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Contents CHEMICAL ENGINEERING WORLD RNI REGISTRATION NO. 11403/66 Chairman Publisher & Printer Chief Executive Officer
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Editor Deputy Editor Editorial Advisory Board Contributing Editors
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NEWS Industry News Technology News
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FEATURES Digital Transformation across EPC Functional Value Chain A CHEMTECH EPC World 2019 Conference Throwback By Jayati Mukherjee
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Digital Transformation Making the Chemical Processes Smart 34 Anil Bhatia, Vice President & Managing Director , Emerson Automation Solutions, India Digitalization: the Way Ahead for Chemical Industry Mr. P L Palaniswamy, Director, Danfoss Drives, Danfoss Indi
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MARKET INSIGHT Ammonia Analyser
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Sharplex Horizontal Pressure Leaf Filter For Crude Oil Filtration
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Filter for Carbon Application
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Sharplex Tubular Centrifuge for Biodiesel Plants
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PRODUCTS
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EVENTS
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PROJECT UPDATE
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BOOK SHELF
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INTERVIEW ‘Drive towards Automation reduces Cost of Manufacturing and offers Huge 70 Opportunity to Develop Technologies’ Andy Postlethwaite, Senior Vice President - Performance Materials, BASF Asia Pacific; & Chairman & Director on the Board of Directors, BASF South East Asia Pte Ltd Demand for Phenol and Acetone is Growing and Finding Application Diversity 74 Meghav Mehta, Whole Time Director, Deepak Phenolics Limited.
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CEW Industry News Aarvi Encon Reported 19% Increase in Turnover for the FY 2018-19 Mumbai, India: Aarvi Encon Limited, one of India’s leading technical manpower outsourcing companies, announced its financial results for the half year and the year ended on 31st March 2019. The company reported a 19 percent jump in turnover, with an increase from ` 173.48 cr in FY 2017-18 to ` 206.03 cr in FY 2018-19. Additionally, it also saw significant gain in net profit, with a notable 17 percent increase within the same timeframe, amounting to ` 9.11 cr as of FY 2018-19. After successfully navigating through the glut in the Oil and Gas sector between FY2015-16, Aarvi Encon registered a 98 percent increase in profit with EBITDA at ` 96,387,125 in FY 2016-17. This was followed by a steady 48 percent increase in profit for FY 2017-18, with EBITDA for the year amounting to ` 113,329,135 and 17 percent increase in profit with EBITDA at ` 124,040,813 in FY 2018 -19. Speaking about the results for FY 2018-19, Mr. Virendra D Sanghavi, Managing Director, Aarvi Encon Limited said, “At Aarvi Encon, it has been our longstanding goal to deliver world-class engineering and manpower outsourcing services to our clients in India and across the globe. With our expert team of experienced personnel in technical, operational, and business fields we have been able to create a dynamic approach for problem-solving and consistently deliver quality services. This has enabled us to establish longstanding relationships with several of our clients over the years, and our results for FY 2018-19 are a testament to this.” He further added, “As for the future, we plan to expand rapidly by getting more clients on board to add greater business stability. It is these strong relationships with a foundation of trust and meeting expectations that have led us to where we are today and will continue to do so in the years to come.” With a track record of over 30 years, Aarvi Encon is a pioneer in the field of technical manpower outsourcing services in India. The company provides services pertaining to the Oil & Gas, Power, Refinery / Petrochemical, Pipeline and Infrastructure sectors. Equipped with a well-formulated approach and expertise in the field, Aarvi Encon has successfully established itself as a category leader, catering to a wide array of clients both in India and overseas.
Aspen Technology and Hexagon Announced New Collaboration to Accelerate Digital Transformation in Process Industries Bedford, Mass and Huntsville, Ala: Aspen Technology Inc – the asset optimization software company, and Hexagon PPM – the leading global provider of engineering software for the design construction and operation of plants ships and offshore facilities, has announced a new level of collaboration founded on a memorandum of understanding (MoU) that will more closely align AspenTech’s conceptual, basic engineering and cost estimation solutions with the detailed engineering suite from Hexagon PPM, to enable a fully data-centric workflow across the asset lifecycle. As the first to market with a fully digital design and engineering process with integrated economic evaluation, AspenTech and Hexagon PPM suites align to help customers better manage the financial risks of complex projects, which is a major challenge today. The combined capabilities can accelerate digital transformation and enable deployment 10 • June 2019
of best-in-class integrated solutions from two leading software providers. Working together, AspenTech and Hexagon PPM can provide a more complete digital twin, inclusive of both the plant infrastructure and the chemical processes occurring within that physical infrastructure, to allow operators to make better decisions that maximize throughput, quality and uptime. AspenTech’s planning, scheduling and reliability software, coupled with the Hexagon PPM expertise for the detailed engineering phase of facility and plant design, will help operators more easily leverage engineering models during operations, obtain the most from their investments and allow them to respond better to changing market conditions. The announcement came during the keynote speech of Hexagon PPM President Mattias Stenberg, at HxGN Live 2019 in Las Vegas, Hexagon’s annual digital solutions conference, where he was joined on stage by Mr. Antonio Pietri, President and Chief Executive Officer of Aspen Technology. Pietri said, “This collaboration will allow customers the flexibility to choose solutions from market-leading providers across the full lifecycle, from the design phase into the systems that operate and maintain a plant. Engineering procurement and construction (EPC) firms and owneroperators will be able to accelerate their digital transformation with complete confidence, supported by best-in-class solutions.” Stenberg said, “Based on our assessments and engagements with joint customers, we are confident there is potential to impact both project and operational efficiency. Aligning project costs to decisions early in the design process reduces budget and schedule risk. Post-project, the combination of predictive maintenance and advanced controls with our information management solutions translates into higher-quality plants that will perform better over their lifetime”. Customers are already in support of this new initiative. “Eni is looking with interest to initiatives like the one between Hexagon PPM and AspenTech”, said Arturo Bellezza, Engineering Manager, Eni. “The resulting direct integration between process simulation, 3D model and operations will allow a major step forward in the digital journey of our industry”.
Agilent Hosted Third Edition of Total Agilent Experience in India Mumbai, India: Agilent Technologies Inc. has recently hosted the third edition of their annual scientific symposium, Total Agilent Experience, in Mumbai. Besides showcasing Agilent's latest analytical solutions and applications, the symposiums also featured industry experts as speakers and interactive workshops centered on data integrity, regulations, and environmental standards. Speaking on the occasion, Mr. Bharat Bhardwaj, Country General Manager, Agilent Technologies, India said, “Total Agilent Experience offers unparalleled opportunities for scientists and industry leaders to discuss new ways to solve problems and make their laboratories more efficient.” Additionally, Agilent also hosted a pharma regulatory summit, a biopharma summit, and an analytical summit for applied markets at the event. In each of these summits, industry experts shared their insights on the emerging trends that are driving adoption of new technologies. Total Agilent Experience has fast become the place to be for professionals from chemical, food and pharma industries over the years, drawing over 300 scientists and researchers from across the country. Chemical Engineering World
CEW Industry News Blackmer Extended its Line of GNX Series Pumps with New 3- and 4-Inch Models
“I have seen the tremendous industrial development in China in the past 30 years. I think India is going to have the same magical change in the next 30 years and Garlock will play important role of this change!” said Mr. Zeng. He added, “We always know India is a prominent strategic market, and we have achieved great success in business growth in this market in the past years with all the continuous support and commitment and partnership from customers and all partners. Today with the inauguration of our new office, we will ensure that we are ready to serve Indian market in coming years, together with you all.” Over the last ten years, the Garlock India team has worked hard to successfully win the outstanding reputation in sealing industry in India with the excellent services and engineering solutions. Now, with the new facility’s establishment, Garlock India is ready to start another remarkable era with its newly expanded operations capacity. Now Garlock is looking forward to work with all the partners, distributors, and customers to write the next chapter in the history of Garlock India.
Grand Rapids, MI: Blackmer, part of PSG, a Dover company and a global leader in specialty pumps and reciprocating compressor technologies, is pleased to announce that its GNX Series Sliding Vane Pumps are now available in 3- and 4-inch models. The market’s only alignmentfree reduced-speed positive displacement pumps, the Blackmer GNX Series have been designed to optimize the transfer of non-corrosive, non-abrasive industrial and petroleum products for both portable and stationary applications. Originally launched in 2017 in 2- and 2.5-inch models, Blackmer GNX Series heavy-duty sliding vane pumps include the proven features of Blackmer legacy GX Series pumps but take them to the next level with the incorporation of a commercial-grade, single-stage gearbox, motor and baseplate. This innovative new gearbox fits between the motor and pump and is held in place by a permanent dowelled connection that creates a structural link between the high-speed and low-speed sides of the system. This results in a pump that will not need to be realigned either at initial installation or following a maintenance procedure, resulting in improved peace of mind for the operator. The 2- and 2.5-inch models have aluminum gearboxes while the new 3- and 4-inch models feature cast iron gearboxes. GNX Series pumps provide flow capacities ranging from 7 to 500 gpm (25 to 1,893 L/min) at working pressures up to 175 psi (12.1 bar). They are also available with optional steel and composite baseplates. The pre-grouted composite baseplate adds additional value to the pump, gearbox and motor setup by providing unmatched surface flatness, significant vibration damping and reduced installation costs. GNX Series pumps have a 90° porting orientation and GNXH Series pumps have a 180° porting orientation. These pumps are available in a full range of motors from 1 to 50 hp.
Garlock India Inaugurated a New Facility as a Part of its Strategic Expansion Plan Pune, India: Garlock has recently announced its new facility as a part of its strategic expansion plan in the country. At the event, Mr James Zeng, Vice President of Garlock Sealing Technologies Asia, and Mr Rajesh Baviskar as GM of Garlock India thanked the customers, partners, distributors, and employees for all of their support. He also shared his great confidence for Indian business growth. 12 • June 2019
DeLille Oxygen Co Leased Two eCOs Units for Costcompetitive Onsite CO Production Copenhagen, Denmark: DeLille Oxygen Co. has opted for two eCOs units. One is located at their customer’s site for reliable and flexible over-the-fence delivery of CO. The other will deliver on-demand CO for the rest of the DeLille’s customers from the company’s headquarter in Columbus, Ohio. “We are convinced that the eCOs solution will support us in delivering an even better customer experience. With this onsite unit, our customer will never have to worry about monitoring stock, ordering new supplies, or dealing with logistics. eCOs produces the volume and quality of gas needed, when it is needed. It can’t get simpler and more reliable than that,” says Josh Weinmann, President, DeLille Oxygen Co. The new unit will be able to produce 96 Nm3/h (3650 SCF/h) CO at ultrahigh purity and is expected to be commissioned in the summer of 2020. The unit is modular which ensures a small footprint and fast installation on site. The lease and service agreement includes continual operational optimization and electrolysis maintenance and training of operators. The eCOs solution reduces CO2 to CO by electrolysis. The process emits only oxygen and can be powered by green electricity from wind turbines or solar panels. In this case, the production is completely carbon- neutral. In the longer run, the eCOs technology opens up for a whole new segment of green and sustainable chemicals from renewable carbon sources. It can be applied at industrial complexes in order to utilize CO2 as a feedstock to produce valuable chemicals and significantly reduce CO2 emissions to the atmosphere. Onsite CO generation is a significant development for the pharmaceutical, metallurgy, electronics and specialty chemicals industries that use carbon monoxide in their production processes as well as gas distributors. The eCOs technology ensure security of supply, eliminates the need for transporting the hazardous gas, and drastically reduce costs related to storage, rentals, and connections. Chemical Engineering World
CEW Industry News Galaxy Surfactants Limited’s FY19 Consolidated Performance
BASF to Build Engineering Plastics and Thermoplastic Polyurethanes Plants at NewVerbund Site in Zhanjiang, China Zhanjiang, China: BASF plans to build an engineering plastics compounding plant and a thermoplastic polyurethane (TPU) plant at the company’s proposed integrated chemical production Verbund site in Zhanjiang, China. These will be the first production plants to come onstream at the site. By 2022, the new engineering plastics compounding plant will supply an additional capacity of 60,000 metric tons per year of BASF engineering plastics compounds in China. This will bring the total BASF capacity of these products in Asia Pacific to 290,000 metric tons per year. As part of the company’s plan to implement a comprehensive smart manufacturing concept at the Verbund site based on cutting-edge technologies, the new plants will utilize automated packaging, high-tech control systems, and automated guided vehicles. “Less than a year after we signed the first MoU, we are delighted to announce the first plants to be established at our smart Verbund site in Zhanjiang,” said Dr. Stephan Kothrade, President Functions Asia Pacific, President and Chairman Greater China, BASF. He added, “The project is moving forward swiftly and customers in southern China will soon benefit from these innovative products to meet their immediate needs.” General facilities for the Zhanjiang Verbund site will also be built along with the two new plants. BASF Integrated Site (Guangdong) Co. Ltd (BIG), BASF’s new wholly-owned subsidiary, has been officially founded. This entity will oversee the operations of the new Verbund site, underlining BASF’s commitment to the Southern China market.
