilisers worldwide, Songwon operates group companies all over the world, offering the combined benefits of a global framework and readily accessible local organisations. Chemical Engineering World
For a life-saving operations Solutions for the Pharmaceutical industry
With our extensive knowledge and experience in the power transmission arena, we continuously innovate and launch new products, aimed at meeting the varied application needs of our customers. Our line of products for the Chemical & Pharmaceutical sector manufactured at our Chennai production facility in India, applying state-of-the-art technology, ensuring superior quality standards and matching the best cost/performance ratio. While the AS Series is most dependable and performing solution for all inline drive applications featuring unsurpassed Quality to Price ratio, the light-weight F Series ensures rugged and effective operations. Compact, and yet extremely powerful, are the units of the 300 series planetary drives that make them the ideal choice for all the severe duty applications where shock loadings and impacts are more the rule than the exception. Precision Planetary gearbox along with new range of AC Servomotors and servo drives along with Brushless DC Motors and drives is complete range of compact and flexible solution that are versatile and featuring control for high performance and unbeatable advantage in scalability. Welcome to the world of Bonfiglioli! Bonfiglioli Transmissions (Pvt) Ltd Survey No. 528, Perambakkam High Road, Mannur Village, Sriperumbudur Taluk • Chennai 602 105, Tamil Nadu www.bonfiglioli.com - salesindia.ins@bonfiglioli.com
CEW Features
Hygienic Drying in a Vacuum- Spherical Dryer for API Production. Air pollution is a major risk factor for several serious conditions including heart disease, stroke, chronic obstructive pulmonary disease, such as emphysema, and lung cancer. It has also been found to increase the risks of acute respiratory infections and exacerbates asthma.
S
pherical dryers are the ideal dryer in the production of high valuable products like pharmaceutical ingredients. The spherical design allows a full discharge and cleaning can be performed easily to avoid the risk of cross contamination. From pure drying up to mixing and granulation the Rosenmund ®spherical dryer can cover a wide range of application. Due to the high heat transfer and optimized peripheral equipment drying time can be reduced significantly. Hygienic drying in a vacuum requires a lot of attributes. The innovative spherical dryer design provides the highest performance according process control and latest GMP standards.
Accessibility, cleanability and a fast and residue-free discharge are the most important prerequisites for the production of high-quality products. Effective trouble free washing and cleaning (WIP/CIP) is required to maintain the systems in order to meet strict hygienic standards. These conditions are a real challenge to agitated vacuum dryers and are met by the characteristics of the patented top driven Rosenmund® Spherical Dryer design. Superior mixing with three arm agitator The spherical dryer achieves a high grade of mixing via a three arm agitator specially designed to conform to the spherical wall.
The agitator drive together with the shaft seal is mounted on the upper sphere. For sealing the rotation either gas or liquid lubricated double acting mechanical seals are supplied. By heating the agitator and a high rational speed, the heat exchange can be increased. A reduced clearance between the body and the agitator improves the heat transfer and prevents wet goods from being baked onto the hub and blades. These are ideal conditions for excellent solid mixing in contact with the heated wall surface which results in short drying times and reproducible drying results. To prevent the formation of agglomerates, a high speed chopper can break up the lumps and assist the removal of moisture from within.
Fully dischargeable Important advantages at a glance • Fast drying, mixing and granulation • Easy cleaning (WIP/CIP) • Total product discharge • Short drying time due to high heat transfer design • Easy to inspect by quick lock opening • Explosion pressure shock resistant design • Compact design allows easy installation in existing production buildings Figure 1: Spherical Dryer in Rosenmund® Design, The lower half of the sphere is removeable either by pivoting or dropping. This allows total and full visual and manual access to the process area and the 20 • July 2017
At the center and lowest point of the sphere, a dead-space free design of valve allows the product to flow without restriction and the risk of building bulk bridges. With this free passage and a gentle rotating agitator valuable products can be fully discharged without being jammed. Pack off system For the packing of the discharged product the dryer can be supplied with a pack off system. These systems are regularly supplied with a continuous liner to prevent active ingredients being exposed to the ambient. With a weighing scale and Chemical Engineering World
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CEW Features A further advantage of this partition into two halves is the possibility to install the dryer between two floors. The product discharge area with its lower part of the sphere can be located in a classified clean room whereby the upper part of the sphere is separated in the technical area. Versatile design features and sizes Since dryers are usually designed for vacuum operation, the risk of thermal decomposition or dust explosion requires them to be designed for higher pressures in many cases. The spherical shape with maximum volume and minimum surface is the ideal geometry for an explosion containing shock resistant design.
Figure 2: Three arm agitator with enhanced heat transfer design and high speed chopper
a permanent actuated discharge valve the product can be dosed to a preset value. A mill can also be placed between the discharge valve and the pack off system as an integrated part to achieve smaller particle sizes. Cleaned in a flash
by pressure of the cleaning liquid from the vessel wall to the center of the sphere and enable a good coverage of the detergents on the product contacted surfaces. When the spraying is completed, the ARD nozzles retract themselves under spring load to be flush with the inner surface of the vessel, thus closing free of dead spaces.
In the pharmaceutical industries federal agencies set requirements for cleaning process equipment. These good manufacturing practices are regulations put in place to ensure equipment is maintained in a clean and orderly fashion. The main concerns is to avoid contamination of the product and crosscontamination (by improper cleaning, bad maintenance) both of which can lead to product call-backs.
Due to the slope in direction to the outlet valve cleaning fluids and dissolved product residues are drained at the lowest point of the vessel.
Due to the spherical design and the location of critical parts like the mechanical seal above the product level, washing and cleaning in place (WIP/CIP) procedures can be carried out efficient with minimum quantity of detergents. Moving and retractable cleaning ARDNozzles (Aftertreatment Regeneration Device) with rotating spray heads enter
Easy access for inspection
22 • July 2017
For the purpose of conducting a qualitative coverage test of the spray devices, a riboflavin test can be performed to measure the accuracy of the cleaning. The results of this procedure can be useful for in the development of cleaning validation protocols.
To allow a quick inspection at any time the Rosenmund® top driven spherical dryer can be opened easily by swiveling the lower half of the sphere. This operation is simply achieved by a hydraulic driven quick lock bayonet at the main flange and a hinge at the joint of the two spheres.
The dryer can be manufactured either in stainless steel or, for high corrosive applications, in nickel alloys with high resistance to acids. The size ranges are from 100 to 4’000l net volume. The vessel is fully jacketed, insulated and covered by welded metal sheeting. Normally the dryer come along with skids for heating / cooling and vacuum including a condensation of the vapors. Particle fines which can be fluidized during drying are withheld by a dust filter with cartridges whereby the filtration media can either be made of a textile cloth or by a sintered wire mesh. To optimize the performance it is important to adjust the peripheral equipment like heating / cooling and condensing / vacuum to match the specific requirements of the drying performance. For heating / cooling mostly indirect loop systems are used in which a thermal liquid such as water, a glycol-water mixture, or thermal oil circulates through the dryer jacket. This liquid passes through a heat exchanger that respectively transfers the heat from the heat source (e.g. steam). Sensitive products may require rapid cooling at the end of the drying to maintain product quality so care must be taken that heat from the product can be removed to the coolant. Chemical Engineering World
CEW Features
Condensers, typically shell-and-tube type, are used mostly to recover valuable process solvents which are evaporated during drying. Condensers used with dryers are operated in a way that vapors are condensed inside the tubes instead
outside. The advantage is that the straight tubes bundles can be cleaned more efficiently. For the fast and gentle drying at reduced evaporation temperature a vacuum system
Module
Description
1000 1025 1100 1300 1700 2000 4500 7500 7600 8000
Sphere Discharge valve Quick lock (bayonet) Sampling valve Hydraulic actuated hinge Drive unit/Agitator Mechanical seal Chopper Spray balls (ARD nozzles) Dust filter
is required. A wide range of pumps are available on the market whereby screw or liquid ring vacuum pumps are generally used. Optimizing and scale up the drying Process Either to optimize existing processes or to develop the best possible process parameters for new or modified products, trials are recommended. The Rosenmund® spherical dryers cover a wide range of applications. From pure drying to combined processes with mixing and granulation results on drying and product quality can be optimized. Therefore pilot scale machines are installed at the site of the pharmaceutical manufacturer to implement the spherical dryer to the running process.
Author’s Details
Figure 3: Rosenmund® Spherical Dryer Pilot Scale Machine 24 • July 2017
Lars Voges Sales Director Business Line Filtration & Drying Europe Email- lars.voges@rosenmund.com Chemical Engineering World
When others stop, Saurus939 carries on. The vacuum pump unique in reliability, performances and operating costs.
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Saurus939, the vacuum piston pump designed and manufactured by Italvacuum, represents the very best of the Made in Italy know-how, combining traditional sturdiness and reliability with the most innovative technologies.
• Easy round-the-clock operation • Best results • Minimum operating costs • Uncontaminated vacuum.
Saurus939 ensures unmatched performances in all the main chemical and pharmaceutical processes, maintaining in time constant flowrates and high vacuum levels. Endurance, resistance, adaptability to any working environment, meaningless oil consumption thanks to the innovative LubriZero ® system, low-energy motors, simple and cheap maintenance. Not only. Italvacuum, thanks to over 75 years of experience, is also a global benchmark player in vacuum dryers manufacturing, with a complete and highly specialized range, at top level of innovation and quality. Italian quality, which always makes the difference.
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CEW Features
Use of Centrifugal Pumps with Difficult Pumping Media When pumps are used in the field of chemistry, reliability and operational safety are of the utmost priority. The reason for this is that when aggressive, corrosive or toxic chemicals and mixtures or waste waters are being pumped, this must be carried out without causing any damage. Even if additional difficulties such as temperatures, solid matter in the medium or small quantities with an irregular feed make the pumping process more difficult, it is essential that the plants, environment and pump are not negatively affected.
E
xamples of problematic substances are ammonium nitrate, nitro phosphate or tetrachloride. The requirements for liquids, gaseous, laden with solid matter or pumped directly from a vacuum, are just as high as for the use of pumps in molten salt, for example. The latter is one of the extremely hot applications. The usual standard centrifugal pumps, which are the most frequently used pumps with a share of approximately 80 – 90% of applications, are usually unable to cope with these complex problems. In contrast, they do not represent an insurmountable obstacle to sturdy special centrifugal pumps. Special pumps made by Bungartz are completely reliable for media containing solids, for example, as they work without enclosed pumping chambers and do not require any valves. They work with a hydraulics system and an impeller, as well as housing with a seal and bearing unit. The main decisive factors when selecting the pump are an exact description of the parameters, such as the place of use, the conditions and – in particular – the media to be pumped. The more precise the details, the better the preconditions for the selection of the important pump hydraulics and the shaft seal. As a rule, the pump manufacturer is responsible for this design. At the same time, the pump or pump system must fulfill the task inexpensively and with a low level of maintenance. The sealing technology is an essential component for the optimum use and a long service life of the pumps. For this reason, the selection and combination of the seal and bearing unit is highly important. 28 • July 2017
Sealing problem and sealing system The sealing system seals off the rotating shaft against the surrounding environment. Here too, the type of application and the medium to be pumped play an important role. The potential hazards associated with this medium are the determining factor for the selection, depending on the national law and regulations (explosion protection, TA Luft (Technical Instructions on Air Quality Control) etc.). Furthermore, the type of seal has a large influence on the performance and the life cycle costs of the pump. Sealing systems such as a stuffing box, single or double mechanical seal, magnetic coupling or even a canned motor are available for selection. In the case of the canned motor pump, the pump and motor form one unit. In contrast to the double mechanical seal, which is sealed using a separate medium, this does not operate independently of the pumping medium. The medium flows around the containment can and slide bearings. Magnetic coupling and canned motor pumps can only pump gas-laden or magnetizable media and solids with the addition of measures such as external flushing. Within the context of a comparison of the life cycle costs, the high energy losses due to induced eddy currents (in the containment can/can) and viscosity effects must also be taken into account. If centrifugal pumps are used with a magnetic coupling, the motor shaft is fitted with an external magnetic rotor in the so-called block design. It transfers the magnetic forces through a containment can to the internal magnet rotor. In the
case of conventional magnetic coupling pumps with slide bearings lubricated by the pumping medium, the containment can, which hermetically seals the medium from the surrounding environment, and the slide bearings must not run dry; they will react directly with malfunctions if there are solids in the pumping medium. In order to prevent this, it is necessary to ensure the dry-running safety of the pump for many types of media. This guarantees that the pumps are not damaged even during phases in which little or no fluid is pumped. However, in the case of conventional pumps, it is only possible to provide dry-running safety by means of complex and costly additional measures. Definition of dry-running safety Dry-running safety is the ability of a pump to handle difficult operating situations without damage or causing a dangerous situation. The difficult situations include pumping processes in which there is only a little or even no pumping medium inside the pump casing, or where gas components occur in the pumping medium. Hydrodynamic seal The advantage of the hydrodynamic shaft seal is its friction-free mode of operation. The hydrodynamic seal was invented and patented by Paul Bungartz in the 1930s. It has been continually developed by Bungartz up to today. The fundamental motive for the need for such sealing physics was the existing problem of ensuring that the transition between the pump casing and rotating shaft was permanently tight; i.e. the task is to pump the medium away from the critical shaft Chemical Engineering World
Munters India Humidity Control Pvt. Ltd.
CEW Features contact and without any wearing parts, no maintenance whatsoever is necessary. Since they are operated for several years with little maintenance and high annual running times, they also offer the advantage of low life cycle costs. Pumps of this type are particularly suitable for continuous operation in the chemical and primary industry.
Figure 1: MPCH Dry Run Energy saving centrifugal pump for difficult and complex pumping tasks
gap transition and in this way to protect the following shaft seal system. In centrifugal shaft seals, ribs are arranged concentrically on the rear of an ordinary centrifugal pump impeller with the shaft stub. The effect of these ribs is that as the rotational speed of the pump increases, the fluid is carried along by the centrifugal forces – i.e. it is induced to rotate and therefore to be conveyed towards the outside.
in the direction of the suction side of the pump. As a result, the conical stuffing box packing used here is separated radially from the shaft. The standstill seal is completely friction-free during pump operation. In combination with stuffing boxes, pumps with these sealing systems are ideally suited for use in the fertilizer and paper industry for pumping non-toxic products containing solids.
The back vanes on the rear of the impeller reinforce this effect, so that the rotational speed of the rotating ring of liquid can reach up to 90% of the pump speed. The rotating ring of liquid reduces the pressure that is applied to the external diameter in the direction of the shaft to the ambient pressure. If the design is correct, no liquid is then found at the shaft penetration while the pump is operating. A friction shaft seal is then superfluous. However, there are problems when the system is at a standstill: the seal is ineffective. A standstill seal is required.
The hydrodynamic sealing technology is also referred to as the basis of the Bungartz “sealing philosophy”. With the so-called secondary seals – which in the past took the form of stuffing box packings, but today are mostly double mechanical seals – they ensure leak-tightness when the system is at a standstill. Almost all pumps of the manufacturer combine the hydrodynamic shaft seal as a primary seal with a downstream secondary seal capable of dry running.