^Includes other Income Mumbai, India: Galaxy Surfactants Limited, a leading manufacturer of performance surfactants and specialty care products with over 200 product grades used in Home and Personal Care industry, has announced its audited financial results for the Quarter and Full Year ended March 31st, 2019. Commenting on the performance Mr U Shekhar, Managing Director, Galaxy Surfactants Limited said, “Our company has delivered a robust performance across all major geographies in FY19, registering a revenue growth of 13.5 percent as compared to FY18. This development was on the back of a healthy volume growth of 8.8 percent driven primarily by the India and ROW Markets. It has been a record year for us in many ways. The team at Galaxy despite the headwinds never gave up. Persistence and patience demonstrated over the years finally bore fruits in the Specialty Care segment which recorded a growth of 18 percent for FY 19. The strong portfolio of preservatives, mild surfactants and other specialty care products witnessed significant traction in the developed markets which led to a 29.2 percent Y-o-Y volume-growth for our Rest of the World market. We remain positive and see the momentum continuing in FY 20. Performance surfactants on the back of improving home and personal care demand in India grew 3.5 percent for the year. The Indian market grew by 12.1 percent in FY 19. With a diverse customer base, product portfolio, committed & experienced team, we at Galaxy are confident in enhancing our stakeholders’ value sustainably and consistently.” 14 • June 2019
“We want to improve our support for customers in the Southern China market and around the world. We will do this by establishing the new plants close to growing customer industries, and through improvements in efficiency realized from our smart manufacturing approach. This will increase our speed of innovation and the efficiency of our services,” said Raimar Jahn, President of BASF’s Performance Materials division. “In particular, electric and electronics companies and automotive manufacturers are turning to BASF to help them address trends such as the electrification of cars and miniaturization of electronic devices”. The growth of the TPU market, in particular for high-end applications, is driven by several factors including increasing regulatory requirements and growing customer expectations for enhanced sustainability performance in such areas as e-mobility, lightweight and automation. BASF solutions support this growth with safety-enhanced cables and wires for automation and automotive, as well as lightweight materials for consumer goods. With customer needs evolving rapidly across the world, BASF is ramping up its investment in emerging markets to address local requirements while continuing to invest in developed economies. BASF signed the first Memorandum of Understanding for the Verbund site with the Guangdong Provincial Government in Berlin in July 2018, and in January 2019 the company signed a Framework Agreement setting out further details of the plan. The Verbund site in Guangdong would be BASF’s largest investment, estimated up to USD 10 billion upon completion, and would be operated under the sole responsibility of BASF. The integrated value chain will connect upstream and downstream plants from basic chemicals to more consumer-oriented products and solutions, serving growth sectors like consumer goods or transportation. The site would ultimately be the third-largest BASF site worldwide, following Ludwigshafen, Germany, and Antwerp, Belgium. Chemical Engineering World
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CEW Technology News BASF Developed Process for Climate-friendly Methanol Ludwigshafen, Germany: The production processes of the most important basic chemicals are responsible for around 70 percent of the greenhouse gas emissions in the chemical industry. BASF experts are working intensely on new technologies to substantially reduce emissions in these processes. The company has bundled all of this work under the roof of its ambitious Carbon Management Program. One of the first visible successes in this area has been achieved by a project team which has applied to patent a process to produce methanol without any greenhouse gas emissions. If it can be successfully implemented at an industrial scale, the entire production process – from syngas production to pure methanol – will no longer release any carbon dioxide emissions. Typically, methanol is made from syngas, which until now has been primarily obtained from natural gas via a combination of steam and autothermal reforming. Using special catalysts, this can then be turned into crude methanol, which can be further processed after purification. In the new BASF process, the syngas is generated by partial oxidation of natural gas, which does not cause any carbon dioxide emissions and has proven to be advantageous in a study jointly conducted with Linde Engineering. The subsequent process steps – methanol synthesis and distillation – can be carried out nearly unchanged. Ingenuity was required to address the merging and processing of the waste gas streams that arise during methanol synthesis and distillation and which cannot be avoided even with optimal process management. These waste gas streams consisting of methane, carbon monoxide, carbon dioxide, and hydrogen are incinerated in an Oxyfuel process with pure oxygen. This results in a small volume of flue gas with a maximum carbon dioxide content. The flue gas is then scrubbed using BASF’s proven OASE process for full recovery of the carbon dioxide. To ensure that the carbon content in the carbon dioxide is not lost and that it can be used again for methanol synthesis, the captured carbon dioxide is fed back into the beginning of the process. This does, however, require additional hydrogen, which BASF also aims to produce without any carbon dioxide emissions, for example, via methane pyrolysis, which is also being developed in the Carbon Management research program. A new chapter in the history of methanol, an important basic chemical: “We are optimistic that our climate-friendly approach will better adapt methanol synthesis to the requirements of the 21 st century,” said project manager Dr. Maximilian Vicari from BASF’s Intermediates division. “Nearly 100 years after the first industrial-scale production of this important basic chemical using BASF’s high-pressure process, we are now taking a leading role in writing the newest chapter in the history of methanol.” Vicari expects it will be around 10 years before this new process is carried out in an industrial-scale plant. The basic chemical methanol is an important starting material for many products in different BASF value chains. Derived products such as formaldehyde, acetic acid and methylamines are very important in terms of volume. Other important derivatives include methyl tert-butyl ether, methyl methacrylate, polyalcohols and silicones. Methanol also serves as an energy supplier and can be used as a raw material for chemical conversion into other fuels or fuel additives. 20 • June 2019
BASF, the Estee Lauder Companies, Roundtable on Sustainable Palm Oil and Solidaridad Partner for Sustainable Palm Project Lampung, Indonesia: BASF, The Estée Lauder Companies and the Roundtable on Sustainable Palm Oil (RSPO) are partnering with the civil society organization Solidaridad to promote sustainable palm oil and palm derivatives production in the district of Waykanan, Lampung, Indonesia. The project supports independent Indonesian smallholder farmers to improve their livelihoods and their sustainable production of palm oil and palm kernel oil. It offers continuous education and technical support on implementing and maintaining sustainable palm oil practices. The project’s target is that a minimum of one-third of the supported smallholder farmers become certified according to the Smallholder Standard of RSPO at the end of three years. The project par tners are collaborating with the Indonesian government to foster a sustainable palm oil production supply chain in Lampung that is free from deforestation and competitive in the global market, while increasing the social and economic benefits for farmers. “Most major European companies have committed to using sustainable palm oil exclusively," said Heske Verburg, Managing Director, Solidaridad Europe. "We are delighted that BASF and The Estée Lauder Companies are reaching beyond just purchasing sustainably, by providing direct support for sustainable palm oil projects. When palm oil is produced sustainably, and in a futureproof manner, it can actually contribute to resolving grave issues for both farmers and the environment.” “We are thrilled to partner with BASF and Solidaridad on this important initiative to support Indonesian smallholder farmers,” said Greg Polcer, Executive Vice President, Global Supply Chain, at The Estée Lauder Companies. “So many livelihoods in this community are inextricably tied to the production and we support ensuring that it is produced sustainably – both for the long-term benefit to the environment and for the long-term benefit to the community itself.” “Approximately 40 percent of the world palm production comes from smallholder farmers who rely on it for their livelihoods,” said Daniele Piergentili, Vice President, Home and Personal Care at BASF in North America. “The partnership with Estée Lauder, Solidaridad and RSPO enables us to support these farmers and at the same time increase the availability of sustainably produced palm oil.” " Fo r s u s t a i n a bl e p r o d u c t i o n t o b e c o m e m a i n s t r e a m a n d fully inclusive, the RSPO believes it is imperative to support smallholders through a variety of different approaches, including the RSPO Smallholder Suppor t Fund (RSSF),” said Ashwin Selvaraj, Head of Smallholder Unit in the RSPO Secretariat. “This collaborative project in Lampung is a great opportunity to scale up sustainable practices, protect natural resources and bring more smallholders under certification through RSPO Best Management Practices.” Chemical Engineering World
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CEW Technology News ExxonMobil Launched New Breakthrough Hydraulic Oil Technology Mobil DTE™ 20 Ultra Series
Cepsa is going to Present its Unique LAB Plant Worldwide at CESIO 2019 Madrid, Spain: Cepsa is upgrading one of its most emblematic chemical plants, located in Puente Mayorga (Cadiz, Spain), making it the first linear alkyl benzene (LAB) facility in the world to replace hydrofluoric (HF) technology with the Detal process, resulting in a more efficient and sustainable operation. The company presented this project at CESIO 2019, the largest international surfactant congress. With an investment of € 100 million, Cepsa plans to revitalize the plant, making it the first in Europe and the second in the world to use a cutting-edge fixedbed Detal catalyst (the first plant to have this innovation was the company's Canadian facility).