One example of the combination of the hydrodynamic seal with a centrifugal system has been created for a horizontal pump. As soon as the pump is started and the hydrodynamic seal takes pressure off the shaft penetration, the shaft is moved axially 30 • July 2017
The advantages are clearly seen in practice: The pumping medium is kept away completely from the actual seal during operation and also during a standstill in the case of very aggressive applications which place high demands on seals. This permanent dry-running safety results in an extremely long service life. Because the hydrodynamic shaft seal operates without
Horizontal centrifugal pump MPCH Dry Run with permanently dry-running magnetic coupling Bungartz is the only manufacturer to also build magnetically coupled pumps with a hydrodynamic shaft seal - that is, with dryrunning containment cans. “It doesn’t matter what is pumped at the front in the pump head, the secondary seal and the magnetic coupling are not affected during operation. In many cases we work with sealing gas blanketing,” explains Michael Wolf, who represents Bungartz as a Consulting Sales Engineer in the Asian region. Thanks to the unique pump characteristics, the company – which is known for its problem solutions – also offers the basis for the optimal selection of magnetic coupling pumps. The horizontal special pump MPCHDryRun has proven its worth in the pumping of hazardous liquids and / or solid-laden, gas-containing media. The special technical features begin with the magnetic coupling, which is permanently dry-running and depressurized. A ceramic containment can located between the inner and outer magnet rotor is depressurized and enables eddy current-free magnetic field transmission without product contact and therefore dry operation. The bearing mount consists of a shaft with grease-lubricated roller bearings which have a minimum service life of 32,000 hours. The life-long lubricated roller bearings are extremely low-maintenance. These increase the efficiency compared to conventional magnet pumps with plain bearings. Safety advantages are also provided by the hydraulic relief on the impeller. As a result, and through the use of compensating bores, the shaft gap pressure drops to the inlet pressure. A labyrinth seal between the impeller and shaft bearing Chemical Engineering World
CEW Features and operates without product contact. Since the bearing and magnetic coupling are not in contact with the pumping medium, this magnetic-coupled pump can be operated more or less independently of the liquid. “It also runs when it runs dry,” is the core statement on the outstanding feature of this special centrifugal pump. The triple seal arrangement guarantees very high operational safety levels, even if the flow of the medium is interrupted. The design impresses even in the case of faulty operation, since it is based on an intrinsic safety method which is incorporated into the system of the pump: Dry-running lip sealing rings automatically secure the system. The use of roller bearings and a ceramic containment can also have a positive effect on the energy balance of the MPCH Dry Run. The eddy current-free magnetic field transmission results in savings in terms of energy costs (for example: for a pump running time of 8,000 operating hours, the annual savings in Germany are up to € 8,000). In addition to the positive energy balance, the operating reliability, a maintenance interval of three years and a very long service life pay for themselves over the long term.
Figure 2: V-AN Self-regulating centrifugal pumps reduce plant costs and can be used as problem-solvers in a wide range of applications.
separates off any solids. These cannot enter the bearing area. It is possible for the impeller, for example, to be equipped with enclosed vanes so that it is tailor-made for every application. Between the back of the impeller and the shaft bearing there is the product-free labyrinth area through which the sealing gas flows. This sealing system and the rest of the structural design ensure a high temperature gradient and therefore a lower bearing temperature. A special lip seal ring upstream of the bearing is activated if the nitrogen supply fails. The ceramic containment can the actual hermetic seal, is thus subject only to low pressures, 32 • July 2017
Conclusion: For the pumping of hazardous liquids and/or solid-laden, gas-containing media, the permanently dry-running magnetic coupling pumps of the MPCH Dry Run type have proved their value all over the world. Intelligent Interaction If the properties of the permanently dry-running magnetic coupling pumps are combined with the vertical centrifugal pumps of the V-AN range, further problems with pumping applications can be solved. V-AN centrifugal pumps made by Bungartz have become wellknown problem-solvers. With the V-AN pump, the special pump manufacturer Bungartz provides a reliable, tried and tested solution: The V-AN regulates itself in order to adapt to the incoming flow rate. Advantage: Due to the pressure reduction without cavitation up to the boiling point, the emptying of liquid gases is also unproblematic. All pumps in the V-AN range are dry-running and operationally safe,
self-ventilating and have a low NPSH value (<0.1 m). They are suitable for use with fluctuating inflow volumes, media at their boiling point or gaseous media. They are often used for tanker and tank wagon emptying. One important factor in pump selection in this area is the residue-free draining of containers and tanks. The pumps in the V-AN range ensure complete discharging without additional pressure. When discharging is carried out from above, this can even be used with heavy media up to a density of 2.4 kg/dm³. The V-AN range is also frequently used with gaseous or boiling media. They are ideal for separation processes with fluctuating inflow volumes because the pumps adapt themselves independently to changing volume flows. It is possible to dispense with the otherwise commonly used additional equipment which is very prone to failure, such as min/max circuitry, speed regulation by means of a frequency converter or volumetric flow measurement. A further criterion when selecting pumps is to save plant costs by reducing the overall height. This is where the pumps of the V-AN range also offer advantages; considerable investment cost savings are possible if the pumps are incorporated in good time into the planning phase (no pits, scaffolding, buffer tanks, etc.). They are in demand all over the world for the residual emptying of all types of containers, for the pumping and collection of condensates on vacuum filters, centrifuges, distillation columns, evaporation plants or on slop containers. A complete pumping system consisting of the V-AN self-regulating centrifugal pump, a pump stand and feed vessel can be used to save space for tanker emptying. It is connected directly to the power supply and the pipes. As all Bungartz pumps, the system can be used entirely without any control unit, regulation or additional monitoring. The V-AN range of pumps has no problem with reliably pumping gases, acids or alkalis – from sulfuric acid, through sodium hydroxide solution to substances such as acrylamide, propylene, isopropanol, Chemical Engineering World
CEW Features plants, e.g. for the pumping of substances such as ammonia, ammonium nitrate, urea solutions or phosphoric acid. Legendary also because they can also be found where other pumps have already given up. Recently, one of these pumps, which had been in use since 1948, was removed from service in a fully functional condition. It has now been replaced by a new model. The horizontal centrifugal pumps operate either with a dry-running magnetic coupling or with the hydrodynamic shaft seal described, where the back vanes seal the shaft gap on the open impeller (star wheel). A centrifugal controller integrated into the bearing block moves the rotor in the direction of the suction connection during start-up. The gap between the conical shaft sleeve and the stuffing box packing prevents the signs of wear which are otherwise found there. When the pump is switched off, the rotor is pulled back into the packing space by a spring force. Here, a stuffing box seals the shaft gap as a standstill seal.
Figure 3: M-UMOR Large circulating pump (900 m3/h) with semi-axial impeller for pumping ammonium nitrate
ammonia or special items such as maleic anhydride – down to the very last drop. V-AN centrifugal pump versions Fields of application (pumping media) with corresponding shaft seals VKA-AN • liquid gases and other TA Luft media, permitted for solids • double gas-lubricated mechanical seal with low gas sealing pressure VKG-AN • liquid gases and other TA Luft media, permitted for solids, suitable for TA Luft • double liquid-lubricated mechanical seal with low sealing pressure VKS-AN • for non-toxic liquids under atmospheric pressure, permitted for solids • dry-running, self-lubricating stuffing box VKC-AN • tried and tested problem-solving pump as a robust alternative to the gas-lubricated DGLRD, suitable for TA Luft with restrictions, 34 • July 2017
• now with gas-sealed shaft seal and new lip seals
MPVAN • heavy media, e.g. sulphuric acid, oleum, zinc tetrachloride, generally solid-free media suitable for TA Luft • liquid-lubricated magnetic couplings
MPCVAN • liquid gases as well as other TA Luft media, permitted for solids, suitable for TA Luft • dry-running magnetic coupling – supplied externally with sealing gas Legendary for a good reason These legendary types M-MOR, M-UMOR slurry pumps are suitable for the pumping of solid-containing, corrosive liquids, especially for suspensions – including acid, fertilizer and sand mixtures. Legendary not only because they can pump corrosive, abrasive, sticky, gaseous, crystallizing or even gelling media without any problems. Pumps from the MOS / UMOS and MOR / UMOR range are highly appreciated worldwide due to their sturdy design and used in a wide variety of
The pump speed can be adjusted without problems by means of the impeller back vanes and an additional seal expeller – without impairing the hydrodynamic sealing effect. Further significant advantages result from the innovative use of a wear-resistant material based on silicon carbide, which is used in the area of the impeller and the housing. Additionally, the silicon carbide ceramic can be incorporated selectively where direct wear occurs. The large circulating pumps (1,200 m3/h) of the M-UMOR type, which have just been put into operation, are completely reliable thanks to the contactless hydrodynamic shaft seal with seal expeller and centrifugal forcecontrolled standstill seal. Operating reliability and generous maintenance intervals add up to massive cost advantages with all of the other special features.
Author’s Details Frank Bungartz Director Paul Bungartz Gmbh & CO. KG Düsseldorf, Germany; Email: bungartz@bungartz.de Chemical Engineering World
CEW Features
The Right Formula for Emission Reductions Air pollution is a major risk factor for several serious conditions including heart disease, stroke, chronic obstructive pulmonary disease, such as emphysema, and lung cancer. It has also been found to increase the risks of acute respiratory infections and exacerbates asthma.
T
he majority of chemical engineering procedures involve processing a combination of raw materials through a range of equipment to achieve the desired end-product or products. The calculations for these processes are usually very complicated, so you need a head for figures. However, sometimes it seems not all the outputs of the chemical equation are given full consideration which can be to the detriment of workers, nearby residents and the business. Along with the many products and solutions developed by the chemical engineering industry there are also potentially harmful side effects from noise and air pollution emissions. At a formulaic level these emissions may seem inescapable. When you insert energy and material into a process, especially using large-scale equipment, there has to be an output; and that will always include noise and other emissions. It is true that it is simply not possible to remove all the negative emissions from a process. However, using software to produce noise or air pollution maps can help facilities owners and managers identify the exact source of the problems, and assist in planning to mitigate it; helping to protect workers’ health, the wider environment, and businesses’ reputations. Considerable problems Thanks in part to economic growth in many of cities, noise and air pollution are commonplace in much of India, but steps are gradually being taken to try and address this. The federal Ministry of Health and Family Welfare established a Steering Committee on Air Pollution
36 • July 2017
and Health-Related Issues to help tackle the devastating effects of air pollution on people’s health for example. It has proposed a series of measures to reduce exposure to air pollution, including a commitment of at least US$1.5 billion to address household air pollution through the provision of clean cooking gas to 50 million poor households. The combination of traffic, dusty construction sites and use of solid fuels for cooking are major contributors to the pollution issues and air pollution is a significant health hazard and a killer. The World Health Organization estimated that 1.5 million people died in India from the effects of air pollution in 2012. Its data shows that across the world, air pollution caused nearly seven million deaths (that’s 11.6% of deaths in 2012), making it the world’s largest single environmental health risk, according to World health statistics 2016. Air pollution is a major risk factor for several serious conditions including heart disease, stroke, chronic obstructive pulmonary disease, such as emphysema, and lung cancer. It has also been found to increase the risks of acute respiratory infections and exacerbates asthma. Exposure to excessive noise should not be overlooked either. The environment ministry has recently reported average levels of noise pollution generally exceed the permissible limits in seven cities, including Mumbai, Delhi, Kolkata and Chennai. Appliances such as air conditioners and refrigerators, as well as motor vehicles and events such as festivals were identified as major contributors to the problem.
Exposure to noise is more than just an annoyance; it can have a substantial impact on people’s health. Hearing loss, for example, is one of the most noticeable and clear impacts of exposure to excessive noise. The affected individual needs a large variation between the levels that they are trying to listen to and any background noise; that is if they can hear anything at all. Permanent hearing loss cannot be corrected by surgery or a hearing aid, so it is important to take action to protect people. It’s important to remember that hearing loss doesn’t just affect a person directly. It also impacts on their family, friends and co-workers. People who suffer hearing loss often undergo social isolation, because they can no longer communicate in the normal way. Other health impacts associated with exposure to noise include strokes, coronary heart disease and cardiovascular disease. The impact on stress levels and other emotional responses such as disturbance, irritation, dissatisfaction and nuisance should not be discounted. Chemical reaction Exposure to noise and its impacts vary across industries, but it is worth noting that the European Agency for Safety and Health at Work reports that some chemical substances are ototoxic or ‘ear poisoning’. It says, “Workers exposed to some of these substances and to loud noise appear to be at greater risk of hearing damage than those exposed to either noise or the substances separately. This synergy has been particularly noted between Chemical Engineering World
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CEW Features
Figure 1: Noise within a Building
noise and some organic solvents, including toluene, styrene, and carbon disulphide. These substances may be used in noisy environments in sectors such as the plastics and printing industries, and paint and lacquer manufacturing.” Noise issues can also affect future generations, as exposure of pregnant workers to high noise levels at work can affect the unborn child, for instance. It is also believed that prolonged exposure to loud noise may lead to increased blood pressure and tiredness. Studies have also shown noise has a negative effect on educational attainment levels. The NORAH (Noise-Related Annoyance, Cognition, and Health) Study in the greater Frankfurt area of Germany compared the effects of the noise from transportation (road, rail and aircraft). Primary school children were found to learn to read more slowly in areas subject to strong aircraft noise than in more quiet areas. A noise increase of 10 40 • July 2017
decibels was shown to delay learning to read by one month. The health of children in very noisy areas has also been shown to be not as good as those in quieter locations. Parents also stated more frequently that their child had already been diagnosed with a speech or language impairment if they were in a noisier area. Economic impact Lower educational attainment levels can have an economic impact in the longer term as it could impact on young people’s employment prospects and therefore the country’s competitiveness. Noise and air pollution are also bad for the economy as they can result in workers taking days of sick with a resultant drop in productivity. Management time is also taken up rescheduling tasks or arranging cover, and there are even more costly outcomes if litigation and fines follow workers becoming ill.
Be part of the solution India is, of course, not alone is suffering issues with noise and air pollution emissions. London, England, breached its annual air pollution limits just five days into 2017 for example. No government can solve these issues alone, so it is important that industries, including chemical engineering, play their part and look to clean up their own processes and procedures to reduce exposure. A key way to do that is to use available data to accurately identify the sources of emissions through software produced noise and air pollution maps. With mapping software it is possible to build a visual demonstration of emissions; including where they come from and where they go. The software can be used to generate maps for a single building or an entire country depending on information available and the scope of the project. Chemical Engineering World
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CEW Features
Figure 2: Noise around a Building
You don’t need a science degree, acoustic expertise or an engineering background, just a computer and the right bit of software. The maps produced are designed to be widely understandable – they are colour coded for instance and can be in 3D where appropriate so that every aspect of the sound’s movement is demonstrated. The software can also animate the maps to show how the emissions move. With this software at your fingertips, different mitigation options can be investigated. Unlike simple measurements, the software can help identify different sources and show how emissions travel. With measurements only the overall levels can be demonstrated. As far as chemical engineering is concerned, mapping could help identify the noisiest equipment, whether that’s a reactor, absorber or distillation column or other site equipment. This gives 42 • July 2017
the opportunity to establish whether replacement options could help or if mitigation measures would help. Mapping can helps when designing chemical engineering processes before they are even begun. Different options to lessen the effect of noise and air pollution can be tried (and the cost calculated) so that the best option is chosen. This can mean trying different sizes or types of barriers for example or selecting different locations for equipment or changing the layout of a facility. The mapping software can be used to demonstrate the impact of workers and visitors within a facility as well as one wider area around it. If the emissions can’t be sufficiently reduced then mapping can, at the very least, show the areas where personal protective equipment (PPE) is required. Knowing this can ensure safety and reduce costs as it could mean some areas do not need PPE supplied.
Opportunity to develop solutions The chemical engineering industry has a responsibility to reduce its own noise and air pollution emission levels, to protect workers and their employers as well as the wider environment and economy. It also has a golden opportunity to play a part in developing the solutions to noise and air pollution by creating products that helps to control wider emissions in the future.
Author’s Details Arne Berndt President SoundPLAN GmbH and SoundPLAN International LLC.
Chemical Engineering World
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CEW Features
Technology Selection for a Chemical Process Technology Selection is a key process for Chemical organizations in their CAPEX projects planned for developing engineering solutions with a view to expand their existing assets and products improvement or even for entirely new businesses. This often involves evaluation and development of new technologies or use existing technologies readily available in public domain.
I
t is the need of the hour to design the plants in a more optimized, sophisticated and safe way as the overall awareness of the owners/ manufacturers has gone up over recent years. Owners are becoming increasingly energy and emission conscious and are keen to select the best possible option which can offer advantages in various areas of technology. Engineering consultants often need to shoulder the responsibility of selecting the best possible technology for owners and optimize the Total Installed Cost (TIC) of the project with the most efficient plant set up. Relevant past experience, multi-disciplinary team of competent engineers and proven methodology based on accepted criteria for evaluation of technology are the main requisite of the activity.
Process Technology selection may be needed differently during the various phases of a Project right from the concept phase to execution phase as listed below: •
•
• •
•
• Following are the main requirements for technology selection team • •
• •
Meet client expectation with respect to technical competency and relevant technology knowledge. Secrecy of the Licensor information Putting information in front of the client in a factual manner i.e. transparently sharing the data collected, calculations performed and basis used for analysis.
Technology evaluation involves major contribution by Process Engineering discipline, however, a strong multidisciplinary team shall be involved to evaluate all the aspects of technology such as CAPEX, OPEX, Environmental impacts, waste generation, utility consumptions etc. 44 • July 2017
Selection out of different process schemes to meet the same objective (this shall be carried out during detailed feasibility report stage) Selection out of different unit operations to meet the same objectives (This shall be carried out during conceptual or pre-FEED stage) Selection out of catalytic & non catalytic process routes (This shall be carried out during conceptual or pre- FEED stage) Selection out of open art and licensed technologies (This shall be carried out during conceptual or preFEED stage) Selection out of different vendors for the same type of process (This shall be carried out after FEED stage) Selection out of different catalyst systems from same vendor (This shall be carried out after FEED stage)
In a typical CAPEX project life cycle, following three phases are involved in a technology selection process: Detailed Feasibility Report Phase – includes a detailed feasibility study of shortlisted technologies, review of proposals, technical suitability, identifying alternatives of the shortlisted technology, if any and their evaluation, preliminary financial analysis, identifying opportunities of in-house technology development • Conceptualisation or Pre-FEED Phase
– includes defining licensors selection criteria, handling licensor enquiries, vendors identification, technological feedback from licensors, design basis revisions based on feedback from licensors and preparation of a final shortlist of qualified licensors • FEED Phase – includes RPF preparation, evaluating technological responses, scoring responses and recommending a licensor, supporting negotiations, refining the design basis, developing a facility design basis, assessing risks, evaluating and filing for any IP protection Preparation of Enquiry Specification: The quality of proposal received depends on the quality of input data supplied to Licensors or vendors as a part of enquiry specification. Properly defined conditions, specification and capacities will help Licensor to select the most appropriate process configuration. The required data from Licensor as a part of proposal like technical details, economic details, and performance guarantees etc. shall be clearly mentioned as a part of enquiry specification. Typical information to be provided as an enquiry specification is as given below. • Plant Capacity, on stream hours and turn down ratio • Plant configuration, no. of units/trains • Feed Specification • Product Specification • Utilities available and battery limit conditions • Specific design requirements based on site conditions i.e. maximization of air cooling, exchanger tube lengths, use of steam turbines or electrical motors etc. Chemical Engineering World
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CEW Features data can be highlighted and requested from Licensor to complete a fair evaluation. It is important that the evaluation engineer or team shall have relevant experience in handling similar technologies and knows the intricacies of the process. In parallel, additional literature search to be done to acquire useful information regarding latest technologies, benchmark energy consumptions, optimization techniques. Evaluation of Proposal: Careful review of received proposal is to be carried out and information received to be tabulated for easy comparison between various options. It shall be noted that Technology Evaluation is not Technical Bid Evaluation and accordingly weightage criteria needs to be properly defined. Missing information from proposal needs to be requested from Licensor and accordingly responses to queries raised to be documented. It is important to document all the communication during the Licensor interaction. • List of facilities/offsite area to be considered under Licensor scope i.e. tank farm, day tanks, and intermediate storage tanks. • List of documents to be furnished by Licensor as a part of technocommercial proposal • Specific environmental norms to be followed by Licensor based on site conditions/local regulations • Process Flow Diagrams with Material Balance • Process Description • Preliminary Equipment List • Performance of the plant and operating requirements i.e. regeneration of beds, decoking, off spec product management, on stream hours etc. • Utility and raw material consumption summary • Guaranteed consumption figures for catalyst, utilities and raw materials • Quantity and composition of the expected gaseous and liquid effluent streams. 46 • July 2017
• Proposed method of disposal and handling of the generated waste from the process • Licensor past track record with number of similar units installed in the past five years, number of operating units and number units in design for similar technology. • Performance Guarantees expected from Licensor Sometimes Licensors are reluctant for providing guarantees on all the utilities and accordingly only key utility guarantees can be asked from Licensor like fuel gas, steam, electricity and cooling water. Review of Technical Proposal and Raising the Technical Queries: Licensors or Vendors will provide the techno-commercial proposal in line with the enquiry specification of issued. A check list can be maintained with respect to data requested as a part of proposal and data received by Licensor. Accordingly missing
Technology evaluation criteria can be applied to all the received proposals and accordingly the comparison table can be prepared. Following are the typical points considered for the technology evaluation criteria. • Technical feasibility of the process to meet the specs as mentioned in enquiry specification • Proven technology • Environmental Aspects • Competitiveness • Sustainability • Raw Material, Chemicals & Catalyst Consumption • Licensor Track Record • Energy Efficiency • Integration with Other Units • Proprietary/Non-proprietary nature of technology • Safety and Ease of Operability • Plot area required for installation of the system • Capital Cost involved (CAPEX) • Operating & Maintenance Cost (OPEX) • Utility requirement Chemical Engineering World
Features CEW • Waste generation and its disposal Each technology can be weighed against a predefined criteria based on provided information by respective Licensor. Additional information if required can be requested for clarifications. Depending on the phase of the project i.e. concept development stage, Pre Feed Stage, FEED Stage or Detail Engineering Phase the information from Licensor can attain more clarity as more specifically defined data can be generated during later stages of the project. Commercial Compatibility of licensor shall also be considered based on following criteria • Total number of plant with their respective capacities Licensed by Licensor • Check whether Licensor has included the list of previous supplied plants and how many of these plants are under operation • Check and confirm the technology offered is not obsolete and Licensor is able to support during operations • No. of units supplied with similar or higher capacities than the unit under consideration. This will give affair idea about Licensor capability and readily providing the scale up design to meet the requirement. Technology Salient features • • • • •
Comparing the PFD and process description Control of kay operating variables Ease of operability and maintainability Safety features provided S p e c i a l e q u ip m e n t a n d f e a t u re s o f o v e ra l l s e t u p
• Effluent generation and summary of emissions • Consistency of process, utility and effluent streams with battery limit conditions needs to be checked and accordingly identify any missing equipment from the preliminary equipment list. • Check is any upstream purification unit is required so as to meet the stringent feed specification for • Licensor unit Process Calculation • Specific raw material, catalyst and energy consumption Chemical Engineering World
• Conversion, yield, EOR and SOR performance • Major equipment sizes • Material of construction specified • Consistency of the heat and material balance provided • Amount of heat integration and possibility of further optimization • Use of solvents, additives etc. in the process • Auxiliary units such as incinerator, refrigeration, hot oil unit • The comparison table shall have numbers for different Licensors calculated in a similar manner to have fair comparison • If there are huge differences in the consumption values then necessary clarifications can be requested from respective Licensor Safety Features of the Technology • Chances of runaway reaction • Overall hydrocarbon inventory expected • Use of hazardous material in the process as solvent or additives
• HAPs • Requirement of primary treatment within ISBL before diverting it to central effluent treatment facility Economic Evaluation Depending on the stage of the project the accuracy of the data from Licensor will get increased. Conceptual stage proposal may have lesser details generated and larger price variation. FEED or detail engineering stage proposals are more accurate and with firm pricing. Accordingly CAPEX for Licensor unit and variable operating cost for unit shall be evaluated. • Completeness of equipment list for cost estimation • List of additional supplementary facilities/units required for Licensor unit • Percentage of cost considered for other disciplines such as piping, civil, structural, electrical and I&C. Proven Technology
Ease of operation and Maintenance • • • • •
Number of fouling service exchangers Coking or choking possibilities Solid handling requirements Dependability of one unit on another Batch or continuous process configuration • Time intervals during catalyst regeneration, loading and activation etc. • Time required for hot and cold start up • Off spec product management
Different Licensors offer different technologies with various features and a careful evaluation needs to be carried out in all the aspects. The number of units operating worldwide, technology development and its integration with upstream and downstream units, potential for improvement, Licensor track record and R&D facilities to support the problems in running units are major factors to be considered during evaluation. Licensor Selection
Effluent Generation and disposal Ef f luent generation and its treatment is a major as pec t now day s . A fair e va luation with res pec t to ty pe of e f f luent i.e. s olid, liquid or gas eous st re am, quantity and c ompos ition of t h e s tream s hall be ev aluated. • Larger relief and blowdown loads will require larger investment in off-site facilities • Requirement of incinerators or thermal oxidizers depending up on type of compounds i.e. VOC or
Licensor Selection is one of the most important steps in the overall process of a Technology Selection. It is essential to properly plan the activities when deciding which licensed technology should be utilized for a specific process. Following activities are required to be carried out for Licensor selection: • Compiling a detailed list of Technology suppliers from available literature/ internet/past experience July 2017 • 47
CEW Features • Reviewing the published information of each of the shortlisted technologies with a view to ensure that they meet overall project objectives. • Contacting each Licensor to know their interest in offering respective technology that would meet project objectives. • Verifying/Cross-checking the claims made by each Licensor by seeking direct feedback from their licensees and/or visiting the licensees’ plants if possible and/or if required. Obtaining budgetary quotes from each Licensor for their respective technologies. • Evaluating all the budgetary quotes and short list the most prospective parties that would substantially meet project objectives/requirement. Criteria for Licensor Selection The Criteria to be used for selecting a licensor are as follows: 1. • • • •
Economical Evaluation License Fees Process Design Package Fees Technical Support Fees Liquidated Damages
2. • • •
Process Design Utility Consumption Technology Emissions and Effluents
3. Catalyst and Yield Performance • Yields • Catalyst Performance 4. • • • • •
Licensor Experience Greenfield units Brownfield Units Pilot plants Semi-commercial plants Retrofits
5. Licensor Proposal Package • Design Basis Description • Performance Guarantees 6. Licensor Technical Support • Process • Product 48 • July 2017
• National • International 7. • • •
CAPEX Investment Impact Number of Major Equipment Proprietary Equipment Long Delivery Items
8. • • • • •
Operations and Maintenance Complexity of design Operational Safety Turndown Modes of Operations Emissions
with client. The evaluation criteria and weightage assigned to different aspects shall be agreed by client and accordingly evaluation shall be carried out. Project department shall lead the Licensor communication and shall involve all the relevant disciplines in the evaluation process. Meetings with Licensor in presence of client at engineering consultant’s office would be helpful in getting direct clarifications on many pending issues. All such discussions shall be properly documented and MOM to be issued to record the information shared.
Licensor Scope of Work Scope of work considered by Licensor against the offered cost shall be verified. BEP of the unit, inspection, site supervision and commissioning support, operator and engineer training, support during operation and troubleshooting etc. needs to be considered and if there is any deviation taken from the enquiry specification. Depending on the stage of the project the accuracy of the data from Licensor will get increased. Conceptual stage proposal may have lesser details generated and larger price variation
Finally the preferred technology can be recommended in consultation client. The final technology evaluation report to be presented to client listing following major content • • • • •
Project Background Design Data considered Enquiry Specification Licensor short listing and communication Received techno-commercial proposals from Licensors • Evaluation criteria applied • Evaluation tables • Conclusion and recommendation.
Conclusion Technology selection and evaluation mentioned in above sections is suitable for in depth analysis of individual Licensor for offered technology and depends on the extent of data available from Licensor. Sometimes the data available from Licensor may not be adequate to carry out in depth evaluation due to improper enquiry specification, short time offered from client, Licensor’s willingness to share the data depending on the phase of the project. In such cases extensive communication with Licensor needs to be carried out and data possible to the maximum extent to be acquired for fair evaluation. Deviation may be taken to omit any specific criteria for evaluation in consultation
Authors Details Abhijit Kharote AGM – Process Engineering, Ingenero Technologies (I) Pvt Ltd
Shardul Shindadkar Sr. Executive-Sales, Marketing &Business Development, Ingenero Technologies (I) Pvt Ltd. Chemical Engineering World
Features CEW
Understanding your Company’s Stages of Maturity Silo-thinking and functionally focused project efforts in continuous improvement have made results unsustainable, and not holistic enough to achieve overall improvements in business performance. Supply Chain expert Roddy Martin believes that this is because these organisations don’t base their business operating strategy on the principle of a Demand-driven Value Network (DDVN). The DDVN is the set of holistic end-toend business process management capabilities that start at the customer and buying point and end in the supply system. In this article, Roddy shares his thoughts on how maturity influences the ability of a business to successfully transform itself and its supply chain.