Mumbai, India: ExxonMobil has recently announced the launch of Mobil DTETM 20 Ultra Series – a technologically advanced series of hydraulic oils. The new series is designed for all types of hydraulic systems and components such as close clearance servovalves and high accuracy numerically controlled (NC) machine tools. Designed to deliver upto 2x longer oil life and exceptional performance in harshest conditions, the new series help industries achieve unprecedented performance goals easily. The Mobil DTE 20 Ultra Series would be of lower maintenance frequency thus minimizing man-machine interaction, which makes the site safer for industrial workers. In addition to this, with 2 time oil life it would also support environmental care by reduction in hydraulic oil consumption. Providing improved deposit control of 89.2 percent for longer oil life and precision operations, Mobil DTE 20 Ultra Series also delivers superior wear protection to extend component life. Extensive testing shows that it comes with better water handling and filter rating. According to Eaton 35VQ25 Test – an industrial test recognized for hydraulic-fluid qualification, the oil provides greater than 72 percent better wear protection. “Hydraulic systems operate under high-pressure and high-output environment. One of the major challenges faced by the industry, is that of performance, productivity and efficiency,” said Shankar Karnik, General Manager, Industrial Lubricants, ExxonMobil Lubricants Private Limited. He added, “With Mobil DTE 20 Ultra Series, consumers now have a new technology developed to deliver trusted performance and extended component life, with reduced maintenance costs and system wear.” Hydraulic systems need maintenance due to both oil and machine factors. As the oil oxidizes with time, deposits are formed causing replacement of both oil and filter. Moreover, often times even valves, pumps and other parts of the machinery wear with age wherein the damaged components require replacement. This maintenance can be reduced and made effortless by using Mobil DTE 20 Ultra as it plays a major role in slowing down equipment ageing and decrease maintenance efforts. 22 • June 2019
The new plant will be completed in 2020. The new technology will allow production of all commercial LAB grades (high and low 2-phenyl) in the same installation, with total flexibility, depending on the demand. This versatility allows the company to meet the specific demands of each client. Detal technology, in addition to improving the quality of the product, will increase the efficiency of the plant and reduce its emissions, since it requires lower consumption of natural gas and electricity. Furthermore, the digital transformation programs designed by the company will also be installed. The YET (Yield, Energy and Throughput) system, an artificial intelligence program and the application of Industry 4.0 technologies (machine learning, big data and advanced analytics), will optimize processes and improve the plant's energy efficiency. This process will also allow the plant’s LAB production capacity to increase by 50,000 tons (a 25 percent increase), with the aim of supplying the growing consumption of emerging economies in Afr ica. The company estimates that between now and 2035, the demand for LAB in these countries will grow by 5 percent annually. During the presentation of the project at CESIO 2019, Salvador García Claros, Director of Development and Innovation of the chemical area of Cepsa, pointed out: "we are world leaders in both the production of LAB and the development of the best technology to produce it, used in more than 80 percent of the new plants that are built worldwide. Our experience and leadership have now led us to be the first to install Detal technology in a plant built for HF. We are convinced that this upgrade will bring greater competitiveness to this plant, as well as increasing our capacity to meet the growing surfactants demand”. LAB is the precursor to linear alkylbenzene sulfonate (LAS), the world's most widely used biodegradable surfactant in laundry detergents. LAS was launched more than half a century ago and its excellent properties make it a necessary ingredient both in traditional detergent formats (powder or detergent bars) and in more sophisticated products (single-dose capsules or highconcentration liquid detergents). Chemical Engineering World
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CEW Features
Digital Transformation across EPC Functional Value Chain A CHEMTECH EPC World 2019 Conference Throwback By Jayati Mukherjee
While 4Th industrial revolution is underway through digital transformation, the manufacturing sector is also aligning with it with the effective implementation of various digital technologies viz. IIoT, digital twin, artificial intelligence, machine learning, augmented reality, virtual reality, and many more. The plants have to be designed, engineered, and built with the required infrastructure in mind to derive the benefits of achieving higher productivity, higher efficiency, lower plant downtime, effective maintenance, and at the end to make more profit for the company. Various stakeholders and partners have to bear in mind that the fruition of digital transformation is only possible, if it can be foreseen and implemented right from the design and engineering stage. With this context, Chemtech Foundation has organized Chemtech EPC World 2019 Conference in Mumbai on 20Th February 2019. The program was themed on digital transformation across functional value chain in EPC industry. The program was chaired by eminent industry icon Mr. B Narayan, Group President (Procurement & Projects), Reliance Industries Ltd & Chairman, Central Advisory Board, Chemtech - EPC World Expo 2019. The program was also star dusted with multitude of industry leaders as keynote speakers, guests of honour, and panelists. This article encapsulates the insights shared in the conference.
(L to R): Mr. Rakesh Verma, Chief Executive Officer, Simon India Limited; Mr. Jason Urso , Vice President - Technology, Honeywell Process Solutions; Mr. B. Narayan, Group President (Procurement & Projects) Reliance Industries Ltd. & Chairman, ChemTECH - EPC World Expo 2019, Central Advisory Board.; Mr. Sanjeev Chopra (IAS) Principal Secretary, Industries Dept., Govt. of Odisha & Chairman, IPICOL; Mr. Maulik Jasubhai, Chairman & Chief Executive, Jasubhai Group & Chemtech Foundation; Mr. Mohamed Takhim, CEO, ECOPHOS; and Mr. Manish Chandra, Managing Director - Accenture Strategy, India @ the Inaugural Session
Why Digitalization for EPC Industry? The very objective of Digitalization for a company is to achieve higher productivity, higher efficiency, lower plant downtime, effective maintenance, and in final quintessence – to make more profit. For manufacturing industry to reap all these benefits through seamless digital transformation, at the very first place the plants have to be – built in, engineered, and designed accordingly. Traditionally, since long, EPC industry has been working using various manual methods viz. building 3D models, document design, etc. However this manual mode is not going to help anymore towards the digital transformation. This is where digitalization of EPC industry plays a very crucial role. On the path of digitalization, 26 • June 2019
EPC industry intends to leverage a fairly newer concept – totex. To elaborate further, totex is the total life cycle cost of the plant comprising of two important expenditure elements: capex and opex. Traditionally, EPC contractors were more focused on capex as their eyes were on the escaspe from the project site soon after the delivery of the project to the respective customers. However, the project majorly runs for years at site after delivery, thus incurring operations-and-maintenance cost. So EPC industry, ever diligent for the need of continuous improvement, contemplates to leverage digitalization boon to realize greater efficiencies in the deployment of capital as well as the subsequent operations and maintenance throughout the plant life cycle.
Digital Twin – an emerging need: According to customers or project owners’ point of view, the very definition of a successful project is the one which can be safely operated with highest level of efficiency in the productivity. Along with focusing on these parameters, it is also very important to consider how to make the projects less complicated and reliable, and at the same time to offer it at a reasonable price. This requirement can be effectively met through the use of data science which includes data acquisition, data management, and analytics to make an informed decision towards improved plantproductivity and plant-efficiency. In order to achieve this milestone, EPC fraternity should work towards providing the projectChemical Engineering World
CEW Features Chemtech EPC Conferences: Recent TimeLine
owner a dataset in the form of digital twin, not in the form of documents. It will enable plant-owners to tuck the operational data right from the beginning. This collected information can then be fed into the digital twin. Machine learning technology can further be applied in the manufacturing state to improve the plant efficiency & productivity, to manage the assets better, and to make a seamless transition of a deliverable project into a manageable product. For creating a digital twin, it is expected that the EPC stakeholders viz. engineering companies, equipment suppliers, technology providers, licensors, and construction contractors along with the project owners to work in tandem.
Block-chain technology – another prime attention grabber: This technology is nothing but the distributed data management to ensure quick and seamless data movement from one entity to another, thus ensuring integrity and security of data at the high speed. Although this block-chain technology has not been applied very extensively so far, it can be implemented
very effectively during the course of project implementation. The ultimate aim for this transformation is to enable the project owner to provide a product, which can be used throughout its life cycle more effectively.
Getting the full value of digitalization: Indian companies are moving towards digitalization, but mostly through disjointed and standalone initiatives. Even though they are good starting points, disjointed initiatives do not ever deliver the full value. To get the full value, starting point should be the platform journey that offers touch-less and lean operation with its user-centric approach. This means the platform serves the users, instead of users using the system. It delivers: • Enhanced productivity • Superior user experience • Embedded process intelligence with intelligent decision support system through analytics and artificial intelligence & • Seamless collaboration In today’s age, most of the companies across geographies tend to look at functional
“4 th industrial revolution is underway and the world is in the process of transforming into the digital world. In line with this trend, manufacturing sector is also moving towards digitalization. Traditionally, the EPC industry has been working on the project delivery in the form of documents such as building 3-D models, B Narayan document-designing, etc. But is this going to Group President (Procurement & Projects), Reliance Industries Limited, and Chairman help us achieve the objective of digitization in Central Advisory Board, the manufacturing sector? Probably not; and Chemtech EPC World Expo 2019. that is where the digitalization of EPC industry can help us achieve this in the future while implementing the projects” 28 • June 2019
optimization. However, for that to happen, seamless collaboration with internal and external ecosystem is of pivotal importance. EPC Industry can leverage digitalization through various value-adding applications viz. BIM (Building Information Modeling), platform journey with open source tools, cloud, mobility, analytics, etc to each individual component of the EPC chain to signify functional productivity enhancement and profitability improvement towards plant lifecycle optimization through the following combination: a. Driving data in document management b. Collaboration with internal & external stakeholders c. Systems & process improvement
Engineering digitization:
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on
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Contextually, these days integrated project management is of prime importance in manufacturing sector as it ensures all the phases are properly sequenced, strung together, and wellcoordinated through apt resource and stakeholder management. It is not only about covering the engineering, procurement, construction, and commissioning phase, but also to bring in the operations and maintenance phase so that the assets can be managed across their lifecycle. In the new digital world, a successfully integrated project management is just not possible without having digitalization enabled EPC 4.0 in place. Today digitalization of a plant is a very big priority for the project-owners. Intelligent information management is on the vogue. To have successfully integrated project management in place, a few very important aspects are to be considered. They are: safety aspects, plant availability, equipment reliability, product quality,
Chemical Engineering World
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CEW Features
Engineering Procurement Construction
(L to R): Mr. Navtej Garewal, EVP - Head of India, Aveva Information Technoloy Pvt. Ltd. ; Mr. A. Srinagesh, Senior Vice President, Project Procurement, Reliance Industries Ltd.; and Mr. Are Follesdal Tjonn , Senior Vice President – Software, Aker Solutions @ the session on Engineering and Integrated Project Management
(L to R): Mr. Bertrand Langlois, Digital Transformation - Onshore / Offshore GBU, TechnipFMC; Mr. Amit Verma, Senior VP & Head of P&C Digital Transformation, Reliance Industries Limited ; Mr.Yatindra Borkar, Vice President-Project Support Asia Pacific and Engineering & Technical Expertise Hub India, A-FTA/S, BASF Chemicals India Pvt. Ltd.; Ms. Inge Wild, Program Manager Digitalization - Linde AG; and Mr. Y.V. Apte, Chief General Manager Engineering & Projects, (Marketing) , BPCL @ the session on
Digitalization in Procurement
(L to R): Mr. Ahmad Abdelrazaq, Executive Vice President, Samsung C&T India Pvt. Ltd.; Mr U. V. Phani Kumar, Chief Executive Officer, Howe Engineering Projects (India) Pvt. Ltd.; Mr. Rakesh Verma, Chief Executive Officer,Simon India Limited; Mr. Suneet Prakash, Head – Group Projects, Aditya Birla Management Corporation Pvt. Ltd.; Mr. S. Anantha Sayana, Chief Digital Officer, Larsen & Toubro @ the session on Digital Transformation
for Construction
(L to R): Mr. Akilur Rahman, Chief Technology Officer, ABB India; Mr. Vinayak Pai, President – Energy, Chemicals and Resources , Jacobs; Mr. B Narayan, Group President (Procurement & Projects),Reliance Industries Limited; and Mr. Sunder Kalyanam, Group Managing Director, Engineering & Construction Growth and Chairman - Petrofac India @ the session on Blue Print for Digital
Success Partners
of
30 • June 2019
all
Value
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Chemical Engineering World
CEW Features “We are at the beginning of the new era of automation technology that unleashes the power of digitalization and creates a new generation of benefits. The first one is towards project standardization: how we can move from mass customization to mass standardization, Mr. Jason Urso Vice President Technology eliminating significant amount of risk towards Honeywell Process Solutions. schedule and cost from our projects by taking advantage of knowledge. The second pillar of opportunity we see is: infinite longevity; because with today’s technology, automation systems should evolve over time-age-and-place, deliver great new benefits but without losing properties that are built into the systems. The third pillar is: opportunity to harness the power of data, to connect it to knowledge, to make that more uniform, and to apply that across the teams and multiple facilities to deliver maximum performance, thus allowing us to sustain maximum throughput” schedule adherence, cost management, etc. However when digitalization in integrated project management is deliberated, the real challenge lies on the fact that it is data driven and how data drives value in engineering and operation. Therefore, it is important to get control on all the data sources in order to embark on plant’s digitalization journey. Blends of interrelated facilitating parameters towards it are: • Integrated digital workflow and engineering solutions through 3D, 4D, 5D systems covering time, cost, and resource dimensions • Application of IoT and smart sensors • Application of big data analytics and advanced algorithms for knowledge management. However, to leverage the full potential of this digital journey, the project owners must be very clear on what they want and how they want that. This has direct impact on efficiency and productivity of the operating plant. Not only that, it saves cost overruns and schedule delays as well.