C
ompanies have engaged globally in continuous improvement initiatives for many years without reporting record-breaking business results across the end-to-end business system. None of these initiatives were ‘wrong’, but improvements happened in pockets and did not apply to the entire system or supply chain. Silo-thinking and functionally focused project efforts made results unsustainable and not holistic enough to achieve overall improvements in business performance by involving people, process and technology (all the key points of the Jay Galbraith model). For example: • IT delivered transaction processing efficiency and integrated data management but was not necessarily connected to the end-to-end supply chain process • Lean initiatives delivered cycle time improvements and operational efficiencies but did not necessarily deliver organisational design and profitable processes from the customer back to supply • Six Sigma delivered operational reliability but was not necessarily used in improving perfect order performance at the customer hand-off • Organisational design structured the business around operating strategic priorities but did not continually adapt the structure and skills to different stages of performance improvement maturity These improvement efforts were not holistically applied and strategically managed from the top down, and did not
Chemical Engineering World
translate into the end-to-end business process network. They were not well aligned with IT and change management either. However, some companies do manage to succeed by basing their business operating strategy on the principle of a Demand-driven Value Network (DDVN). These companies achieve phenomenal business results because their processes are holistic, end-to-end and based on building maturity-based processes. The DDVN starts at the point at which a customer chooses or buys a product or service and ends in the network at the point that supplies the product or service. Improvements start at the shopper and go back down the demand management system into the supply network. They involve an aligned combination of people, process and technology. Even the business vision should be focused on shelf availability. Systems and networks are designed and improved on the basis of shelf back efforts and priorities. Sadly, many businesses have in contrast applied techniques, methodologies and initiatives in silos, which has led to increased complexity (with results also segregated in silos) rather than driving the end- to-end business capability that delivers profitable perfect orders with less working capital. In addition, being able to sustain performance improvement even when demand suddenly changes requires the supply system to adapt quickly and reliably.
The DDVN is the set of holistic endto-end business process management capabilities that start at the customer and buying point and end in the supply system. These process capabilities focus on achieving the following: 1. Accurately sense and characterize demand at the point of purchase 2. Reliably make and supply to demand 3. Make balanced process-based tradeoffs to profitably meet commitments in processes such as sales and operations planning (S&OP) and integrated business planning (IBP) 4. Understand buying and demand patterns so well that innovation and demand shaping are focused on creating demand and growth Leading companies benefiting from these activities have taken many years to develop the maturity in their end-to-end process capabilities and operate as a DDVN. Those successful on the journey have seen that a few core capabilities are fundamental to the successful transformation of the business: • Measuring the right metrics • Customer back process orientation • A culture of continuous improvement and change management • Goal, talent and structural alignment Leaders of these successful companies accept that sustaining performance and building capabilities is a change leadership transformation journey; and that companies must move through stages of maturity to build the foundations of sustainable performance improvement and demand-driven processes. July 2017 • 49
CEW Features
Figure 1: Stages of Performance Improvement Maturity
The illustration above shows a five-stage journey of performance maturity: 1. In Stage 1, companies react to problems without a systemic capability or any processes for performance improvement. 2. In Stage 2, companies build projects with experts to solve problems (e.g. quality, demand forecast 3. accuracy, Lean). The issue is that a collection of projects on its own is difficult to manage and build end-toend process value network capabilities. 4. In Stage 3, integrated functional processes are created around core business processes, but they 5. are not holistically end-to-end and demand-driven as described (for example quality or demand planning). This is, however, the first transition to process-based operations and a cultural shift (necessary but not sufficient). 6. In Stage 4, the company unconsciously operates as an end-to-end demanddriven network. All 7. aspects or people, process and technology combine holistically to 50 • July 2017
create a culture of performance improvement. This stage is the big cultural jump. 8. In Stage 5, the business operates as an end-to-end DDVN focused on translating value from demand 9. into the business. Without knowing a company’s stage of maturity and approach to performance improvement, it is easy to design Stage 4 and Stage 5 solutions and drop them onto a Stage 2 organisation which is not ready. As a result, many of the benefits and gaps to advancing capabilities are masked within disconnected projects and processes in Stage 2, and progress is difficult. The net result is that the advanced Stage 5 scope is adapted to fit the comfortable Stage 2 of maturity and then gets ‘stuck’ and gets complex. This is particularly true for large-scale Enterprise Resource Planning (ERP) projects that are designed as Stage 5 configurations and deployed in a Stage 2 organisation with high degrees of customisation to ‘make it work’. It ends up being a barrier to improvement.
In order to realise sustainable business benefits from integrative performance improvement initiatives, a company must ensure that their current stage of maturity is understood and that the end goal in terms of capability is understood. This determines the scope of the performance improvement journey. If the scope of current maturity is clear and there is an end state capability in mind, the transformation journey can be mapped, prioritised, and led by leaders. Importantly, this stage-based journey can be tracked and adapted to encompass even deeper change as the performance improvement capabilities improve and the business is at a better level of readiness to leverage them.
Author’s Details Sharad Mittal Business Partner Competitive Capabilities International Chemical Engineering World
CEW
Case Study
Cooling Water Network Analysis: A Case Study To assure the competitiveness and sustainability of the process the optimum use of utilities (Water, steam and electricity) represent the major challenge to the chemical industr y. To minimize water and energy use in chemical industr y, process integration methodologies are applied. More than 20 % of the energy consumption in industr y is associated with cooling and heating water. Dr Anil Khadse, Sunil Hadkar and Manoj Tiwari through their paper explain the details of cooling water network analysis for a chemical plant. A steady state cooling water network model developed in â&#x20AC;&#x153;AFT Fathomâ&#x20AC;? software and the model is validated against the actual plant data (i.e. flow rate, pressure drop and valve % opening). 1.1 Introduction: Process integration (PI) is defined as systematic, holistic approach to process design and operation, to simultaneously reduce resource usage, while minimizing waste production. An important area in process integration is the development of methodologies to minimize water and energy use in industry. More than 20 % of the energy consumption in industry is associated with cooling and heating water. The traditional cooling water system can be regarded as an integrated system consisting of three main components: cooler network, cooling tower, and circulation water pump. The cooling water used in the heat exchanger network returns to the cooling tower where the hot return cooling water is cooled (Figure 1). Blowdown is necessary to avoid the build-up of undesirable materials in the re-circulating water as a result of evaporation. The Fowrate loss caused by evaporation and blowdown is compensated by make-up. To investigate interactions within cooling water systems, a cooling water system model including the cooling tower and other system components is needed. A model of the cooling tower is basic to this. A simplified diagram of such system is shown in Figure. 1.
exchangers. After the cooling water has been used in each heat exchanger, the hot cooling water returns to the cooling tower (Figure 2a). The minimum cooling water demand is determined by minimizing the Flowrate to the individual heat exchangers (Figure 2b). Under a parallel arrangement, return cooling water Flowrate becomes maximized but the return temperature is minimized.
network from a parallel to a series design as shown in Figure 3. A series arrangement, in which cooling water is re-used in the network, will return the cooling water with a higher temperature and lower flowrate. From the predictions of the cooling tower model, the heat removal of cooling towers can be expected to increase under these conditions. Cooling water network case study
These conditions will lead to a poor cooling tower performance. The traditional parallel design method is not Flexible when dealing with various process restrictions. All cooling duties do not require cooling water at the cooling water supply temperature. This allows us, if appropriate, to change the cooling water
Chemical Plant which uses Cooling water (CW) as a cold utility for several consumers. Six pumps (P-A/B/C/D/E/F) are installed onsite to supply cooling water to all consumers. Four pumps out of 6 pumps run at a time. Out of the four pumps P-D runs on variable frequency drive (VFD). Plant operator
2.1 Design of cooling water networks The current practice for cooling water network design most often uses parallel configurations. In a parallel configuration, the fresh cooling water is supplied directly to individual heat Chemical Engineering World
Figure 1: Cooling water network
July 2017 â&#x20AC;˘ 51
CEW
Case Study
Figure 2: Parallel configuration (a)
observed that, whenever any two reactors, located at grade level, are taken in operation, the consumers at highest elevation do not receive the required cooling water flow. Entire cooling water network has manual isolation valves. Ingenero carried out the cooling water network analysis and recommend the corrective actions for the stated issue in the plant. Objective of the study is to achieve the minimum required flowrate for each consumer when the reactors R-A/B are offline. Ingenero has developed a steady state hydraulic model for the cooling water network, using AFT Fathom software to study the cooling water network behavior and mitigation. 3.1 Basis and Methodology Steady state hydraulic model for cooling
Figure 2: Flowrate (b)
water network is developed in software “AFT Fathom” with following basis and methodology: • Details of actual pipe elevation, pipe size, pipe length, fittings type, valves and their type are referred from piping isometrics and piping specification document. • Pumps characteristic curves from pump datasheets are provided as input to the model. • Three full capacity pumps and one pump on VFD have impeller diameter of 340 mm each. • VFD pump is simulated with operating curve at different RPM. • Control valves “CV” and “% opening” are given as input to the model. • Resistance coefficients i.e. “K” with respect to “% opening” for all the manual valves are given as input to the model according to their type. • Resistance coefficients i.e. “K” for the
consumers are calculated based on the actual cooling water flows and pressure drops measured for individual consumers in the plant • The model is validated for the measured plant operating data. As per the observation by Plant personnel, the consumers located at higher elevation are not receiving adequate quantity of cooling water while any two reactors located at grade level are online. Reactor R-A/B offline for this study within the following criteria: • Client insisted that cooling water demand for every consumer should met with minimum excess flowrate and manual isolation valves 100% open. ROs are to be used to regulate the cooling water flowrate and pressure drop. • Minimum pressure at the consumers inlet should be 1 kg/cm2g.
Figure 3: New design method (from parallel to a series) 52 • July 2017
Chemical Engineering World
CEW
Case Study Required Conditio n Flow rate
Plant Measured Flow rate Flow rate
Equipment
Operating Case Matched CW flow rate, Inlet Pressure, and valve opening as measured in Plant Manual Valve CWS
m3/hr
m3/hr
%Open
CV
Inlet Press. Flow rate
CWR
%Open
% Open
kg/cm2g
m3/hr
Deviation w.r.t. plant
Deviation
measured
w.r.t.
R-504
20.0
19
100
100
2.5
19.6
R-506
20.0
22
100
100
2.5
21.9
flow rate 0.2 (m3/hr) -0.1
E-302P
30.0
37
100
10
1.2
36.7
-0.2
required -0.4 flow rate 1.9 (m3/hr) 6.7
E-2
30.0
20
100
50
1.3
20.5
0.2
-9.5
E-202P
30.0
51
100
80
0.6
51.9
1.0
21.9
E-4
30.0
25
100
75
1.2
25.6
0.3
-4.4
E-001P
30.0
53
100
55
0.6
52.1
-1.0
22.1
E-201P
30.0
42
100
60
1.2
43.0
1.1
13.0
E-002
70.0
74
100
60
1.0
76.1
2.2
6.1
E-101P
30.0
40
100
50
1.2
39.8
-0.3
9.8
E-602P
30.0
33
100
33
1.3
33.4
0.1
3.4
E-601P
30.0
51
100
30
1.2
50.8
0.1
20.8
E-102P
30.0
32
100
50
1.2
32.2
0.4
2.2
50
1.4
0.0
-3.3
HE-7
5.0
2
35
X-1
115.0
99
100
80
80
2.1
99.7
0.7
X-2
25.0
18
100
32
1.9
18.7
0.3
-6.3
X-001-7A
151.0
235
100
No Valve 80
100
2.1
236.0
1.4
85.0
X-001-7
151.0
289
100
56
2.1
296.5
7.2
X-5
35.0
74
100
1.3
74.7
1.0
R-A
46.0
2.4
R-B
46.0
57
Not Inline 100
2.1
58.6
1.4
12.6
C-501A
70.0
63
90
75
0.9
63.2
0.4
-6.8
C-501B
70.0
59
90
75
1.0
58.5
-0.2
-11.5
C-501C
70.0
72
100
60
0.8
71.1
-1.2
1.1
-0.1
3.7
50
Not in Line Not in Line 100
1.7
0.0
145.5 39.7 -46.0
E-401
5.0
9
50/ 50
50
1.3
HE-4C
5.0
14
100
50
2.4
14.2
-0.1
9.2
50
2.6
25.1
-0.1
0.1
1530
15
301
T-5 Total Flow Rate (m3/hr)
25.0 1229
25
90
1516
8.7
-
-15.3
Table 1: The comparison of model results for operating case with plant measurements Chemical Engineering World
July 2017 â&#x20AC;˘ 53
CEW
Case Study Operating Case Pumps
Scenario-A
Scenario-B
Scenario-C
Flow rate Diff. Head Flow rate Diff. Head Flow rate Diff. Head Flow rate
Diff. Head
m3/hr
m
m3/hr
M
m3/hr
m
m3/hr
m
P-A
415.0
31.0
348.6
34.8
366.1
33.9
329.2
35.7
P-B
415.0
31.0
348.5
34.8
366.0
33.9
329.1
35.7
P-C
414.0
31.0
347.2
34.9
364.7
33.9
327.9
35.7
286.0
30.0
115.2
33.5
161.2
32.5
329.0
35.7
P-D (VFD operated) P-E
off
off
off
Off
off
off
Off
off
P-F
off
off
off
Off
off
off
Off
off
Total Flow Rate
1530
1160
1258
1315
Table 2: The comparison of model results for operating case with plant measurements ••
••
••
Maximum pressure at the consumers inlet should be 3.5 kg/cm2g. Consumer outlet nozzle should not experience vacuum. Flow velocity in all the consumers lateral should not exceed 3 m/s.
Different scenarios that were developed and studied are described below: •• Scenario-A: Three full capacity pumps and one pump on VFD (1323 RPM) all having impeller dia. 340 mm are operating. All manual valves in the cooling water network are kept 100% open. ROs are installed at the downstream of the consumers to meet the flowrate as well as pressure requirement. Line sizes are changed wherever required. Reactors R-A/B are “offline”. •• Scenario-B: Entire cooling water network hardware configuration is same as “Scenario-A” except the Reactors R-A/B are “online”. •• Scenario-C: Entire cooling water network hardware configuration is same as “Scenario-B” except the VFD operated pump running at 1470 RPM and Reactors R-A/B are “online”.
results for these different scenarios are as explained below: 3.2.1 Plant Operating Case: In the plant operating case, R-B is online & R-A is offline and all other equipment considered in this study are in operation. Simulation model is validated with the plant operating data. The observations are as below: • • Plant flowrate, Pressure drop across the equipment and Valve % opening matched with the plant measurements. •• % deviation in flowrate with respect to measured flowrate is matched within ± 5 %. • • It was observed that, flowrate for the seven consumers (E-2, E-4, HE-7, X-1, X-2, X-5 and T-1) in operating case is less than the minimum required flowrate. • • The comparison of model results for operating case with plant measurements is tabulated in detail in Table-1. This particular case is evaluated to firm up the base model accuracy to evaluate all the subsequent scenarios.