Procurement – revamping through digitalization: Digitalization of procurement is not only about IT; instead it is more of innovation. It is about optimizing the business matrix, as well as supplementing the procurement and contracting through laying a layer on traditional methodologies. To manage the project complexities, the orientation priorities get changed over the period of time from cost driven to schedule
32 • June 2019
driven, to reliability driven, and then finally to operation driven projects. Therefore, managing these complexities is a critical task and digitalization plays a pivotal role in it. To extend furthermore, it is important to consider the business perspective of India as well as across the globe. India carries the third largest import bills for chemicals, which draws an inference towards a huge growth opportunity. With this context, it is important to bring in innovation and reliability into this whole space. Managing the structural cost in spite of having various issues is on the primary focal point. Application of cloud sourcing and big data analytics, supply chain management, vendor management and order tracking, inventory management, real time integrated schedule management with advanced algorithms, and customer engagement are the quotients to be considered along with the procurement challenges being faced by the PSUs and also the existing governmental policies in force.
Construction – future with digital footprint: Construction is one area where probing of digitalization is so far the least happened and the most required. For almost last 100 years nothing has been changed in the construction site. Therefore the question that has been aroused today is: how to implement the digital tools for construction and how to build the complete cycle of information exchange. Phase-wise implementation of digitalization through the application of smart technology to establish the big data, and then to one-step ahead – construction automation are in real
consideration. BIM, IIoT, drone utilization, 3-D modelling, mapping, etc to oversee the real time project-progress are the enablers. A special emphasis are being put on the productivity analysis towards digitizing the plant & machinery through application of IoT and data analytics, urbanization of work force (skilled craft data), application of big data analytics, and advanced algorithms for resource productivity.
Conclusive take-away: When a user company procures a digitalized project, their ultimate look out in terms of result boils down to safe operation of the project with highest level of efficiency in productivity. Keeping this in mind, the points to really think through are: can these projects be less complicated, highly reliable, and deliverable at a reasonable price? Today quite a few disjointed standalone initiatives are happening in each compartment of EPC industry i.e. engineering, procurement, and construction. However, if they are not properly sequenced and strung together, they will not be able to deliver the full value. To get the full value through the implementation of digitalization, integration across the value chain is a must. Digitalization is presently at a very nascent stage in the EPC industry. Industry uses digital tools to a great extent in engineering & design stage; and their use is slowly picking up in procurement. However, the domain of construction needs attention. Although the digital tools are majorly confined to the engineering design stage, it needs to be emulated in procurement & construction too. The various aspects to be considered with regard to this are: step-bystep procedural sequence establishment for various manufacturing and service industries, strategic adoption for a business to gain competitive edge, digital maturity with the next-level targets, dovetailing the development work through capability need assessment to embrace digital ecosystem, reskilling the workforce towards it, and the associated arenas for EPC companies. A recent survey indicates that the potential to improve profitability of EPC companies is majorly through leveraging the entire digital journey. Companies do not even have the option of not doing it, because not going the digital way will result in huge drop in profitability and sustainability. Digitalization will enable the EPC companies to acquire new business model opportunities through enhanced customer experience. Chemical Engineering World
CEW Features
Digital Transformation Making the Chemical Processes Smart Imagine no routine manual collection of maintenance, reliability, and data integrity with portable testers or time-consuming interpretation. Imagine no delays waiting for an expert to mobilize to site or trying to explain a problem in the field to a supervisor over a telephonic conversation. Instead, data is collected automatically, transmitted digitally, and analyzed by software to detect early signs of problems. Digital Transformation is about changing from manual paper-based tasks to data-driven tasks. This article, written by Mr. Anil Bhatia, Vice President & Managing Director, Emerson Automation Solutions India, acquaints us in depth with the various features of the automated Smart Plant Concept.
M
ost chemical companies have been using sensor technology for decades. However, Digital Transformation represents an entirely new model for how data from these sensors becomes part of the company’s endto-end process. Not only does DX offer optimization of the production process, but it can also improve efficiency, while reducing both energy consumption and operational costs.
makes predictive maintenance possible by providing actionable information, such as abnormal operation or imminent failure alerts. By examining networks real-time to spotting anomalies and taking timely corrective action in applications such as pumps, motors, steam traps, heat exchangers, valves and piping systems, operators can maximize production and improve overall plant reliability, safety, and efficiency.
With advancement in new technologies, such as non-intrusive and wide area sensing along with wireless communications, it is now easier and more cost-effective to add measurement points throughout a chemical plant. These technology-shifts have empowered the development of Pervasive Sensing solutions.
Unscheduled outages and production slowdowns, classified as mechanical unavailability, occur due to common problems such as – rotating equipment failure, exchanger fouling, piping corrosion, and fired equipment constraints. Energy loss occurring from heat exchanger fouling, failed steam traps, and process unit inefficiencies—
Unanticipated fouling in heat exchangers can drive up energy costs and if severe enough, can result in an unscheduled shutdown. Online monitoring of heat exchangers through addition of wireless measurements of temperature and vibration allows you to improve operational efficiency by detecting accelerated fouling early. Pervasive Sensing solutions enable automatic data collection and analytics for applications that were previously either monitored manually or ignored. Enabled with predictive analytics, this technology 34 • June 2019
all of which may go undiscovered from a lack of complete energy measurements. Chemical Plants understand macro energy performance through their Energy Intensity Index. However, determining
exactly where energy is lost in a chemical plant tends to be a typical challenge when driving an energy improvement program. Smart Process or Smart Plant In plants, the basic process control and safety are already automated. Yet, around the plant there are still lots of manual tasks being carried out for supporting functions. Digital Transformation is about changing from manual paperbased tasks to data-driven tasks. This article narrates Smart Solutions for a typical chemical process plant driven by the leading technology providers like Emerson Automation Solutions. Smart Inspection Imagine no routine manual collection of maintenance, reliability, and data integrity with portable testers or time-consuming interpretation. Instead, data is collected automatically, transmitted digitally, and analyzed by software to detect early signs of problems. Overall Equipment health index is also tracked by software. Smart Collaboration Imagine no delays waiting for an expert to mobilize to site or trying to explain a problem in the field to a supervisor over a telephonic conversation. Instead, a twoway digital video and audio between field technician with a wearable camera at site enables an expert anywhere in the world to see the problem up close and live, to provide immediate solutions. Chemical Engineering World
CEW Features Enabled with predictive analytics, Pervasive Sensing solution technology makes predictive maintenance possible by providing actionable information. and maintenance needs etc. Instead, management / operations team receives real-time notes and digital photos of incidents, hazards, leaks, and damaged equipment that are captured on software enabled tablets.
Figure 1 Pump Health Monitoring using Wireless Pressure, Temperature, and Vibration Transmitters
Smart Distress Calls Imagine no walkie-talkie required for distress calls. Instead, automatic detection, digital transmission, and alarm on safety shower activation or mandown, not moving, in operator software and location tracking software help early detection of issues for smoother operations. Digital Safety Checks Imagine no ad-hoc visits to the plant to check if a manual valve was closed or dipping to see if tank is nearly full, and similar safety checks. Instead, automatic detection, digital transmission, and
38 • June 2019
indication in control room software, as well as use in interlocks always ensure a seamless production process. Digital Mustering and Locating Imagine no paper lists and walkietalkie to account for people during emergency evacuation mustering and no search parties required to find missing personnel. Instead, the location of every person is digitally tracked in real-time and automatically tallied in software. Digital Logbook Imagine no paper notebooks for jotting down near miss incidents, hazards,
Application Note #1: Availability Loss – Pump Monitoring For example, consider the light end areas of a chemical plant. Typically, there are 10-15 pumps in a plant that are usually checked manually once in a month for vibration, and bad factors are checked once in a week. With ever-changing process conditions, such manual and sporadic spot inspections are insufficient to detect pump problems and seal failures. In this application, even chemical leaks that take place due to seal failures leading to production loss, fires, and other safety incidents can be avoided. Online monitoring of pumps through the addition of wireless measurement of vibration, pressure, and seal fluid levels allows early detection of excessive vibration, cavitation and seal failure problems. By monitoring and creating predictive alerts,
Chemical Engineering World
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There is no question about the fact that in today’s highly competitive market, chemical plant operators who can quickly adopt innovations like Digital Technologies and Industrial Internet of Things (IIoT) will reap most of the benefits. What leadership will have to ensure is a correct execution
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Most of the heat required by chemical process plants comes from heat exchangers. Unanticipated fouling can drive up energy costs and, if severe enough, result in an unscheduled shutdown to clean bundles or a process slowdown until the next shutdown. Online monitoring of heat exchangers through
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Application Note #2: Energy Saving Example – Fouled Heat Exchanger
we do business. Organizations will start implementing this in a small way and by tasting success, will see the benefit of scaling it up very quickly. Organizations will have to relook their hiring process and upskill existing talent at a very fast pace to optimally handle this transformation.
maintenance staff can be notified of impending problems before they occur. This can lead to improved production through fewer unscheduled outages.
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APRIL-MAY 2017 MUMBAI ` 100
HYDERABAD - 2017
GUJARAT - 2018
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23-25, January 2018 20-23, February 2019 Venue: Ahmedabad, Gujarat, India Venue: Mumbai, India
MUMBAI - 2019
Digital Transformation will have a profound effect on chemical process operations and will transform the way we do business. What leadership will have to ensure is a correct execution strategy with the right processes and organization culture. addition of wireless measurements of temperature and vibration allows you to improve operational efficiency by detecting accelerated fouling early, allowing you to clean your exchangers according to a more optimal schedule. Final Thought: Closing this article with a practical thought viz. Steam Powered Engines revolutionized transportation, – Digital Transformation will have a profound effect on chemical process operations and will transform the way 40 • June 2019
strategy with the right processes and organization culture.
Author Details
Anil Bhatia Vice President & Managing Director Emerson Automation Solutions, India
JASUBHAI MEDIA PVT. LTD. Taj Bldg., 3 rd Floor, 210 Dr. D. N. Road Fort, Mumbai-400 001 Tel.: 91-22-40373636 Fax: 91-22-40373635 E-mail: industrialmags@jasubhai.com
Chemical Engineering World
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CEW Features
Digitalization: the Way Ahead for Chemical Industry On its way to more improved dynamism, Chemical Industry these days has been witnessing a multitude of rapid changes in demand with various orders viz. potential to change value chains, lead to hire productivity and innovation, create new channels to market, and many more. This article comprehensively unfolds how digitalization has become a game changer for the industry.