3.2. Results & Discussion
3.2.2 Scenario-A: R-A/B Offline, all Manual valves 100 % open, Line size change & ROs installed:
The basis for different scenarios is explained in the “Basis & Methodology” section. The
This scenario is simulated with three full capacity pumps and one pump on VFD
54 • July 2017
(1323 RPM) all having impeller diameter 340 mm are operating. All manual valves in the cooling water network are kept 100% open. RO is installed at the downstream of the consumers to meet the required cooling water flowrate and pressure. Line sizes are changed wherever required. The results are as below: ••
••
••
••
Existing laterals of the consumers E-2, E-4, HE-7, HE-2 and T-1 offer higher resistances than the skin friction factor is supposed to offer. Such situation can be observed due to corrosion, deposition or blockage in the lines, which cannot be examined from outside. Hence the flow through the mentioned consumers is less. Replacing the laterals of the consumers with new lines having clean internals will reduce these excess resistances and flow through the consumers becomes adequate. Cooling water demand for the fifteen (15) consumers (R-504, R-506, E-302, E-2, E-3, E-4, E-5, E-6, E-8, E-9, E-10, E-11, E-12, HE-2, T-1, X-4) are met by placing ROs. The ROs can be placed anywhere at downstream (return) lateral of the mentioned consumers. Cooling water demand for the consumer X-1 is achieved by increasing the existing Chemical Engineering World
CEW
Case Study line size. The line size is increased from 155.4 mm to 202.7 mm. Though, the line size is increased, control valve (TV003) of 155.4 mm is retained. Cooling water demand for the consumers X-5 is achieved by increasing the existing line size and placing RO. Cooling water demand for the consumers C-A/B/C is achieved by increasing the existing line size and placing RO. RO is placed at the downstream lateral of the respective consumers. 3.2.3 Scenario-B: R-A/B online, all Manual valves 100 % open, Line size change & ROs installed: The results are as below: • Cooling water demand for the fourteen (14) consumers (E-2, E-3, E-7, HE7, E-10, X-1, X-2, X-4, X-3, X-5, C-501-A, C-501-B, C-501-C and T-1) are reduced marginally. • Velocity only in R-A/B laterals exceeds 3 m/s (i.e. 3.8 m/s). Since R-A/B online is an intermittent operation, the velocity of 3.5 m/s in R-A/B lateral is acceptable. • Maximum inlet pressure achieved at the consumers inlet at highest elevation is 1.7 kg/cm2g which is more than the minimum required pressure of 1 kg/cm2g. • Maximum inlet pressure achieved at the consumers inlet at lowest elevation is 3.1 kg/cm2g which is less than the maximum allowable pressure of 3.5 kg/cm2g. • Pressure at all the consumers outlet is positive. Hence no consumer is under vacuum. 3.2.4 Scenario-C: R-A/B online, All Manual valves 100 % open, Line size change, ROs installed & VFD pump at higher RPM: The objective of this scenario is to evaluate the change in cooling water flowrate for each consumer in the cooing water network, by increasing the VFD pump RPM from 1323 to 1470 and keeping the reactors R-A/B online. In this scenario entire cooling water network hardware configuration is kept same as that of scenario-B, except that the VFD pump should operate at 1470 RPM. Chemical Engineering World
The results are as below: C o o l i n g wa t e r d e m a n d fo r a l l t h e consumers are met by keeping R-A/B online. • Velocity only in R-A/B laterals exceeds 3 m/s (i.e. 3.8 m/s). Since R-A/B online is an intermittent operation, the velocity of 3.5 m/s in R-A/B lateral is acceptable. • Maximum inlet pressure achieved at the consumers inlet at highest elevation is 1.8 kg/cm2g which is more than the minimum required pressure of 1 kg/cm2g. • Maximum inlet pressure achieved at the consumers inlet at lowest elevation is 3.2 kg/cm2g which is less than the maximum allowable pressure of 3.5 kg/cm2g. • Pressure at all the consumers outlet is positive.
•
conservation, and long-term planning. All of these objectives translate into a positive impact on the sustainability of the companies and the ability to remain competitive in a global market. Implementation of identified process designs can be sequenced as a part of a master-plan investment strategy for the company. Implementation may start with the low-cost projects and proceeds to the high-cost projects as the financial resources become available.
The pump discharge flowrate and differential head in all scenarios are tabulated in Table-2. 3.3 Recommendations In the “reactor offline” mode, it is possible to meet the cooling water demand and inlet pressure requirement for all the consumers by doing the following: •
•
•
•
Operating three full capacity pumps and one pump on VFD with 1323 R P M , a l l h av i n g ex i s t i n g i m p e l l e r diameter of 340 mm By changing the line size for six (6) consumers By providing restriction orifice “RO” at outlet of twenty-two (22) equipment. After making the above changes in the network, when reactors R A/B is taken online, the cooling water demand and inlet pressure requirement for all the consumers can be met by changing the RPM of the VFD pump from 1323 RPM to 1470 RPM.
Authors Details Dr. Anil Khadse, Process Manager Ingenero Technologies (I) Pvt Ltd
Sunil Hadkar AGM Project Development Ingenero Technologies (I) Pvt Ltd Email: shadkar@ingenero.com
Summary These process integration design tools can be used to address and reconcile a wide variety of process objectives including productivity enhancement, resource
Mr Manoj Tiwari Senior Process Design Engineer Ingenero Technologies (I) Pvt Ltd
July 2017 • 55
CEW
Marketing Initiatives
From simulation to operation with a click of the mouse Optimized engineering with 3D SuperTrak simulation A new visualization tool from B&R accelerates development of automation solutions featuring its SuperTrak industrial transport system. The tool displays a 3D simulation of all SuperTrak shuttle movements, as well as synchronized subsystems such as robotics and CNC. Machine builders and operators can accelerate the commissioning process by validating their designs and sequential programming in advance.
3D simulation with machine code T h e v i s u a l i z a t i o n t o o l a n d ex t e n s i ve
p r o c e s s e s s e n s o r s i g n a l s t o d i s p l ay machine movements on the HMI screen in real time. 3D visualization
simulation options are fully integrated
is the perfect way to monitor your
in B&R's Automation Studio soft-ware
manufacturing processes.
development environment. All simulations are based on real machine code and n o a d d i t i o n a l s i mu l a t i o n s o f t wa r e o r interfaces are required.
3D simulation shows the behavior of all shuttles in combination with synchronized subsystems like robotics and CNC.
In simulation mode, a 3D visualization in the development environment allows
About B&R
processes to be fine-tuned prior to mouse, the optimized machine code is
B&R is an innovative automation company with headquar ters in Austria and offices
then transferred to the target hardware.
all around the world. As a global
At runtime, the visualization tool
leader in industr ial automation, B&R
commissioning. With a few clicks of the
combines state-of-the-ar t technology with advanced engineering to provide customers in vir tually ever y industr y w i t h c o m p l e t e s o l u t i o n s fo r m a c h i n e and factory automation, motion control, HMI and integrated safety technology. With Industrial IoT communication standards like OPC UA, POWERLINK and openSAFETY as well as the powerful Automation Studio software development environment, B&R is constantly redefining the future of automation engineering. The innovative spirit that keeps B&R at the forefront of industrial automation is driven by a commitment to simplifying processes and exceeding customer expectations.
Contact Details: B&R Industrial Automation
Corporate Communications t +43 7748 6586-0 press@br-automation.com B&R-Strasse 1 5142 Eggelsberg, Austria Website: www.br-automation.com
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Industrial IoT solutions at Automation Expo Automation solutions for every step towards Industrial IoT B&R will be presenting “Automation solutions for every step towards Industrial IoT“, at Automation Expo 2017, Hall 1/ S1 on 9th to 12th August 2017. At the exhibition, B&R will be showcasing Orange Box as well as other allied solutions, which make machines and factories smart and achieve operational excellence. Orange Box enables factories and plants to fully transform into smart manufacturing setups and connect obsolete and digitally isolated machines.
Orange Box : Manufacturing intelligence for brownfield
SuperTrak : Next generation industrial transport
T h e O r a n g e B ox i s e n t i r e l y f l ex i b l e a n d m o d u l a r. To c o l l e c t a n d a n a l y ze basic operating data, all you need is a 25-millimeter-wide compact PLC and the software component mapp OEE. For more advanced features – such as alarm management or energy monitoring – the solution can easily be scaled up with more powerful PLCs and additional software components. To give the Orange Box a modern user interface in addition to PLC functionality, a Power Panel or a Panel PC can be used.
Another highlight topic at the booth will be B&R’s SuperTrak which is dependable, precise and remarkably low maintenance; it enables agile, efficient production at any batch size. Programming takes place in the Automation Studio software development environment. SuperTrak has been specially developed for 24/7 operation in harsh industrial environments. The system is reliable, safe and remarkably ser vicefriendly. Indi-vidual segments and shuttles can easily be replaced without having to disassemble the track. This results in a very low mean repair time and increases
the productivity of the entire plant. Like all B&R's products, Su-perTrak is fully integrated in B&R automation solutions. This high degree of integration eliminates system discontinuities and opens up all options when putting together a complete system. About B&R B&R is an innovative automation company with headquar ters in Austria and offices all around the world. As a global leader in industrial automation, B&R combines state-of-the-art technology with advanced engineering to provide customers in vir tually ever y industr y w i t h c o m p l e t e s o l u t i o n s fo r m a c h i n e and factory automation, motion control, HMI and integrated safety technology. With industrial fieldbus communication standards like POWERLINK and openSAFETY as well as the powerful Automation Studio software development environment, B&R is constantly redefining the future of automation engineering. The innovative spirit that keeps B&R at the forefront of industrial automation is driven by a commitment to simplifying processes and exceeding customer expectations.
Contact Details: Shyam Padwal
Orange Box enables machine operators to collect and analyze data from previously isolated machines and lines and get them fit for the smart factory. Chemical Engineering World
t +91 / 20 4147 - 8999 office.in@br-automation.com B&R Industrial Automation Pvt. Ltd. 8, Tara Heights, Mumbai - Pune Road, Wakdewadi, 411003 Pune Website: www.br-automation.com. July 2017 • 57
CEW Products Temperature Controller Oven’s 5R6-900 temperature controller with ramp/soak capabilities is something that every laboratory should have. The 5R6-900 benchtop controller has many outstanding user-friendly benefits. Contained all in one enclosure, the device can be plugged into the wall as a self-contained temperature control system, which has its own power supply. This distinctive detail makes the device unique, as well as highly convenient for users. The temperature controller can also be used universally, which allows the user to use the device wherever they are located. As a solid state MOSFET bidirectional compact unit featuring an internal power supply, it is also capable of loading currents up to 10 A. The compact size, as well as the isolated communication port, makes using the 5R6-900 benchtop temperature controller a breeze.Great for usage in universities, science laboratories, PCR research and any businesses that specialize in temperature control. The controller features an easy-to-read digital display for controlling functions, including adjusting output voltage and setting the desired temperature. Complete with an auto output shutdown if the sensor is opened or shorted, the unit also includes high, low and no alarm settings. For details contact: OVEN Industries Inc 434 Railroad Avenue, Camp Hill, PA 17011, U.S.A. Tel: (717) 766-0721 Fax: (717) 766-4786 E-mail: r.wescott@ovenind.com sales@ovenind.com or Circle Readers’ Service Card 1
Modular Industrial Gear Units With these additions to the line-up, the series comprises 11 gearbox sizes that deliver output torques up to 250 kNm. The NORD industrial gear series offers a particularly great variety of configuration options for application-specific drive solutions. The modular NORD product range includes dual-gear setups, auxiliary drives, brakes, torque arms, backstops, swing bases and extruder flanges. In addition, there are a variety of sealing options and solutions for monitoring and temperature management. The gear units can be mounted on all six sides. Gear ratios can be configured in fine increments from 5.54 : 1 to over 30,000 : 1 – with two, three, or four gear stages, and with an auxiliary primary gear stage if so required. All NORD industrial gear units feature a single-piece UNICASE housing. This ensures excellent longevity, a very high power density, compact dimensions and high overload capacities. Combining industrial gear units with motors and drive electronics, NORD configures complete drive systems for heavy-duty operation in conveying systems, pumps and agitators. Designated major application fields for these units include bulk handling, the cement industry, steel industry, process engineering and wastewater management. For details contact: NORD Drivesystems Pvt Ltd 282/2, 283/2, Village Mann Tel: Mulshi, Adj. Hinjewadi MIDC II Pune, Maharashtra 411 057 E-mail: marketing.in@nord.com / Muthusekkar@nord.com or Circle Readers’ Service Card 23
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Products CEW Flare Fittings Excel Metal & Engg Industries offers wide range of instrumentation fitting and valves for use in diverse range of industries and are capable to provide their customers with best possible solutions to meet their various requirements. The production process followed is of higher standards with its modern production and quality assurance facilities where due attention is paid at every level with maximum resource utilization. Excel Metal & Engg Industries offers flare fittings in SS, brass, carbon steel, alloys, etc, in size range from 1/8 to 2 inch piping; NPT, ISO/BSP and SAE threads. Excellent threads constructed to ensure leak-proof and reliable systems. For details contact: Excel Metal & Engg Industries 177/181 J T Bldg, 3rd Kumbharwada Lane, Mumbai 400 004 Tel: 022-23892476, 66394004 Fax: 91-022-23884109 E-mail: info@excelmetal.net / excelmetal@mtnl.net.in or Circle Readers’ Service Card 3
Rapid Mixer Granulator Brilliant Process mixer is designed to meet special needs of tablet manufacturing technology. This is achieved by reducing processing time, more homogenous mixing, uniformity of granule size and above all maintaining improved hygienic standards within the highest GMP norms. Brilliant mixer is designed to achieve all the requirements of current good manufacturing practices. The components are easily dismantable, can be cleaned thoroughly and assembled in quick time. The shaft seals are very effective to check any leakages and cross-contamination due to adherents. The bowl and all the components are of highly polished SS and without sharp corners or crevices For details contact: Brilliant Process Machinery Pvt Ltd Unit No: 1, 2, 14 Mordan Indl Estate Opp: Ipol, Waliv Phata Vasai (E), Dist: Thane Maharashtra 401 208 Tel: 0250-3293636 E-mail: brilliantprocess@rediffmail.com sales@brilliantprocess.com
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CEW Products Conductivity Meter ILIUM Technology offers Model 2100 Conductivity Meter. The Model 2100 and its associated line of high-accuracy smart probes can measure liquid conductivities ranging from 10 -3 S/cm, typical of low concentration aqueous solutions, down to 10 -15 S/cm, typical of low concentration solutions in non-polar solvents. The Model 2100’s ability to follow conductivity changes over such a wide and low range with a single meter, and up to nine decades with a single factory-calibrated probe, has revolutionized the field by eliminating the need to correlate multiple meters and swap and calibrate multiple probes. For decades, measuring the electrical conductivity of liquids has been a workhorse technique in aqueous systems. The Model 2100‘s wide, low range makes it ideal for characterizing inks, paints, pharma and personal care formulations, resins, liquid toners, and other non-polar as well as polar fluid systems.
For details contact: ILIUM Technology, Inc 242 E Border Road Medford, MA 02155-1106, U.S.A. Tel: 781-333-4000 E-mail: info@iliumtechnology.com / rich@iliuminc.com or Circle Readers’ Service Card 5
Leak Detector Edwards offers the new ELD500 precision leak detector. It is designed for fast, accurate leak detection and is customisable for any application. Edwards’ ELD500 is ready to go in under two minutes from power on. Users can benefit from simple pass/fail readings through to detailed analysis via the easy to read control interface, and due to the low weight and integrated carry handles it is mobile enough to be bench top or trolley mounted. At the push of a button the ELD500 can easily be set to work in either vacuum mode for precise measurement of leak rate or sniffer mode for identifying the leak location. The proven design of Edwards’ ELD500 leak detector, combined with low energy consumption, extended warranty and even longer life ion source, ensures exceptional low cost of ownership with no compromise on performance. Edwards’ ELD500 achieves excellent repeatable accuracy through calibration with the integrated test leak source and high quality mass spectrometer, so it could be used on a production line, where consistent measurement repeatability is critical or in a laboratory environment where typically the measurement of extremely low leak rates is needed. The ELD500 has three variants, the FLEX, WET and DRY plus an extensive catalogue of accessories. For details contact: Edwards Ltd Innovation Drive, Burgess Hill West Sussex RH15 9TW, U.K. Tel: +44 (0) 1293 52 88 44 E-mail: rebecca.walder@edwardsvacuum.com pr@edwardsvacuum.com or Circle Readers’ Service Card 6
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Products CEW Anchor/Gate Type Impeller Anchors/Gate Type impellers are close-clearance impellers that fit the contour of the vessel. These impellers provide adequate mixing under the laminar flow conditions encountered in high viscosity applications for heat transfer. These impellers sweep the whole wall surface of the vessel and agitate most of the fluid batch through physical contact. Anchor impellers are used for liquid viscosities between 5,000 and 50,000 cP. When reaction/mixing homogeneity is required, other types of impellers are recommended. For details contact: FEDA Inc B/37 Maruti Indl Estate Plot No: 59/1/2/3, Phase 1, GIDC Vatva Ahmedabad, Gujarat 382 445 E-mail: ashok.chaurasia@fedainc.com or Circle Readers’ Service Card 7
Remote Data Communicator Remote monitoring solution is based on rugged hardware (RDC) and highly available, configurable, extensible software platform. The solution includes a controller and GSM/GPRS modem (wireless) or Ethernet/IP (wire line) on the client (located at remote sites) and highly available software and server on the internet. The server software is designed for secured, highly available 24x7 operations. The solution is widely deployed in monitoring diesel genset performance, fuel level monitoring, water flow/pressure monitoring, telecom tower monitoring, effluent treatment plants and solar plants. The battery version of the product is suitable for monitoring remote sites where no power is available. The unit works on rechargeable battery with low power consumption and low battery replacement costs. Another variation of this unit is available for deployment with solar panels with very low battery maintenance costs. For details contact: SUN Industrial Automation & Solutions Plot No: 95, Developed Electronic Indl Estate Perungudi, Chennai 600 096 Tel: 044-30788900 E-mail: sias@vsnl.com or Circle Readers’ Service Card 8
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CEW Products FEP Encapsulated O-rings & Gaskets The seamless, uniform Teflon polymer encapsulation provides the chem-rings near universal sealing capability, whilst the continuous reset and the constant pressure of the encapsulation on to the sealing point is performed by the elastomeric core. The result is an overall sealing compression that increases with media pressure. The Chem-Ring behaves like a highly viscous fluid, any pressure exerted on the seal is transmitted practically undiminished in all directions. The Chem-Ring is an O-ring, consisting of a seamless and uniform Teflon encapsulation, which completely encloses the core material of silicone or Viton. In brief, the seal is manufactured by pressure injecting the rubber core material into thin wall Teflon tubing. This eliminates any potential gap between the core and the tube wall. The Teflon tubing is joined by a special heat moulding process to give a true, seamless, encapsulation. On Shree Gaurav Chem-Ring, the mould area exhibits no discernible different characteristics to the rest of the circumferance of the seal. There are no joints nor ridges to effect the seal’s performance nor life. The nature of the moulding process is critical to the quality of the ring. Standards for the manufacture of moulded rubber O-rings call for close tolerances on the IDs and particularly, the cross-sections of the rings. Outside these tolerances, any step in the cross-section can severely affect the O-rings ability to seal. FEP encaspsulated O-rings are hand moulded in a very precise and skilled operation. For details contact: Shree Gaurav Rubber Products 112-B Marudhar Indl Estate Opp: Old Syndicate Bank, Goddev Road Bhayandar (E), Dist: Thane, Maharashtra 401 105 Telefax: 91-022-28197355 E-mail: Gaurav_rubber@rediffmail.com or Circle Readers’ Service Card 9
Ultrasonic Cleaner/Bath Citizen ultrasonic units are used in industrial and analytical laboratories. With their high power, optimised parameter settings and strict parameter monitoring and assisted by a large range of useful accessories the ultrasonic units guarantee safe and reliable results for the multi-faceted laboratory applications. The Citizen’s laboratory equipment is complete with a full programmable of cleaning chemicals developed and produced in their own laboratory. Citizen ultrasonic cleaners are extremely versatile. They can also be used in laboratory applications for cell separation, mixing emulsifying, sample preparation and degassing of liquids. The demands of light industrial workflow require an ultrasonic bath that can stand up to the challenge. Their baths are perfect for deep cleaning to remove dirst, grease, waxes and oils from light industrial parts and components of all kinds including steel, light and nonferrous metals, plastic and glass, jewellery and clockworks of every type. For details contact: Citizen Scale (I) Pvt Ltd Citizen House, Unit No: E-2, Plot No: 11, WICEL Opp: SEEPZ Gate No: 1, Andheri (E), Mumbai 400 093 Tel: 022-42437700 E-mail: sales@citizenscales.com
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Products CEW Pneumatic Stirrers Shefa Industries offers a qualitative assortment of automatic and manual pneumatic stirrer which can be operated automatically as well as manually depending on the requirement. Besides, these automatic and manual pneumatic stirrers are designed as per the clients’ specifications in terms of size, dimensions and capacities. Pneumatic stirrer is operated on pneumatic compressor air for homogeneous mixing of paint, to avoid settling heavy particles, metallic particles, resin, pigmentation, etc, at the bottom of the container. Stirrer can be mounted on sand, PFT and container.
For details contact: Shefa Industries Gala No: 1, U K Quari Compound Gandhi Nagar, Vikhroli (W) Mumbai 400 083 Tel: 022-25942473 E-mail: shefaindustries@yahoo.co.in or Circle Readers’ Service Card 11
TSQ Duo GC-MS/MS The Thermo Scientific TSQ Duo GCMS/MS system is like no other. It is tailored to chromatographers and single quadrupole GC-MS users who need easy access to powerful new workflows through MS/MS while satisfying their current methods requirements. The system accomplishes this by providing excellent performance, in both single quadrupole and triple quadrupole modes. Whether you are new to GCMS/MS or not, all you need is your current compound list and/or method and the intuitive software will create, optimise and manage your single and triple quadrupole methods. The TSQ Duo GC-MS/MS is the only cost-sensitive instrument that enables truly simple, single and triple stage mass spectrometry in a single investment. For details contact: Thermo Fisher Scientific India Pvt Ltd 102, 104, Delphi ‘C’ Wing Hiranandani Business Park, Powai, Mumbai 400 076 Tel: 022-67429494, Fax: 91-022-67429495 E-mail: sagar.chavan@thermofisher.com or Circle Readers’ Service Card 12
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CEW Products Temperature Calibrators
Multi Mill
Precision dry block temperature calibrators cover a temperature range from -30 to 1,300oC. These are used for calibration of temperature sensors. Regular calibration of the temperature sensors used in crucial applications is absolutely essential for economic and technical safety reasons and is prescribed as obligatory in many sectors. Calibration is performed by comparision of the temperature measured by the test piece and the block temperature indicated by the calibrator.
Multi mill relies on impact in air. Material is dropped axially from a feed hopper into the comminuting chamber where it comes in contact with blades rotating at high speed. Differentially edged (flat and knife) blades in desired direction of rotation achieve shear. Material entering the chamber is imparted to the periphery and passes through the circular screen tangentially and radically achieving size reduction.
For details contact: Toshniwal Sensors Pvt Ltd E-19/20 Indl Estate Makhupura, Ajmer, Rajasthan 305 002 Tel: 0145-2695536, 2695482, Fax: 91-0145-2695006 E-mail: info@tspl-india.com or Circle Readers’ Service Card 13
For details contact: Kunal Machines 104 Kothari Indl Estate Next to Asian Paints, LBS Marg, Bhandup (W) Mumbai 400 078 Tel: 022-61271111, 67251949 E-mail: kunalmachines@gmail.com or Circle Readers’ Service Card 14
Sami Wedge Plug Valves Rasaii Flow Lines Pvt Ltd has established as specialist valve manufacturer for corrosive and erosive applications in oil and gas plants, petroleum refinery, petrochemical plants, pharma, heavy water plants, mining industry. The valves have proven performance in handling erosive and clogging area.Rasaii offers the wedge plug valves to serve as good replacement of metal seated globe and ball valves. Sami wedge plug valves are specifically designed to handle Liquid with sludge. dirty liquids, acetic acid, liquids clogged with solid particles. The wedge plug claves perform in a superior way compound to metal to metal seated ball valves with their nil cavity possibility for suspension of flowing liquids and as well by avoiding any secondary replacement flexible soft sealing materials as primary isolation material. No scratch actions by embedded particles due to scrapping and cleaning of plug avoiding any metals embedding on to seats. The valves shall be operated with fully lubricated gearbox as well as can be operated with the linear electrical actuators of internationally proven makes. The gearbox will lift the plug and reseat for lower torque operation during open and close position. Wedge Plug Valves are more reliable, easy to maintain by flushing on regular interval without removing the valves from pipeline. Valve can handle stem, catalyst effluent, hard materials, and hard liquids like high viscosity clogging media and sticking media. It is easy to operate. It has the lowest torque resulting smallest actuator and best performance in sealing. It finds application in toluene diisocyanate, polyester terephthalate, pure terephthalic acid, propane dehydrogenation, and styrene polystyrene, CTG For details contact: Rasaii Flow Lines Pvt Ltd TS No: 93/3, Poonamalle Road, Ekkatuthangal, Chennai 600 032 Tel: 044-22252021, 22252022 E-mail: admin@rflvalves.com or Circle Readers’ Service Card 15
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Products CEW Weld Nipple Fittings Excel Metal & Engg Industries offers wide range of instrumentation fitting and valves for use in diverse range of industries and are capable to provide their customers with best possible solutions to meet their various requirements. The production process followed is of higher standards with its modern production and quality assurance facilities where due attention is paid at every level with maximum resource utilization. Excel Metal & Engg Industries offers Ermeto/Bite fittings in SS, brass, MS, etc, in the size range of 1/8 to 2 inch; elastomeric seal – O-ring: Viton, NBR. Excellent threads constructed to ensure leak-proof and reliable systems. It finds application in pneumatic/hydraulic. For details contact: Excel Metal & Engg Industries 177/181 J T Bldg, 3rd Kumbharwada Lane Mumbai 400 004 Tel: 022-23892476, 66394004 Fax: 91-022-23884109 E-mail: info@excelmetal.net / excelmetal@mtnl.net.in or Circle Readers’ Service Card 16
Motorised Diverter Motorised diverters can be offered where there is a requirement for transfer of filled and stitched bags to another conveyor at an angle approximately 120 degrees with the main conveyor. This can also be used in the rejection system. The more the angle the better will be the transfer. The motorised diverter consists of the geared motor (vertically mounted), frame and pulleys for belt operations, pneumatic mechanism for diverter operations, fixing and angle adjustment mechanism and belt. The belt moves towards the delivery side. In case of accepted bags, the pneumatic mechanism of the diverter remains parallel to the rejection conveyor allowing the bags to transfer to the next device. If the bag is rejected at previous device then the pneumatic mechanism turns into the path of the rejection conveyor and the bag is diverted. For details contact: Jasubhai Engg 64/a, GIDC Indl Estate, Phase 1, Vatwa Ahmedabad, Gujarat 382 445 Tel: 079-49003636, Fax: 91-079-25831825 E-mail: mhd-sales@jasubhai.com or Circle Readers’ Service Card 17
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CEW Products Conveyorised Metal Detector Conveyorised metal detector metaltrap SS30-CONV is an eddy current based digital metal detection system specially designed for food and pharma industry for detecting metal contamination in food products. The system is designed and manufactured to meet the stringent requirement and hygienic standards of food and pharma industry. Features extremely super sensitive detection for all types of metals; HMI display; auto product tracking; validation using prompt; statistical data with event time stamping; digital gains and filters for enhanced sensitivity; different type of rejection mechanism depending on type and nature of product/pack.
For details contact: Technofour Electronics Pvt Ltd Gat No: 3 (PT), 5 (PT), 243 (PT), Kasurdi (Kheba) Khed Shivapur-Saswad Road Post: Khed Shivapur, Tal: Bhor Dist: Pune, Maharashtra 412 205 Tel: 02113-305200, 305246 Fax: 91-02113-305250 E-mail: pcssales@tepl.co.in / teplinbox@gmail.com
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Hexapod Aerotech’s HexGen hexapods represent a significant advance in six-degree-of-freedom positioning performance. The HEX300-230HL, is targeted at medium-load, ultra-precision applications ranging from sensor testing to synchrotron sample manipulation. Aerotech’s HexGen hexapods are the only hexapods on the market today that provide positioning accuracy specifications below 5 µm. The HEX300-230HL is actuated with six high-accuracy struts built with precision preloaded bearings, ball screws and drive components. Unlike competitive hexapods driven by DC brush servomotors, the HEX300-230HL is driven by Aerotech’s AC brushless, slotless servomotors that maximize its performance and longevity. Directly coupling the AC brushless servomotors to the ball screw results in increased drive stiffness, higher positioning accuracy and better minimum incremental motion (20 nm in XYZ and 0.2 µrad for ɵxɵyɵz), compared to competitive designs using belts, gearheads or compliant couplings. Specially-engineered strut pivot-joints provide low friction and high stiffness, enhancing the hexapod’s overall performance. The HEX300-230HL’s superior structural design offers the user a generous load capacity of up to 45 kg. The HEX300-230HL’s platform and base can be easily modified with user-specific features or mounting patterns. It features a 100 mm dia clear aperture in the platform, while a 60 mm dia clear aperture in the base allows workpiece access from the bottom. The base mounting holes adapt directly to English and metric optical tables.Aerotech hexapods can be vacuum-prepared for demanding applications such as synchrotron sample or optics manipulation, semiconductor manufacturing and inspection or satellite sensor testing. Driving the HEX300230HL is Aerotech’s A3200 motion control software. Built on years of experience with difficult kinematics applications, the A3200 controller allows easy programming and control of the hexapod in any user-defined coordinate system.Aerotech’s HexSimsoftware gives users the ability to easily visualize and simulate the available workspace. Tight integration between HexSim and the A3200 motion controller provides real-time motion visualization in any user-defined coordinate system. An intuitive graphical interface permits selection of the active coordinate system for easy virtual pivot-point programming and motion. For details contact: Aerotech, Inc 101 Zeta Drive Pittsburgh, PA 15238-2811, U.S.A. Tel: +1 (412) 967 6854 E-mail: smclane@aerotech.com or Circle Readers’ Service Card 19
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Products CEW Programmable Electronic DC Load
Flammable Gas Analyser
Programmable electronic DC load is a single channel electronic DC load. Best equipment for testing batteries and DC power supplies. Power supplies can be loaded in terms of constant voltage, constant current, constant resistance, etc.