P
ositioning of the Indian Chemical Industry: Classified amongst the most dynamic businesses of the World, the Indian Chemical industry is one of the largest and most diversified sectors covering over 80,000 commercial products, making it the 6th largest producer of chemicals globally. The prosperity of the chemical industry in today’s booming economy is in tandem with the development of industries like engineering, construction, clothing, automotive, making it the backbone for the growth of the industrial and agricultural sectors. India has been one of the preferred destinations for investment in the chemical industry and this is expected
42 • June 2019
to double to USD 300 billion by 2025, clocking an annual growth rate of 15-20 per cent. In order to reach this target, the government is working on a draft chemical policy, which focuses on meeting the rising demand for chemicals and reducing imports. Apart from investment allowances and tax deductions, the government has drafted a number of schemes to support the development of the chemical industry. To begin with, it permits 100 per cent foreign direct investment (FDI) in the sector. Moreover, manufacturing most chemical products inter-alia covering organic/inorganic, dyestuff and pesticides is de-licensed in the country. Underpinning Challenges the Possibilities: Though
and the
Indian Chemical industry has shown tremendous growth records with a 2.62 per cent increase from 2016-17 to 201718, the industry faces a lot of challenges in terms of availability of raw materials. For Instance, the chief feedstock in India is high priced as compared to the other countries, thus making it difficult for the manufacturers to procure them, and thereby impacting the production. While the country has vast investment opportunities in the sector, imposition of heavy duty tax on various raw materials discourages manufacturing and encourages import. Apart from this, there is a lack of infrastructure facilities in terms of logistics, poor pipeline connectivity, and insufficient power supply making it difficult to source Chemical Engineering World
CEW Features “India has been one of the preferred destinations for investment in the chemical industry and this is expected to be doubled to USD 300 billion by 2025, clocking an annual growth rate of 15-20 per cent. It permits 100% foreign direct investment (FDI) in the sector.” raw materials from various product suppliers in India. However, due to the continuous rise in environmental concerns, there is a high demand for biodegradable polymers, performance plastics, and other value added chemical products. The PCPIR (Petroleum, Chemical and Petrochemical Investment Region) approach by the Government to promote PCP sectors in an integrated and environmental friendly manner has been adopted by several states; and has attracted a lot of investments in the country. Digitalization – a Game Changer: When it comes to an environmentfriendly approach, one concept that has promoted sustainability in the industry is – ‘Digitalization’. Referred to as Industry 4.0, digitalization is being redesigning all facets of the manufacturing industry leading to the next Industrial revolution in the sector. Owing to its potential in offering quick turnaround time and its healthy sync with latest market conditions that improve the supply chain, digitalization has become a vital need. With the rationalized process provided by digitalization, companies are now willing to make heavy investments in key technologies like- artificial intelligence, IoT, robotics, big data, etc – which bring down the time taken for manufacturing by half through efficient product lines. These technologies are improving the business productivity while reducing the worldwide energy consumption, hence making digitalization the key to sustainability and attaining maximum energy efficiency. Digitalization has transformed functions at every level. Using the digitally enabled chemical plants, 44 • June 2019
• Manufacturers are able to optimize production network • Companies are able financial transparency
to
maintain
• Real time control of all processes in supply chain • Improvise productivity and reliability of production lines • Companies are able to integrate better waste management system with improved workforce safety AND • Customers are well informed about the trends and the cyclicality of the market All of the above enables access to greater amounts of in-depth data and new communications technology between systems and operators; smart factories are able to bring a higher level of automation and digitization to the production line and supply chain. Industrial manufacturing in an Industry 4.0 environment enables the provision of better quality, and improved sales results. The Concluding Take-away: Digitalization has been a game changer for companies in transforming the manufacturing processes, through devices being inter-connected, processes being streamlined, and ensuring greater productivity from design & development to services & logistics. The biggest achievement of digitalization in the chemical industry is the evolution and facilitation of a digital manufacturing with better collaboration which leads to improved financial decisions, energy savings and better asset management. Institutions that are quickly adapting to the digital world are
embracing rapid changes and moving towards a mature stage of being energy efficient with the use of technology. The need of the hour is for companies to synchronize their business plans with digital solutions and streamlining functions in the new ecosystem for better efficiency and improved visibility. With a bundle of opportunities for expansion, innovation, and growth in the chemical industry, – digitalization is the key for improving business models, functional excellence, and fulfilling the industry’s rising demands all the while conserving energy and maintaining sustainability. Data-source: http://www.makeinindia.com/article/-/v/ make-in-india-sector-survey-chemicals https://www.ibef.org/exports/chemicalindustry-india.aspx https://www.investindia.gov.in/sector/ chemicals
“The need of the hour is for companies to synchronize their business plans with digital solutions and streamlining functions in the new ecosystem for better efficiency and improved visibility.”
Author Details
Mr. P L Palaniswamy Director Danfoss Drives, Danfoss India Call: +91 8001009289 E-mail: Danfoss.india@danfoss.com Chemical Engineering World
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Ammonia Analyser Maintenance Free Ammonia Measurement Measurement Technique: A Unique Method UV-Vis Spectroscopy after gas stripping Tethys Instruments, SAS manufacture Online ammonia analyser for industrial and municipal waste water application. Tethys ammonia measurement is based on the UV absorption of the ammonia gas after a stripping phase. NH4 converted in to gas phase by addition of NaOH. NH4 is measured in the gas phase through UV Absorption spectroscopy principal. Consequently, the turbidity or colour of the sample has absolutely no influence and measurements can even be carried on activated sludge. It gives exceptionally selective measurement for ammonia without any drift as an automatic zero is performed on each measurement on ambient air. The ammonia gas has a typical periodic absorption spectrum that is analysed using a fast Fourier transform (FFT) that brings an exceptional selectivity. No interference has ever been reported after years of operation on many different applications.
1: stripping pot/ 2: temperature probe/ 3: gas flow cell/ 4: gas pump/ 5: xenon flash lamp/ 6: spectrograph
VALUE SELLING POINTS • Ammonia measurement without influence of other Ion present in sample. • Completely drift free measurement, span calibration is not generally required for long time. • No effect of colour or suspended solid, tested on activated Sludge. • Patented Flow cell allows very high level of suspended solid without clogging. No filtration required on most of waste water application. • Auto cleaning facility available. • Auto zero calibration facility ensures drift free measurement. • Sample is not in direct touch with detector & light source. • Narrow spectrum bandwidth so completely interference free measurement. • Multi parameter possible: For example NH4, COD, BOD, pH, TSS, NO 3, PO 4, OIL, all measurement in one analyser.
46 • June 2019
Chemical Engineering World
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For details contact: TETHYS Instruments 57, Chemin du Vieux Chene, 38240 Meylan-France Tel : +33 4 76 41 86 39 Fax : +33 4 76 41 92 27 Mail : sales@tethys-instruments.com Web : www.tethys-instruments.com
User-Friendly Interface The colour touch screen and intuitive interface makes very easy to test or
configure
the
analyser.
Many
test functions allows to test and troubleshoot quickly a maintenance diagnostic. An acid resistant protection
film on the screen assumes an efficient long term protection.
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Sharplex Horizontal Pressure Leaf Filter For Crude Oil Filtration
T
he crude vegetable oils such as Soyabean Oil, Sunflower Oil, Mustard Oil, Rice Bran Oil from expeller or Solvent Extraction Plant in addition to Glycerides and fatty acids, contains other impurities which may be removed prior to neutralization . These impurities may be grouped as follows :-
• Solid Impurities • Mucilaginous material, phosphates peroxides etc. • Volatile Impurities (Water solvent ether etc.) It is therefore important to remove these impurities prior to purification/refining. If these impurities are not filtered out before refining, following inconveniences are often encountered during the lengthy refining cycle : • Formation of, difficult to process sludge in storage tanks • Higher oil losses during the neutralization stage because fines act as emulsifying agent • Slowing down of the processing cycle
in all cases where neutralization is carried out in centrifugal separators because these are unable to expel the solid materials which rapidly clog the bowls requiring the operation to be stopped for cleaning. As can be easily understood, the solid foreign matter should be separated prior to storage and refining of oil. This operation is technically referred to as ‘Desliming' and though it has world wide acknowledgement as essential step to ensure good keeping properties of the oil. It was hardly ever done because until recently simple, efficient and economical was not available. For this filtration Horizontal Pressure Leaf Filter is found most simple and economical filtration equipment. SHARPLEX has carried out extensive trials with different crude oils. It is observed that with suitable pre-coat material it is very easy to filter out all impurities with Horizontal Pressure Leaf Filter. Moreover SHARPLEX Horizontal
Pressure Leaf Filter are automatic and cake after filtration can be dried by compressed air and dislodged by pneumatic vibrator. Another advantage is you do not require filter cloth at all. Operation is easy allows visual inspection of the filter cake discharge. For crude oil filtration the filter screen has to be carefully selected in respect to the quality of solids present and type of crude oil to be filtered. Our expertise in this application enables us to specify the right type of screen for various oils to be filtered. The actual filter cycle comprises of following steps : • • • • • •
Pre- coating Re-circulation till clarity Filtration Draining Drying the solids Dislodging of cake
The filter cake is subsequently returned to the solvent extraction plant or expellers in order to remove oil as much as possible which is retained in the filter cake. Conclusion • Filtration of crude oil to remove all solid material make downstream processing easier. • The use of totally enclosed, hermetic Horizontal Pressure Leaf Filter will reduce labour and improve house keeping • Lower neutralization losses give more yield of oil. • Lower consumption of bleaching earth during bleaching operation. • Oil can be stored for a long time thus observing high standards of keeping quality. • Incase of lecithin manufacturing, good quality food grade lecithin can be obtained. For details contact: SHARPLEX FILTERS (INDIA) PVT. LTD. R-664, T.T.C. INDUSTRIAL AREA, MIDC, RABALE, NAVI MUMBAI-400701, INDIA TEL.: +91-22-69409850 FAX: +91-22-27696325 E-MAIL: sales@sharplexfilters.com Website: www.sharplex.com
52 • June 2019
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Filter for Carbon Application
S
harplex today is a popular name in filtration equipment’s. We not only supply the equipment but try to understand the filtration in totally and the need of the process. Some degree of compromise is there in terms of ease of operation, maximum possible recovery of the product, maximum filtrate clarity and ease of discharge of the solids from the filter, in order to set right the filtration in various industries once the filter capacity is full. The problems in the filtration are enormous though outwardly it looks to be simple solid-liquid separation.
Sharplex team of technocrats takes special efforts to find out a Candle Filter for carbon separation that gives following distinctive advantages compared to conventional sparkler filter. • Candle filter has a completely enclosed operation. • As all the operations are enclosed G.M.P is achived automatically • Candle filter is available in any suitable area and size. • MOC of candles can be offered in PP/PVDF/SS 304/SS 316/SS 316L for carbon separation
• Candle construction is based on pressure equilibria principle which enables the slurry discharge easier. • The installation at one of the reputed bulk drug manufacturing unit has yielded the result. • Activated carbon of 280 MB value is successfully separated, washed and slurry discharged to the E.T.P. The candle filter is most suitable for carbon separation at any intermediate stage of the process as wide range of cloths are available in India to be selected depending upon conditions of pH and temperature of operation.
• Basic operation infiltration is on pressure side insitu is • Washing possible with mother liquor or water or any solvent • The filter has no moving parts and hence no question of inflammable connection arises in case solvent of inflammable nature is involved in the slurry to be filtered. • Filter discharge is automised for (a) Solid Discharge & (b) Liquid Discharge to the desired place by suitable conveying method. • With properly selected compatible filter cloth hoses fixed on candles and pre-coat of suitable filter aid the filtrate obtained is so clear that no solids traceable by any method 54 • June 2019
For details contact: SHARPLEX FILTERS (INDIA) PVT. LTD. R-664, T.T.C. INDUSTRIAL AREA, MIDC, RABALE, NAVI MUMBAI-400701, INDIA TEL.: +9136921232 To 39 E-MAIL: sales@sharplexfilters.com Website: www.sharplex.com Chemical Engineering World
UNIQUE MODULAR CONCEPT MULTIPLE MEASUREMENT TECHNOLOGY IN ONE ANALYSER RRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRR
Thanks to the Tethys R&D team who invented innovative and unique modular concept for online water analysers which allows integration of various technologies in one analyser. For example, Tethys can offer in one analyser – measurements like COD (UV Spectroscopy), Ammonia NH4 (UV Spectroscopy after gas stripping), Oil-in-water (UV Fluorescence), Phosphate (Colorimetric), Turbidity (Nephelometric), pH, DO, TSS (External Sensor attachment). Kindly visit our company’s official webpage http://www.tethys-instruments.com/MakeYourConfiguration .aspx to make your own configuration.
Application: Industrial Waste Water Municipal Waste Water Surface/Rain Water Drinking Water Industrial Process Water
Tethys Instruments SAS, 57 chemin du Vieux Chêne,38240 Meylan Inovallée - France Phone: +33 (0)4 76 41 86 39 | sales@tethys-instruments.com | www.tethys-instruments.com
Brilliant technology Italian quality Saurus939: The vacuum pump made to live longer. Unique in reliability, performance and consumption.
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Sharplex Tubular Centrifuge for Biodiesel Plants
S
harplex Tubular Centrifuge is extensively used for washing stage in Biodiesel Plants.
For Commercial use Biodiesel must be washed to remove any remaining methanol,
glycerin, catalyst, soaps and other impurities. The Tubular Centrifuge comprises of bowl, specially designed slow acceleration motor and starter. The bowl rotates at 15000 rpm generating a centrifugal force of 16000 times the gravitational force. The liquid mixture to be separated enters the nozzle of the Centrifuge placed at the bottom base. The Centrifugal force acts on the liquid entering and separates the two liquids according to their specific gravities. The lighter liquid forms the inside layer and heavier liquid forms the outside ( Toward wall of bowl ) layer. Since the mixture is entering continuously in the bowl, two phases are discharged continuously from two separate holes provided on the top portion of the bowl. For effective washing, Sharplex Tubular Centrifuge design is modified to give higher centrifugal force. The bowl is rotating at
15000 rpm. Special vapourseal covers are adopted so that vapours will not leak to the atmosphere. For washing stage one SA – 26 model Tubular Centrifuge gives capacity of 1000 kgs/hr. The machine is designed to run continuously. For European countries Sharplex Tubular Centrifuge is supplied with 'CE' marketing. For details contact: SHARPLEX FILTERS (INDIA) PVT. LTD. AN ISO 9001 : 2015 COMPANY R-664, Rabale, M.I.D.C, T.T.C Industrial Area, Thane Belapur Road, Navi Mumbai - 400701, INDIA. Tel:+91-9136921232 up to 39 Email:sales@sharplexfilters.com www.sharplex.com
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To know more about ChemTECH Foundation, Jasubhai Media and other publication and events, please visit our Website – www.chemtech-online.com Thank you, Regards, Mittravinda Ranjan Editor Jasubhai Media Pvt Ltd Tel: +91-22-40373636 (Direct: 40373615) E-mail: mittra_ranjan@jasubhai.com
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Taj Building, 3rd Floor, 210 Dr D N Road Toshniwal Instruments (Madras) Pvt. Ltd. Fort, Mumbai - 400 001 267, Kilpauk Garden Road, Chennai - 600 010. India / Tel: +91 44 26448983 / 8558 Email: sales@toshniwal.net / Web: www.toshniwal.net Tel: 022-4037 3636, Fax: 022-4037 3635 Email: industrialmags@jasubhai.com Branches : Bangalore, Delhi, Hyderabad, Kolkata, Mumbai, Vadodara
CEW Products Processing Machine The laboratory-scale version of the Romaco Innojet VENTILUS V 5 is used for granulating, drying and coating particle sizes from 10 µm to 2 mm. Due to its special design and enhanced processing efficiency, the VENTILUS V 5 allows up to 25 per cent shorter batch times. The homogeneous flow conditions inside the cylindrical product container enable extremely gentle intermixing of the batch. The process air is controlled by the ORBITER booster, an ingenious container bottom consisting of overlapping circular plates. Together with the ROTOJET, the central bottom spray nozzle, the ORBITER booster forms an innovative functional unit that meets all the requirements for linear scale-ups. The air flow bed technology ensures accurate control of the product movement and equally precise application of the spray liquids. The resulting formulations can achieve the required release profile with between 10 and 15 per cent less spray liquid. For details contact: Romaco Group Am Heegwald 11 76227 Karlsruhe Germany Tel: +49 (0)721 4804 0 Fax: +49 (0)721 4804 225 E-mail: susanne.silva@romaco.com
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WDG-V Blowback Analyzer AMETEK Process Instruments has broadened its line of WDG-V Series flue gas analyzers to include a Blowback option for high particulate applications. The WDG-V Blowback, leveraging industry proven zirconium oxide (ZrO2), provides efficient blowback cleaning of the sample probe and filter from an integrated, direct-mounted enclosure. The WDG-V Blowback is ideal for combustion optimization in power and steam boilers (coal, wood waste and heavy oil fired) and is the analyzer of choice for particulate loadings of up to 30 mg/m³. With an integrated sample system, the WDG-V Blowback analyzer is simple and easy to use. By using an existing AMEVision HMI, operators can automate the blowback or perform it manually on the spot. An integrated flow measurement allows for blowback automation on a timed basis (eg, once per hour), at a low flow threshold (eg, 40 per cent flow) or both. Users can also track or hold analogue readings during the blowback period, as needed. The integrated enclosure means that the analyzer can be direct-mounted within a smaller footprint. It also eliminates the need for heated sample lines, minimizing installation time and simplifying air and power lines to single connections. To further reduce maintenance time, the enclosure is designed to allow users to service both the sample probe and filter without removing the analyzer from the process flange. Finally, the WDG-V Blowback is designed for reliability and safety. In addition to the predictive diagnostics and proactive alarms of the WDG-V Series analyzer, the blowback option includes a heated accumulator to preheat the air and prevent condensation within the sample line during blowback. The system shares a self-regulated heater to maintain temperatures within the enclosure and to proactively signal low temperature via a contact alarm output. With its unique engineered design and automation, the WDG-V Blowback brings safety, reliability and serviceability to the forefront of combustion control in high particulate applications. For details contact: AMETEK Process Instruments 150 Freeport Road Pittsburgh, PA 15238 U.S.A. Tel: 412-828-9040 Fax: 412-826-0399. E-mail: sales.info@ametek.com / karla.graves@ametek.com or Circle Readers’ Service Card 02
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CEW Products Decentralised Drive Technology NORD decentralised drive technology is used in many applications throughout the world – including airport technology, where for example it contributes to the smooth operation of baggage handling systems. Innovative inverters with integrated PLC perform functions close to the drive and reduce the load on the higher level control system. The drive components have a power range of up to 22 kW and can be supplied with all commonly available plug connectors. They can be freely configured and adapted to any application. Thanks to the PLC which is integrated into the inverter, the decentralised drives can form master-slave groups, which communicate with each other and assume control tasks independently. The PLC processes the data from sensors and actuators and can autonomously initiate control sequences, as well as communicating drive and application data to a control centre, networked components or to cloud storage. This allows continuous condition monitoring and therefore forms the basis for predictive maintenance concepts as well as optimum plant dimensioning. For details contact: NORD DRIVESYSTEMS Pvt Ltd 282/2 & 283/2, Plot No: 15, Village Mann Tal: Mulshi, Adj Hinjewadi MIDC Phase II Pune, Maharashtra 411 057 Tel: 020-39801217 Fax: 91-020-39801416 E-mail: monika.mishra@nord.com / pl.muthusekkar@nord.com or Circle Readers’ Service Card 03
TwinCAT IoT Communicator The TwinCAT IoT Communicator makes it easy for PLCs to communicate with mobile devices by connecting the TwinCAT controller directly and securely to a messaging service through TLS encryption. For smartphone and tablet users, the associated IoT Communicator App ensures that process data can be represented on all mobile devices in a clear overview. Alarms are sent to the device as push messages. The TwinCAT 3 IoT Communicator exchanges data using a publish/subscribe mechanism. Since no special firewall settings are needed, integration into an existing IT network is easy. Information is exchanged via a message broker that uses the standardised MQTT protocol and acts as a central messaging service in a cloud or local network. A high level of communication security is guaranteed by proven TLS encryption (up to Version 1.2). Transmitted process data can be displayed on mobile devices using the IoT Communicator App, which is available for both Android and iOS operating systems. The IoT Communicator App also incorporates an integrated QR code scanner to facilitate entry of access data for communication between the broker and individual users. The TwinCAT IoT Communicator simplifies the transmission of push messages. It offers a number of advantages over conventional e-mail and SMS messages by visualizing live data, variables and status values. This makes the IoT Communicator an ideal addition to the related TwinCAT IoT and TwinCAT Analytics software products. For details contact: BECKHOFF Automation Pvt Ltd Suite 4, Level 6, Muttha Towers Don Bosco Marg, Yerwada Pune, Maharashtra 411 006 Tel: 020-40004802 Fax: 91-020-40004999 E-mail: a.phatak@beckhoff.com
60 • June 2019
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CEW Products Filtration Unit
Future-oriented Packaging Concepts This filtering unit provides double filtering for oil and diesel fuel and absorbs any water and impurities. The unit features a supply and suction pipe with integrated bottom valve.
It has a sturdy wheeled structure; large wheel diameter ; flow rate 56 l/min; filtering capacity – first stage 30 µ with water absor ption, second stage 5 µ for impurities; flow rate up to 56 l/min; two step filtration; continuous AC operation 230 V; and duty cycle 30 min DC version. For details contact: Toshniwal Hyvac Pvt Ltd 267 Kilpauk Garden Road Chennai 600 010 Tel: 044-26445626 /8983 E-mail: sales@toshniwal.net or Circle Readers’ Service Card 05
The desiccant specialist will, amongst others, offers its drop-in solutions for moisture-sensitive pharmaceuticals. The AdPack desiccant sachets made of Tyvek offer an ideal combination of moisture protection, breathability and durability. The desiccant capsules AdCap combine the advantages of conventional desiccant capsules and canisters. They make sure that moisture or odours are optimally adsorbed right after filling. According to demands, they are available with silica gel, molecular sieves, activated carbon or combinations. Sanner offers the broadest portfolio of plastic tubes and closures for effervescent tablets worldwide. For details contact: Commha Consulting GmbH & Co KG Annette Crowther Poststraße 48 69115 Heidelberg Germany Tel: +49 (0) 6221 18779-27 E-mail: sanner@commhaconsulting.com or Circle Readers’ Service Card 06
Fire-resistant Shelters Novel outdoor equipment shelters from Intertec Instrumentation have been chosen to help a leading European chemical manufacturer to upgrade its distributed plant control system. Constructed using unique composite GRP (glass fibre reinforced polyester) materials, four Intertec shelters will provide advanced fire-resistance properties. This attribute will simplify the housing and protection of electronic control and instrumentation equipment at optimised satellite locations within the processing plant. Additionally, the GRP-based fabrication materials significantly reduce the weight of the shelters compared with traditional metal- or concrete-based constructions. In this application, this weight reduction will allow the plant operator to further optimise the positioning of the control system by mounting three of the shelters at height on steelwork frames. The shelters offer F60-rated passive fire-resistance, providing a barrier to fire spread for 60 minutes. This is achieved by means of a unique composite material that combines GRP sheets with embedded layers of mineral wool. The shelters provide large interior floor areas up to 55 m2 (5 x 11 m). To help speed this plant upgrade project, Intertec is providing the plant buildings fitted with lighting, a raised floor to accommodate cabling, and ducting for the cooling air with a sophisticated downflow cooling system to protect the electronics equipment. For details contact: Intertec Instrumentation Pvt Ltd B-535 Taimoor Nagar Gurudwara Road New Friends Colony New Delhi 110 065 Tel: 011-41628183 E-mail: india@intertec.info or Circle Readers’ Service Card 07
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Products CEW Thermal Mass Flow Meter Thermal Mass Flow Meter is accurate, easy to install, having no moving parts and best suitable solution for measuring and controlling compressed air, oxygen, nitrogen, biogas, digester gases, ethane and natural gas flow. Heat dispersion (mass flow) technology provide proportional mass flow measurement resulting in higher accuracy performance at a lower cost than orifice flow meter, Vortex shedding flow meter and other gas flow measuring devices. The thermal principle operates by observing the cooling effect of a gas flow as it passes over a heated transducer. The temperature sensor monitors the actual gas temperature whilst the heater transducer is maintained at a constant differential temperature by caring the required current from electronic to maintain the differential temperature. Greater the flow, greater will be cooling effect and power required to maintain the differential temperature. The energy required maintaining this temperature differential is directly proportional to the mass flow rate. Thus, there is no need for additional temperature or pressure compensation in thermal mass flow meter. This meter is also used for compressed air flow measurement. For details contact: Process Control Devices Plot No: 22, Rautara Indl Estate B/s Hanuman Hotel, Shil-Mahape Road Shilphata, Thane, Maharashtra 400 612 E-mail: sales@pcd-flowmeter.com / sales.pcdpl@gmail.com
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Industrial Gear Unit Robust, high load capacity and long life – Industrial gear units by NORD DRIVESYSTEMS move agitators, mixers and grinders. Two additional sizes as well as extruder flanges supplement the modular series and provide new solutions for heavy duty applications. MAXXDRIVETM industrial gear units by NORD DRIVESYSTEMS are characterised by high power density, quiet operation, and top reliability. Large rolling bearings ensure extremely high axial and radial load capacities and a long service life. The technological heavyweight drives also offer a modular, flexible design as well as varied mounting options. This makes the robust helical and bevel gear units in one-piece UNICASE housings ideal for a great number of heavy duty applications. On the basis of the industrial gear units, NORD plans complete drive systems for heavy duty operation with motors and drive electronics, for tasks including conveyor technology, pumps and agitators. NORD now extended the successful series of industrial gear units: Two new sizes, 5 and 6, extend the previous range with rated torques of 15 kNm and 20 kNm. Offering a total of 11 sizes, the drive specialist now covers a torque range from 15 to 250 kNm. All options of the previous range are available for the new types as well. In addition, NORD has supplemented sizes 5 to 11 (rated torques from 15 to 80 kNm) of its modular series with extruder flanges. Users benefit from generously dimensioned thrust bearings which easily absorb process forces and ensure a long service life. The “extruder flange” option can be customised to the customer’s shaft and optimally matched to the customer’s demands with several bearing variants. Offering many options for input and output shafts, mounting, seals, and monitoring (temperature, vibration, etc), NORD’s extensive range of industrial gear units provide a high level of flexibility for designing demanding applications. NORD is the industrial gear unit manufacturer with the world’s largest industrial gear units in a UNICASE housing. For details contact: Getriebebau NORD GmbH & Co KG Getriebebau-Nord-Straße 1 22941 Bargteheide/Hamburg Germany Tel: +49 45 32 / 2 89 -0 Fax: +49 45 32 / 2 89 -22 53 E-mail: pl.muthusekkar@nord.com / Joerg.Niermann@nord.com or Circle Readers’ Service Card 09
Chemical Engineering World
June 2019 • 63
CEW Products
Antistatic Silicone Tube
Anti-static Silicone Tubing
Anti-static Silicone Tube
Anti-static silicone tubing a nontransparent colour (milky white or black) is specially developed to remove static electric charge while transfer of flammable fluid. Used for flammable solvent transfer peristaltic pump application.