The SERVOPRO 4210 multigas analyser is designed to monitor flammable gas samples including H2/CO, HYCO or Syngas mixtures for trace level contaminants and per cent level components. The 4210 offers oxygen control using servomex’s unique paramagnetic cell, trace level measurement of CO, CO2, N2O and CH4 using photometric sensor technology and IR technology for measurement of carbon monoxide, carbon dioxide and methane at per cent levels.
For details contact: Vasavi Electronics No: 95, 1st Floor, Road No: 6A Jyothi Colony, Secunderabad Andhra Pradesh 500 015 Tel: 040-27744445 E-mail: vasavi@vasavi.com
For details contact: Spectris Technologies Pvt Ltd Plot No: A-168 MIDC Thane-Belapur Road, Khairane Navi Mumbai 400 710 Tel: 022-39342700 E-mail: MEI_Sales@servomex.com or Circle Readers’ Service Card 20
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Digital Timers
V-Blender
Programmable timer is 4-digit timer in 72 x 72 mm housing. This has four models – On delay, Off delay, Cyclic On First, Cyclic Off First. Time is selectable by user. Output offered is through 2 changeover relay contacts.
GMP compliant, contact parts manufactured in SS. The V shape ensures good rolling and cross-mixing. A-shaped frames provide stability of structure. Main drive provided with variable frequency drive to control blender RPM. It has a start-stop arrangement to ensure that the blender always stops in an upright position. Internal baffles ensure good blending and break lumps. Intensifier bars can be provided. Guard rails are provided with limit switch for safety. PLC/HMI based control panel.
Time toraliser/hour meter is used for time management. Count and display time is either on hours, minutes or hours, minutes, sec and is offered in 6-digits. Sequential timer is suitable for process automation having sequence of operations. The unit has a relay output, which are sequentially made On and Off.
For details contact: Kunal Machines 104 Kothari Indl Estate Next to Asian Paints LBS Marg, Bhandup (W) Mumbai 400 078 Tel: 022-61271111, 67251949 E-mail: kunalmachines@gmail.com
For details contact: Electronic Switches (India) Pvt Ltd Plot No: K-1, MIDC Area, Ambad Nashik, Maharashtra 422 010 Tel: 0253-6697701, 6603954 Fax: 91-0253-2380918 E-mail: electronic.switches@gmail.com or Circle Readers’ Service Card 22
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CEW Products Push Fitting Excel Metal & Engg Industries offers wide range of instrumentation fitting and valves for use in diverse range of industries and are capable to provide their customers with best possible solutions to meet their various requirements. The production process followed is of higher standards with its modern production and quality assurance facilities where due attention is paid at every level with maximum resource utilization. Excel Metal & Engg Industries offers push fittings in SS, PU, PE, PTFE in size range from 1/8 to 1 inch; NPT, BSPT, BSPP and SAE. It has reliable locking systems and is leak-proof. For details contact: Excel Metal & Engg Industries 177/181 J T Bldg, 3rd Kumbharwada Lane Mumbai 400 004 Tel: 022-23892476, 66394004 Fax: 91-022-23884109 E-mail: info@excelmetal.net / excelmetal@mtnl.net.in or Circle Readers’ Service Card 24
Density Compensated Water Cut Monitor AMETEK Drexelbrook has enhanced its Universal IV Density Compensated Water Cut Monitor with updated firmware to allow for up to 10 different density calibration points to reduce recalibration requirements and ensure maximum accuracy load to load. The new Universal IV In-Line Water Cut Monitor (CM) with Multi-Cal Density Compensation automatically compensates for density changes that may occur in the composition of products and reduces the calibration requirements due to those changes. The Universal IV CM is designed for high-accuracy water in oil measurement. The DCM allows the Universal IV CM to maintain its stated accuracy with variations in density up to 10 API, ensuring measurement accuracy from load to load regardless of changes in product composition. All Universal IV CMs come factory precalibrated and require only one-point validation. Field configuration can be done anywhere along a two-wire loop with the STExplorer software. Users also can configure the instrument vial local display/keypad without the need for a laptop or handheld communicators. The Universal IV CM utilizes electrical measurement (capacitance) and correlates that to water cut (% of oil in water). Those measurements can be affected by changes in density. Density compensation is done to correct for changes in electrical properties that may impact output measurement and is particularly suitable for midstream refinery and oil pipeline operators. Along with optional Density Compensation, the Universal IV CM features an in-line probe design that allows it to analyze a large representative sample of flowing fluid in real time. Its sensing element extends into the main process line, taking an average of the capacitive property of the fluid over its entire length. The monitor’s onboard electronics then computes the relationship between capacitance change and water cut. The Universal IV CM offers the industry’s highest pressure and temperature capabilities (1500 PSI and temperatures up to 450oF) as well as field-proven Cote-Shield technology, which ignores coating buildup on the probe. A temperature-compenzsation (TC) version is available that measures product temperature internally and calculates a true water cut reading at any temperature as long as the water is in liquid state. Applications for the Universal IV CM include automatic well testing (AWT), lease automatic custody transfer (LACT), basic sediment and water (BS&W), separation vessels, pipeline slug detection, truck unloading, pipe protection, dielectric analysis and machinery lube oil monitoring. For details contact: AMETEK Drexelbrook 205 Keith Valley Rd, Horsham, PA 19044, U.S.A. Tel: +1 215-674-1234 Fax: 215-674-2731 E-mail: drexelbrook.info@ametek.com or Circle Readers’ Service Card 25
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Products CEW Oval Gear Meter
Roots Pumping Systems
The measurement element of this positive displacement oval gear meters consists of two precision oval gears. The revolution can be sensed by a magnetic-field-controlled pulse generator, resulting in only two moving parts, ie, ovalwheels. These oval gear meters can be used for application of nearly all operating conditions. Features very high/low temperatures; low and extreme high viscosities; nominal diameter DN 4 to DN 400; direct measurement of volume respective of volumetric flowrate; measurement at high viscosities and high accuracy; and 2-wire-technique.
Roots pumping system is used where in high pumping capacity is required at lower operating pressure. The capacity available ranges from 250 m3³/hr to 10,000 m3³/hr. Toshniwal also provides appropriate accessories like condensers, filters, etc, to reduce the cycle time,protection of the pumping system; decrease power - savings in the range 30-40 per cent; improve the quality and productivity; and have a compact design that is easy to service and easy to install.
For details contact: Toshniwal Hyvac Pvt Ltd 267 Kilpauk Garden Road Chennai 600 010 Tel: 044-26445626, 26448983 E-mail: sales@toshnwial.net
For details contact: Toshniwal Instruments (Madras) Pvt Ltd 267 Kilpauk Garden Road, Chennai 600 010 Tel: 044-26448983, 26448558 Fax: 91-044-26441820 E-mail: sales@toshniwal.net or Circle Readers’ Service Card 26
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Fully Automatic Double Disc Counting Machine
Water Ring Vacuum Pumps
Fully automatic double disc counting machine is equipped with highly featured technology and superior production techniques for faster production in counting and filling lines of capsules/tablets. Up to six bottles can be filled automatically at a time through twin 3 track filler and up to 150 bottles per minute fill depending upon the number of counts per fill. It is best to counting tablets or capsules in bottles or container. Capable of counting 50 to 1,000 tablets/capsules per hour in one machine by changing the disc. It is easy to operate and is user friendly. Dust extracting system can be attached if required.
Indovac water ring vacuum pumps are positive displacement type, the shaft mounted multibladed impeller is located eccentrically in the stator. It is supported by antifrictional bearing at bearing housing on either ends. Service liquid is introduced into the pump through the control valve. Due to the rotation of the eccentrically-mounted multi-bladed impeller, service liquid is thrown towards the periphery of the stator, thus forming a sealant ring. The service liquid functions as a sealant and coolant as well. In this continuous operation suction cycle is initiated.
For details contact: Pharma Chem Machineries 311/2484 Motilal Nagar No: 2 M G Road, Goregaon (W) Mumbai 400 090 Tel: 022-28735321 E-mail: pharmach@gmail.com pharmachem79@gmail.com
For details contact: Indovac Pumps & Engg Co 21 Anand Raj Indl Estate Sonapur Lane, B/h Asian Paints Off L B S Marg, Bhandup (W) Mumbai 400 078 Tel: 022-25664937 Telefax: 91-022-25664917 E-mail: indovac@yahoo.co.in or Circle Readers’ Service Card 28
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CEW Products Octagonal Blender
Paste Kettle Brilliant Process Machinery Pvt Ltd offers octagonal blender in 25 to 2,000 litre capacity. Contact parts are in SS-316. Baffles provided for ease of mixing/ blending. Manhole with gasket is provided to fix baffles and for ease of cleaning the main pan.
Charging and discharging is through a butterfly valve. A conical adaptor can be provided for fixing charging drum after butterfly valve. Unit can be provided with bin charging arrangement. All moving parts are enclosed in guards. A safety railing with a limit switch is provided for operator safety. Manual inching arrangement can be provided. Flame proof motors with flame proof pushbutton stations can be provided as an optional. For details contact: Brilliant Process Machinery Pvt Ltd Unit No: 1, 2, 14 Mordan Indl Estate Opp: Ipol, Waliv Phata Vasai (E), Dist: Thane Maharashtra 401208 Tel: 0250-3293636 E-mail: brilliantprocess@rediffmail.com
IPEC Engg Pvt Ltd offers paste kettle in standard cGMP and customised models with SS304/316/316L contact parts, Features hemispherical design for proper mixing of paste; discharge from bottom via butterfly valve; driven via motor and gearbox assembly mounted on top; anchor type impeller design for proper mixing of paste; hydraulic lifting with tilting arrangement; etc. It serves as an effective purpose in heating of paste, pulp, juice of fruits and vegetables to the desired temperature. They are available in batch capacities ranging from 50 to 1,000 kgs as per client’s requirements. For details contact: IPEC Engg Pvt Ltd Plot No: 5175, GIDC, Ankleshwar Gujarat 393 002 Tel: 02646-221175 Telefax: 91-2646-225175 E-mail: md@ipecengg.com / marketing@ipecengg.com
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Ermeto/Bite Fitting Excel Metal & Engg Industries offers wide range of instrumentation fitting and valves for use in diverse range of industries and are capable to provide their customers with best possible solutions to meet their various requirements. The production process followed is of higher standards with its modern production and quality assurance facilities where due attention is paid at every level with maximum resource utilization. Excel Metal & Engg Industries offers Ermeto/Bite fittings in SS, brass, MS, etc, in the size range of 1/8 to 2 inch; elastomeric seal – O-ring: Viton, NBR. Excellent threads constructed to ensure leak-proof and reliable systems. It finds application in pneumatic/hydraulic.
For details contact: Excel Metal & Engg Industries 177/181 J T Bldg, 3rd Kumbharwada Lane, Mumbai 400 004 Tel: 022-23892476, 66394004 Fax: 91-022-23884109 E-mail: info@excelmetal.net / excelmetal@mtnl.net.in
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Products CEW Multi-mill
Mink Dry Claw Vacuum Pumps and Compressors Shefa Industries offers multi-mill which is used in pharma industry is also used in chemical and cosmetic industries. The company uses pharma grade SS to manufacture the range of multi-mill. The durable and high performing multimill can also be offered in custumised specifications.