Anti-static silicone tube complies with FDA 21 CFR 177.2600. It has anti-static properties to dissipate charges through rubber surface and volume and is used for flammable solvent transfer and peristaltic pump application. It has nontransparent colour (milky white or Available in 60 Shore A 70 Shore A hardness orAntistatic as per andFDA is 21available in 60 Shore A and 70 Shore A hardness or Silicone Tube is black) complies with CFR 177.2600. Antistatic properties to dissipate requirement. Anti-static tubing is successfully testedcharges for food through rubber surface & volume. It is used for flammable solvent transfer & peristaltic as per requirement. It is sterilisable by using different techniques pump application. It has non-transparent color (milky white or black). It is available in 60 Shore A & grade FDA 21 CFR 177.2600 test. Specially developed Static 70 Shore A hardness or aslike per autoclaving, requirement. It is ethylene sterilizable byoxide using different techniques like and gamma radiation. It is available Autoclaving, Ethylene Oxide and Gamma Radiation. It is available with FDA compliant color coding Dissipative Formulation (10 7 to 10 9 Ω-cm). with FDA compliant colour coding for ease of identification and is for ease of identification and custom dimension, hardness & length size also available. It has anti-static properties to dissipate charges through also available in custom dimension, hardness and length size. rubber surface volume. Ami Polymer Pvt. Ltd. For details contact: AmiOpp. Polymer Pvt Ltd 319, Mahesh Industrial Estate, Silver Park, Mira-Bhayander Road, Mira Road (E), Thane For details contact: 401104, Maharashtra. INDIA 319 Mahesh Indl Estate Ami Polymer Pvt Ltd Tel.: +91 22 28555 107 / 631Opp: / 914 | Silver Cell: +91 86910 Park13935 319 Mahesh Indl Estate, Opp: Silver Park Mira-Bhayander Rd Email: mktg@amipolymer.com | Web: www.amipolymer.com Mira-Bhayander Rd, Mira Road (E) Mira Road (E) Thane, Maharashtra 401 104 Thane, Maharashtra 401 104 Tel: 022-28555107, 28555631, 28555914 Tel: 022-28555107, 28555631, 28555914 E-mail: mktg@amipolymer.com E-mail: mktg@amipolymer.com or Circle Readers’ Service Card 10
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Hygienic Aluminium Drives The innovative nsd tupH surface treatment by NORD DRIVESYSTEMS makes aluminium as corrosion-resistant as SS. The nsd tupH surface treatment is an outstanding anti-corrosion treatment for gear units, smooth motors, frequency inverters and motor starters in washdown-optimised cast aluminium housings. It produces a protective layer which is permanently bonded to the substrate material and makes gear units with aluminium housings as robust and durable as SS versions. In contrast to painting or coating, nothing can detach or flake-off. Damage remains locally restricted and does not spread. The surface is easy to clean and largely resistant to acids and alkalis. Even the use of high pressure cleaners or contact with many aggressive media is possible, so that nsd tupH drives are therefore an efficient alternative to painted geared motors or SS versions. In contrast to SS drives offered in only few variants, the nsd tupH surface treatment is feasible for almost all NORD aluminium products. For nsd tupH aluminium drives all DIN and standard components, including drive shafts, are made from SS. The fanless smooth surfaced motors prevent the spreading of germs and run very quietly. They are available as synchronous and asynchronous motors and comply with Efficiency Classes IE2, IE3 and IE4. NORD drives with nsd tupH comply with FDA Title 21 CFR 175.300 and are therefore suitable for food applications. They have been successfully tested according to ASTM D714 (blistering), ASTM D610-08 (corrosion), ASTM D1654-08 according to DIN EN ISO 2409 (scratching), ASTM B117-09 according to DIN EN ISO 9227 (salt spray test) and ASTM D3170 (Gravelometer). In addition, their resistance to cleaning agents which are commonly used in the food industry has been confirmed in tests. For details contact: NORD DRIVESYSTEMS Pvt Ltd 282/2 & 283/2, Plot No: 15, Village Mann Tal: Mulshi, Adj Hinjewadi MIDC Phase II Pune, Maharashtra 411 057 Tel: 020-39801-217 Fax: 91-020-39801-416 E-mail: monika.mishra@nord.com / pl.muthusekkar@nord.com or Circle Readers’ Service Card 12
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Products CEW Air Coolers and Air Chillers Air coolers and chillers of the following types are offered by Reliable Thermocraft: water cooled finned air coolers, finned air cooling coils; chilled water cooled finned tube; brine cooled finned air coolers (cooling coils); glycol cooled air coolers (finned cooling coils). Cooling of air may be necessitated when air is being re-circulated over equipment getting heated up during operation. Air coolers are used to cool air for cooling of large motors, alternators and generators. Air chiller is used to cool air to a temperature low enough to condense out the moisture to achieve required relative humidity suitable for use in dryers after heating the chilled air. Our designs and construction is compact and economical even where the LMTD is low. Wire-wound fin tubes are used for making the finned air coolers and chiller coils. This makes these heat exchangers compact, economical with lower pressure drops. Base tubes of carbon steels, copper and copper alloys, SS-304 and SS-316 and other SS grades finned with galvanized mild steel, copper and SS fins are used in fabrication of air cooled condenser. The body material used so far is carbon steel and SS. For details contact: Reliable Thermocraft S No: 81/82, Plot No: 18, MIDC, Ambad Nashik, Maharashtra 422 010 Tel: 0253-6628665 E-mail: works@reliablecrafts.com or Circle Readers’ Service Card 13
Level Transmitters AMETEK Drexelbrook has expanded its open-air radar level offering with the addition of the DRX400 (24 GHz) and DRX500 Series (80 GHz) level transmitters. Both incorporate state-of-the-art features and components. The DRX400 Series consists of 3 new Models (DR5400, DR6400 and DR7400). This set of 24 GHz radar transmitters covers a broad range of applications including liquids and solids. These products will be replacing the Drexelbrook DR7000 and DR6300 open-air radar models. The DRX500 Series consists of 3 new models (DR3500, DR6500 and DR7500). This set of 80 GHz radar transmitters covers applications with liquids, slurries and solids for both hygienic and non-hygienic requirements. All 80 GHz radar transmitters are especially beneficial for level measurements in narrow tanks with internal obstructions due to their small beam angle. The DRX500 transmitters, with its flush-mounted polyether ether ketone (PEEK) lens antenna and wide process connection options, is ideal for hygienic liquids. Both series products feature a large, backlit LCD screen with 4-button keypad that can be assessed with a bar magnet without opening the housing cover. Each uses software that has a quick set up assistant for easy installation. Each conforms to NAMUR recommendations NE 21, NE 43 and NE 53 and can measure fast-moving processes. The transmitters are available with aluminum or SS housings. Radar is among the most accurate technology choices for process level and storage tank applications for continuous level measurement under demanding conditions. All of these transmitters utilize Frequency Modulated Continuous Wave (FMCW) technology that offers superior signal processing capabilities and a more reliable measurement than other techniques. The state-of-the-art signal processing capabilities of these transmitters, along with their frequency range helps to ensure optimum application coverage. Both additions to the DR Series measure distance, level and volume of liquids, slurries and solids. They also offer an empty spectrum function that filters false reflections caused by equipment and other tank obstructions. AMETEK Drexelbrook’s level measurement instruments are used in a wide range of industries, including petroleum, chemical, petrochemical, food/beverage, water/wastewater, power, pharma, pulp/paper, mining, aggregates, feed/grain among others. For details contact: AMETEK Drexelbrook 205 Keith Valley Road, Horsham, PA 19044, U.S.A. Tel: 215-674-1234, Fax: 215-674-2731 E-mail: drexelbrook.info@ametek.com / bob.irving@ametek.com or Circle Readers’ Service Card 14
Chemical Engineering World
June 2019 • 65
CEW
NATIONAL Expo Paint &Coatings
ENGIMACH
Dates: 10-12 July 2019 Venue: Pragati Maidan, New Delhi Event: This event provides a platform to the needs of every facade of
Dates: 04-08 December 2019 Venue: The Exhibition Centre, Gandhinagar, Gujarat Event: ENGIMACH is a leading engineering and machine tools
the coating industry right from raw materials, formulation, application, technology, finishing, quality assurance, recycling and disposal. The exhibition will feature a wide range of products, raw materials, application systems, machines, tools, current trends, development and innovations shaping the future of coating industry. This expo will bring together leading local and international manufacturers, formulators, buyers, industry professionals, consultants, enthusiasts and prospective entrants from the paint and coatings, surface finishing and allied industry presenting unrivaled opportunities to network, exchange best practices, do business, unveil new products and source cutting-edge product and technologies. For details contact: Toredo Fairs India Pvt Ltd 16/1, 1st Floor, 2nd Cross Mission Rd Srinivasa Colony Bengaluru Karnataka 560 027
show and showcase engineering products and services, heavy and light machines, machinery equipment and accessories, tools and par ts, technological devices and products, engineering tools and allied products and services. It is the most trusted machines and tools show that exhibits latest products and services, latest innovations and technologies. It is an ideal event that witnesses the best buyer and seller par tnership and is a dynamic platform. For details contact: K And D Communications Ltd Kailash-A Sumangalam Society, 3rd Floor Above HDFC Bank Opp: Drive-In Cinema Bodakdev Ahmedabad, Gujarat
Machine Tool Expo
Dates: 8-11 August 2019 Venue: India Exposition Mart, Greater Noida Event: This event is a address the manufacturing requirements
of the OEMs of various industry sectors in Tier II and Tier III cities of India. It will cover the entire gamut of metal working machine tools for both metal cutting and metal forming including automation and robotics, tooling systems, CAD/CAM and other technologies essential for today’s manufacturing.