For details contact: Shefa Industries Gala No: 1, U K Quari Compound Gandhi Nagar, Vikhroli (W) Mumbai 400 083 Tel: 022-25942473 E-mail: shefaindustries@yahoo.co.in
Busch Vacuum India Pvt Ltd offers mink dry claw vacuum pumps and compressors. Oil and water-free operation, especially for use in industrial applications where a constant vacuum, high suction capacity and totally oil-free compression are essential. They operate contact-free. For details contact: Busch Vacuum India Pvt Ltd 103, Sector 5, IMT Manesar Gurgaon, Haryana 122 050 Tel: 0124-4050091 Fax: 91-0124-2292103 E-mail: sales@buschindia.com
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Level indicators Visual level indicators combine up to three functions in one instrument: Level indicator, level switch and level transmitter. The display that can be read even over large distances works without energy and automatically as a result of the physical law of liquids in communicating vessels. The WEKA visual level indicators are characterized by their compact design and the wide range of applications. Operating pressures can range from a vacuum up to 500 bar as well as calculation pressures for the float standpipe up to the nominal pressure PN 630. Liquid densities >0.27 g/cm3 as well as a temperature range from 77 K to 673 K (-196o°C-to 400°C) allow use in applications for cryogenic liquid gases as well as in water hydraulics and steam boilers. Hermetically sealed floats for condensing media are available up to a max operating pressure of 320 bar. Flexibility through choice of suitable materials - standard materials: 316/316L 1.4435/1.4404, Group A4 stainless austenitic steel. Other possible stainless austenitic steels: 304/304L 1.4301/1.4306, 1.4571, 321, 1.4541. The WEKA visual level indicator is ideal for the commissioning of systems. The display works without energy and automatically as a result of the physical law of liquids in communicating vessels. Independent of a controller - and thus also independent in the event of a power supply failure - visual level indication on site is ensured. The wide, red- and silver-colored flag indicator system is easily and clearly readable, even from over large distances. The fully transparent flag indicator system made of polycarbonate (PC) also ensures readability from the side. The liquids, which are not always unproblematic and sometimes also hazardous, are safely enclosed in the dense and pressure-tight float standpipe and separated from the indicator. As described, WEKA visual level indicators offer the ideal solution for almost all operating conditions. For most applications, you will find a suitable device from their standard program. Again and again, however, customized solutions are also required for special operating conditions. Many designs can, for example, also be used in hazardous areas according to ATEX or IECEx. (ATEX is a widely used synonym for the ATEX guidelines of the European Union). The designation ATEX is derived from the french abbreviation for atmosphere explosibles. Their instruments can thus also be used in potentially explosive atmospheres. It finds application in explosion-proof plants; mechanical engineering and plant engineering; water management; ship building; energy; space and research. For details contact: Toshniwal Hyvac Pvt Ltd 267 Kilpauk Garden Road Chennai 600 010 Tel: 044 26445626, 26448983 E-mail: sales@toshniwal.net or Circle Readers’ Service Card 35
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International Exhibition and Conference for Automation 2017 Dates: 09-12 August 2017 | Venue: Bombay Convention and Exhibition Centre Mumbai Event: Automation in Mumbai is a great exhibition for industrial automation, factory automation, industrial robotics, drives and controls, logistics, hydraulics and pneumatics, building automation, pumps, valves and software solutions in Asia. Visitors can also see on it the latest products and services to the industry and meet personally with vendors. The numerous exhibits from international providers show the entire global product range. For details contact: IED Communications Ltd. 64, Empire Building D N Road, Fort 400001 Mumbai, India Tel: +91 (0)22 22079567 Display e-mail address www.iedcommunications.com PackEX India 2017 Date: 21-23 August 2017
China International Chemical Industry Fair Dates: 30 August - 1 September 2017 Venue: Shanghai World Expo Exhibition and Convention Center, Shanghai, China Event: This fair is an international fair that has created enough space for the petrochemicals and processing, basic inorganic chemicals, basic organic chemicals, agrochemicals, fine and specialty chemicals, new chemical materials, chemical equipment and engineering products, chemical control apparatus and instruments and other chemical services. The fair allows the exhibitors to enter the Chinese market and discover new business traits and prospects. Through his fair, the exhibitors can penetrate through Chinese economy and develop new business ideas and solutions. For details contact: CCPIT Sub-Council of Chemical Industry Building 16, Block 7, Hepingli Dongcheng District, Beijing, China
Venue: Pragati Maidan Exhibition Centre Event: The Packex India is an international exhibition for packaging materials and technology, that will be held once a year alternately between Mumbai and New Delhi. With the steadily increasing number of visitors, the Packex India has established itself as an important platform for the entire packaging industry and covers the entire demand for new technologies in the Indian subcontinent. Exhibitors show the trends, innovations and latest machines, materials, closures, films and raw materials in the industry to interested visitors from various industrial sectors such as food, beverages, dairy products, pharmaceuticals, consumer products, cosmetics, chemicals, retail, consumer goods and textiles For details contact: Koelnmesse YA Tradefair Pvt. Ltd. Office 1102, 11th Floor DLH Park, S. V. Road 400067 Mumbai, India Tel: +91 (0)22 28715200 Fax: +91 (0)22 28715222 Display e-mail address www.koelnmesse-india.com Waste Technology India Expo Dates: 18-20 January 2018 Venue: Bombay Convention & Exhibition Centre, Mumbai Event: Waste Technology India Expo is a 3 day event in Mumbai. The waste management and recycling exhibition will have solutions for managing and recycling of different kinds of waste, both solid and liquid, generated in industries, cities, homes, etc, to ensure clean surroundings. This event showcases product from air and water management, environment and waste management industries. For details contact: Virtual Info System Pvt Ltd 231 Mastermind-1, Royal Palms Mayur Nagar, Aarey Milk Colony Goregaon (E), Mumbai 72 â&#x20AC;˘ July 2017
AgroChemEx 2017 Date: 15-17 October,2017 Venue: Shanghai World Expo Exhibition and Convention Center (SWEECC) Event: One of the largest international event for agrochemicals, whether to meet with governmental authorities, high-level decision makers or visit to see the exhibition gathering most of qualified manufactures, formulators in China, AgroChemEx provides you excellent one-stop service. For details contact: Overseas Visitor Contact:Linda HSU Tel: +86-10-84885108 Email:ccpiaxyq@126.com Overseas Exhibitor Contact:Jack ZHAO Tel: +86-10-84885931 Email:ccpiazyj@126.com Yapex Building Exhibition 2017 Date: 15 November 2017 - 18 November 2017 Venue: Antalya Expo Center, Antalya, Turkey Event: Yapex Building Exhibition 2017 is an International Trade Fair for Building Materials, Construction Technology and Building Renovation. Yapex Building Exhibition 2017 to be held on 15-18 Nov 2017 at Antalya Expo Center, Antalya, Turkey. It is an excellent occasion to meet the expanding building market of Turkey, to present the latest products to international professional visitors and to establish new contacts with industrialists and businessmen. For details contact: Mr. Faith Onkar Tel: 90-242-3164600 Chemical Engineering World
Project Update CEW New Contracts/Expansions/Revamps The following list is a brief insight into the latest new projects by various companies in India.
CHEMICALS M Chemicals proposes an expansion from 10-TPM to 35-TPM of its synthetic organic chemicals manufacturing unit in GIDC Sachin, district: Surat, Gujarat. The estimated cost of the expansion is ` 12-million. The current status of the project could not be ascertained. According to MoEF sources, EIA report has been prepared by Aqua-Air Environmental Engineers. The existing plant manufactures 10-TPM 6-Nitro, 1-Diazo, 2-Napthol, 4-Sulphonic Acid. The expansion entails addition of new products namely, 25-TPM G-Salt, R-Salt, Amido G-Acid, Aniline 2,4 DSA, Aniline 2,5 DSA, Para Nitro Chloro Benzoyl Sulphonic Acid, Sulfo Tobias Acid, Para Cresidine Ortho Sulphonic Acid, Schaffer’s Acid, Broenner’s Acid. Total plot area is approximately 1,650-sq m, out of which, 300-m 2 has been used for green belt development. 5-KLD effluent will be treated in-house ETP and 10-KLD effluent will be sent to common MEE of MEPL for evaporation.
Modvadar, district: Kutch, Gujarat. The current status of the project could not be ascertained. According to MoEF sources, existing products are 3-million sq m per month plywood, flush door, block board and veneer. The manufactured resin will be used for in-house consumption at the wood products plant. The project will come up on 11,603.62-sq m of existing land. The greenbelt area is 600-sq m. A base platform will be constructed for the resin plant; remaining will be MS structure.
Mamta Texdyes (Samba) proposes a synthetic organic chemicals manufacturing unit in GIDC Sarigam, district: Valsad, Gujarat. The project is spread over 2,250-sq m. The estimated cost of the project is ` 32-million. The current status of the project could not be ascertained. According to SEIAA sources, Eco Chem Sales Services is the environmental consultant. The proposed products are 200-TPM sulphur black grains, 300-TPM sulphur black liquid and the by-products are 250.1-TPM sodium thio sulphate crystal and 47.12-TPM sodium chloride salt. 700-sq m area has been proposed for green belt development. Industrial waste water will be treated in primary and tertiary treatment plant and treated waste water will be discharged into CETP Sarigam.
Eternis Fine Chemicals proposes an expansion of synthetic organic chemicals manufacturing unit from 42,200-TPA to 60,000-TPA in MIDC Kurkumbh, district: Pune, Maharashtra. The current status of the project could not be ascer tained. According to MoEF sources, total land area is 100,400-sq m and built-up area is 42,710-sq m. 33 per cent will be developed as green belt area. The project will entail: 1) capacity expansion of existing products and by-products; 2) addition of similar products and by-products; 3) introduction of new eco-friendly biomass boiler as replacement to furnace oil. Project involves manufacturing of fragrance from organic raw materials by chemical process like hydrogenation, esterification, Diels-Alder reaction, cyclisation, dehydrogenation, aldol condensation, etc, followed by distillation to match precise quality standards. By-products capacity will be augmented from 11,400-TPA to 20,000-TPA. The estimated cost of the project is ` 1,050-million. The power requirement 12,000KVA will be available through Government Electricity Board.
Resipol Adhesives proposes an expansion of synthetic organic chemicals manufacturing unit in village: Rajpur, district: Mehsana, Gujarat. The estimated cost of the expansion is ` 40-million. The current status of the project could not be ascertained. According to SEAC sources, the manufacturing of existing products, 2.0TPM benzyl alcohol, 1.1-TPM benzyl benzoate, 3.0-TPM benzoic acetate, 1.4-TPM sodium benzoate, 1.8-TPM sodium acetate will be discontinued and 300-TPM polyester resins (different grades) and alkyd resins (different grades), 90-TPM melamine formaldehyde resin and 85-TPM urea formaldehyde resin will be manufactured as new products. The plot area is approximately 6,033.00-sq m. Unit has proposed 2,000-sq m area for green belt development. Industrial effluent of 0.42-KLD after primary treatment will be evaporated in kettle type evaporator. Two DG sets each of 65-KVA will be provided. It was decided to recommend the project to SEIAA, Gujarat for grant of environmental clearance. Royal Wood proposes a 90-TPM phenol formaldehyde resin, urea formaldehyde resin, melamine urea formaldehyde resin and melamine formaldehyde resin manufacturing unit in village:
Panoli Intermediates (India) proposes an expansion of its specialty chemicals manufacturing unit and a new 10-MW coal-based captive power project in Unit-III, GIDC Nandesari, district: Vadodara, Gujarat. The estimated cost of the project is ` 100-million. The current status of the project could not be ascer tained. According to MoEF sources, the total plot area is 15,480-sq m. The capacity of isomers and DNCB such as 2:4 DCNB, 2:6 DCNB, 2:5 DCNB is to be augmented from 200-TPM to 2,200-TPM, or tho anisidine/para anisidine from 100-TPM to 1,100-TPM, or tho nitro aniline/para nitro aniline from 300-TPM to 2,300-TPM, isomers of DCA from 80-TPM to 1,080-TPM, isomers and DCNB such as 2:3 DCNB, 2:5 DCNB. isomers of DCNB such as 2:3 DCNB, 2:5 DCNB, 3:4 DCNB from 200-TPM to 2,200-TPM, H-acid from 50-TPM to 500-TPM and addition of a new product namely, 1,500-TPM derivatives of nitro phenol and a new 10-MW coal-based captive power project. 10-MW power requirement is to be met from MGVCL and 10-MW from the captive power project. The effluent will be treated in proposed effluent treatment plant.
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CEW Project Update 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. Environment clearance has been obtained for the products â&#x20AC;&#x201C; 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 400TPD 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 Polyphosphate (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 synthetic organic chemicals manufacturing unit (viz, pharmaceutical bulk drugs and drug intermediates) from 65.70-TPM to 131.60-TPM in Padra, district: Vadodara, Gujarat. The estimated cost of the project is ` 87.046-million. Environmental Consultant to this project is Envisafe Environment Consultants. According to MoEF 74 â&#x20AC;˘ July 2017
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-cu m/day) will be treated in the ETP comprising primary, secondary and tertiary treatment. Treated effluent will be sent to CETP for further treatment. ETP sludge, inorganic residue and incineration ash will be sent to TSDF. Spent carbon, organic residue will be sent to incinerator. 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 washery 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 4,350Kcal/kg), middling (ash content about 58%) of GCV around 2,350-Kcal/kg useable as fuel in FBC boilers. The proposed expansion will be the state-of-the-art 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. Chemical Engineering World
Book Shelf CEW Pollution Control in Chemical and Allied Industries: With Focus on Air and Water Pollution Authors : Hanley N Price : ` 1,678.00 (Paperback) Pages : 664 pages Publisher : CBS Publishers and Distributors Pvt LTD About the Book : The intent of this reference textbook is to describe environmentally preferable or ‘green’ approaches to the design and development of chemical processes and products. The entire text is divided into 4 section covering 31 chapters. All the sections present the material in a cogent and lucid style to meet the student’s expectations from basic textbook. Diagrams and tables supplement the text. This reference textbook is an essential reading for all students and teachers of engineering, environment and life sciences. The researchers and consultants in environmental field with special emphasis on chemical industries, chemists and industrialists will also find it highly useful and informative.
Downstream Processing (Advances in Biochemical Engineering/Biotechnology)
Authors : D. J. Bell , P. Dunnill , K. Esser , E. Flaschel, M. Hoare, J. Holló , M.R. Kula, Ch. Lang-Hinrichs , L. Nyeste , M. Pécs, B. Sevella, Ch. Wandrey Price : ` 7,299 (Paperback) Pages : 212 Publisher : Springer-Verlag Berlin and Heidelberg GmbH and Co. About the Book : TThis book series reviews current trends in modern biotechnology and biochemical engineering. Its aim is to cover all aspects of these interdisciplinary disciplines, where knowledge, methods and expertise are required from chemistry, biochemistry, microbiology, molecular biology, chemical engineering and computer science. Volumes are organized topically and provide a comprehensive discussion of developments in the field over the past 3–5 years. The series also discusses new discoveries and applications. Special volumes are dedicated to selected topics which focus on new biotechnological products and new processes for their synthesis and purification. In general, volumes are edited by wellknown guest editors. The series editor and publisher will, however, always be pleased to receive suggestions and supplementary information. Manuscripts are accepted in English.
The Future Is Better Than You Think Author : Peter H. Diamandis, Steven Kotler Price : ` 375/Pages : 400 Publisher : Free Press About the Book: - We will soon be able to meet and exceed the basic needs of every man, woman and child on the planet. Abundance for all is within our grasp. This bold, contrarian view, backed up by exhaustive research, introduces our near-term future, where exponentially growing technologies and three other powerful forces are conspiring to better the lives of billions. An antidote to pessimism by tech entrepreneur turned philanthropist, Peter H. Diamandis and award-winning science writer Steven Kotler. Since the dawn of humanity, a privileged few have lived in stark contrast to the hardscrabble majority. Conventional wisdom says this gap cannot be closed. But it is closing—fast. The authors document how four forces—exponential technologies, the DIY innovator, the Techno philanthropist, and the Rising Billion—are conspiring to solve our biggest problems. Abundance establishes hard targets for change and lays out a strategic roadmap for governments, industry and entrepreneurs, giving us plenty of reason for optimism. Chemical Engineering World
Chemical Engineering for NonChemical Engineers Author: Jack Hipple Price: ` 4,227(Hardcover) Pages: 416 Publisher: Wiley-AIChE; 1 edition (5 January 2017) About the Book : Covers the basic concepts of chemical engineering in an easy to understand way enabling non–chemical engineers to better interface with and understand chemical engineers and the basic concepts of chemical processing, design, and operation Chemical engineering is a skill and profession in widespread within chemical manufacturing, oil and gas refining and processing, food processing, pharmaceutical manufacturing, plastics production and use, electronics manufacturing, as well as in new energy recovery and generation technologies. Though these types of processes are typically designed by chemical engineers, and it is important that those who interface with chemical engineers in the design and operation of these plants understand basic chemical engineering principles, allowing them to better understand the basis for operation and design of their facilities, the constraints of process operations, and the business opportunities which chemical engineering expertise can support and enable. Chemical Engineering for Non– Chemical Engineers covers: Important differences between laboratory and industrial scale practice of chemistry, consequences of scale–up mistakes, and approaches needed to safely scale a lab reaction process to a commercial scale, including the fundamentals of reactive chemicals hazards Basics chemical reaction equations, balancing, economies of scale, and the nature of various types of flow sheets Basics and characterization of fluid flow and various pumping and transport systems How separation processes such as distillation, absorption, stripping, chromatography, membranes, and leaching are used to recover and purify chemical July 2017 • 75
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7
HRS Process Systems Ltd
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18
Sulzer India Pvt Ltd
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ImageGrafix Engineering Services Pvt. Ltd
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Suraj Ltd
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International Combustion (India) Ltd
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UNP Polyvalves (India) Pvt Ltd
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