INTERNATIONAL
For details contact: Indian Machine Tool Manufacturers’ Assn Bangalore International Exhibition Centre 10th Mile, Tumkur Road, Madavara Post Bengaluru, Karnataka 562 123 Tel: 080-66246600, E-mail: imtma@imtma.in Pharma Tech Expo
Dates: 20-22 August 2019 Venue: Gujarat University Convention and Exhibition Centre (GUCEC), Ahmedabad
Event: PharmaTech Expo 2018 & LabTech Expo 2018 is an
International Exhibition on pharma machinery, lab, analytical, pharma formulations, nutraceutical and packaging equipment. This will give oppor tunities to suppliers, manufacturers, industrialists, entrepreneurs, buyers and consultants to assemble at this common platform. The focus will be on the Pharmaceutical Formulations, Nutraceuticals, API’s, Cosmetic and Ayurveda sector. For details contact: PharmaTechnologyIndex.com Pvt Ltd 701-702 Corporate House Nr Dinesh Hall, Income Tax Ashram Rd Ahmedabad, Gujarat 66 • June 2019
International Exhibition of Chemical Industry and Science
Dates: 16-19 September 2019 Venue: Expocentre, Moscow, Russia Event: This event will display products like raw materials for the chemical and petrochemical industry, and inorganic chemistry, refining and petrochemicals, fuels, lubricants, organic synthesis, small volume chemicals, chemical fibers and yarns, composite materials, fiberglass, household chemicals, perfumes and cosmetics, reagents, catalysts, film photographic, magnetic media, design of chemical plants, warehouses, terminals, personal protective equipment, tools fire and explosion, chemical production management, transportation of chemicals and petrochemicals, logistics solutions, containers and packaging, chemical technology, research and more For details contact: Expocentre Krasnopresnenskaya nab 14 Moscow, Russia, 123100 Chemical Engineering World
Project Update New Contracts/Expansions/Revamps The following list is a brief insight into the latest new projects by various companies in India.
CHEMICALS Shalimar Paints lays down the foundation of its Nashik manufacturing plant with a planned monthly production capacity of 2,180-kilolitres. Set to commence operations by April 2019, Shalimar's state-of-the-art Nashik facility will increase the brand's overall production capacity by 65 per cent. It is also expected to stimulate the local economy by creating around 200+ employment opportunities for prospective jobseekers in the region. The newest Shalimar plant hints at the brand's aggressive push to capitalise on the growing market demand for its high-quality, high-performance paint and coating products, as well as to further consolidate its position as one of the fastest growing paints companies in the country. Shalimar has also pledged further investment into its Nashik plant and aims to establish it as a key component within its regional distribution network, as well as its pan-India supply chain. The paint industry has been growing at a rapid rate in India and measures between 1.5 to 2 times GDP growths. Rapid urbanization, better transparency and consumer evolvement has been leading the growth of the industry. Songwon Industrial Co Ltd a specialty chemicals company of South Korea has launched its new pilot plant in Panoli (Gujarat), thereby strengthening the organisation’s overall specialty chemicals development capability. Built on Songwon’s Indian site with all the necessary main unit operations, the new plant is equipped with the most up-to-date technologies and materials for producing a wide range of chemicals for a broad spectrum of applications - from one kilo up to several hundred kilo samples. To reinforce the organisation’s position in existing areas of business and enhance its ability to enter new areas, the new pilot plant will be supported by the Songwon’s strong local R&D team in Panoli, as well as its central technology innovation center located in Maeam, Korea. Insecticides (India) Ltd has announced a ` 200-crore expansion plan to increase its capacity in the next three years. In the first two years, it would spend about ` 100-crore, followed by an investment of ` 100-crore in 2020. The firm is planning to set up an Export Oriented Unit in Gujarat with an eye on increasing export component of the business. Exports contributed about ` 35-crore in the total turnover of ` 1,109-crore in 2017-18. The firm has a share of about 5 per cent in the ` 18,000-crore crop protection market in the country.
MINING MOIL recently said production at its Parsoda manganese mine is expected to begin soon. The mine will be operated by opencast mining method. MOIL has been granted mining lease of Parsoda manganese mine near village Parsoda, 46-km from Nagpur in the year 2016. The lease extends for 50 year period, ie, from April 22, 2016 to April 21, 2066 and the project cost is estimated to be ` 19.54-crore. The production is expected to be started soon. MOIL, Chemical Engineering World
under the Ministry of Steel, operates around 10 mines, including six in Maharashtra and four in Madhya Pradesh. Balaghat mine is its largest, which produces top quality manganese ore. Hindustan Copper Limited held a groundbreaking ceremony at Ghatsila Unit for construction of concentrator plant at Rakha, initiating Chapri-Sidheswar mine, a new mine development and Rakha mine re-opening projects. CMD informed that considering the opportunity to further increase the resource base of copper mineral in the State has finalized plan to undertake depth exploration up to 1,000-meter from surface in its existing lease area in next two years. Hindustan Copper Limited, the only copper mining Company in India, in its Unit located at Ghatsila has planned to implement total five mine expansion projects to increase the mine capacity from current 4.0 to 72.0-lakh tonne. Successful implementation of the project will also reduce country's dependence on imported copper concentrate. Coal India (CIL) is expected to put another 25-30 million tonnes (MT) of coal under the hammer in the ongoing quarter. This comes after e-auction volumes dipped following the decision to pump more coal into the coal-starved power sector through fuel-supply agreements (FSAs). The coal behemoth has been able to book 54-MT of coal through e-auction till December (first three quarters) as against 79-MT in the similar period of the last fiscal year, registering a 31.65 per cent dip. On the other hand, its offtake via the FSA route to power plants increased by over 12 per cent. As more coal gets routed via the FSA route, e-auction volume will be low. Production in January-March was expected to be substantial, which will leave Coal India with more to offer in auctions. It is expected that another 25-30 MT of coal will be offered this quarter on the auction platform. South Eastern Coalfields (SECL), its most important subsidiary, registered a 13.1 per cent fall in production in December at 12.52-MT while Mahanadi Coalfields, the second-largest subsidiary, registered a 3.2 per cent dip at 13.05-MT. These two subsidiaries account for more than 45 per cent of Coal India’s production. Sales were low at 52.77-MT, which is a 1.2 per cent fall compared to December 2017-18. However, in the next fiscal year, the e-auction volumes are expected to dip further. E-auctions directly add to Coal India’s bottom line because the prices are often higher by at least 60 per cent over the notified price. Thus, effectively while the miner spends the same amount of money to mine the coal which is either sold as linkage or put under the hammer, it earns 20 per cent higher in auctions. Prices in the e-auction, however, are expected to remain stagnant in the ` 2,400 a tonne level backed by muted global coal prices. According to S&P Global Platts, the price of FOB Kalimantan 4,200-kilo calorie per kilogram GAR (gross as received) - which is imported in huge volumes by both India and China - has declined almost 22 per cent since October 1, given the sagging demand in China and improving supply in Indonesia.
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CEW
CEW
Project Update NTPC Ltd hopes its captive coal production will reach 100-million tonne as soon as its five coal blocks commence operations, aided by faster regulatory clearances and the part-privatization model of Mine Development and Operator (MDO). The success of the plan would determine fuel security of the operations of India's largest power producer. Coal India aims to raise output from its troubled Rajmahal mine in Jharkhand to 60,000 tonnes a day, having resolved land-acquisition related problems which had crimped production to 20,000 tonnes per day. Coal from the Rajmahal mine helps NTPC run close to 4,200MW of power generation plants in eastern India, which supply power to Bihar, Jharkhand and West Bengal, and also to northern India including Delhi and Uttar Pradesh. NTPC’s generation capacities were faced with depleting coal stocks and lower power generation as supplies from Rajmahal dwindled. Reserves at Rajmahal within the land acquired by Coal India were almost exhausted and required expansion to keep production levels intact. However, land acquisition at two villages - Bansbiha and Taljhari - spanning 160-hectares, adjacent to the existing project turned out to be a lengthy process. It led to drastic fall in supplies and stocks at the coalfield, as well as at two critical power plants in the region - at Farakka and Kahalgaon. At present, Coal India is using 15 goods trains to transport coal from the Rajmahal mine to power stations in the region. One goods train can load up to 3,500 tonnes of coal. Coal India is also sending five loaded goods trains from West Bengal’s Ranigunj coalfields to augment supplies at power stations. At present, the entire production from Rajmahal is getting delivered to power plants and there has been no stock buildup yet. CIL, ONGC to produce coal-bed methane from 10 new mines: The Coal Ministry has identified 11 mines to produce coal bed methane (CBM). Of these, 10 will be worked on jointly by ONGC and Coal India Ltd (CIL). The two entities will also work on one mine with SAIL. Initially, ONGC will harness the gas and then CIL will extract coal from them. In addition to the mines with CIL, the two (ONGC and CIL) will also help develop Steel Authority of India Ltd’s Parbatpur coal block (Jharkhand). Here too, ONGC will first harness the CBM. SAIL had surrendered the Sitanala and Parbatpur coal mines. In its representations while surrendering the Parbatpur mine, SAIL had said there was a reduction in the area available for coal mining due to overlapping of mining area. SAIL had engaged MECON to prepare a techno commercial viability report, which declared the project unviable. The SAIL board had then decided to return the Parbatpur mine to the Coal Ministry. JSW Energy, part of the Sajjan Jindal-led JSW Group, is believed to be in the race for buying out the thermal power assets of Monnet Power and Jindal India Thermal Power Ltd (JITPL) in Odisha. Monnet Power’s 1,050-MW coal-based power plant near Angul was in advanced stage of commissioning. Monnet Power’s parent company, Monnet Ispat & Energy had won the Mandakini coal block in Odisha in competitive bidding, it surrendered the block later on grounds of economic unviability. Monnet Power had accumulated 68 • June 2019
debt in excess of ` 5,000-crore. Though lenders had earlier denied a haircut in JSW Energy’s prospective deal to acquire majority equity in Monnet Power, the Sajjan Jindal-owned firm is still believed to be in the hunt for the asset. Besides Monnet Power, JSW Energy is also eyeing takeover of BC Jindal controlled JITPL’s 1,200-MW coal-based plant at Derang near Angul. The first unit (600-MW) of the 1,200-MW plant had begun commercial operations and started power supplies to the Odisha grid. This project has been completed at a cost of ` 7,537-crore which includes a debt component of ` 5,900-crore. JITPL has power purchase agreements (PPAs) with Odisha’s Gridco Ltd, Kerala State Electricity Board and Tata Power Trading Corporation. Apart from JSW Energy, JITPL also had competing offers from Adani Power and Singapore’s SembCorp. The valuation of the prospective deal is not known. NLC India (formerly Neyveli Lignite Corporation) which is in the hunt for buying out power assets, is understood to have shown interest in the 700-MW Odisha plant of Hyderabad-based Ind-Barath Power Infra Ltd (IBPIL). The power plant located at Sahajbahal, near Jharsuguda, has commenced commercial operations. Though the exact size of the potential deal is not known, the valuation could be anywhere in the range of ` 5,000-5,500-crore. In August last year, NLC India had floated an Expression of Interest (EoI) from companies owning coal and lignite-based power projects, for a possible acquisition. NLC India’s installed thermal power capacity is 3,240-MW. It runs a 10-MW solar power unit and wind power assets with a capacity totalling 37.5-MW. Western Coalfields has received the environment clearance for its ` 263-crore expansion project in Nagpur district, Maharashtra. The proposal is to enhance the production capacity of the Gokul open-cast mine to 1.875-million tonnes per annum (MTPA) from the existing 1-MTPA. The mine, located in 767.17-hectare, has a mineable reserve of 14.50-million tonnes. The clearance to the project is subject to certain conditions. Total cost is estimated to be ` 263-crore. Among the conditions specified, the company has been asked to get 'Consent to Operate' certificate from the State Pollution Control Board for the existing production capacity of 1-MTPA and also the 'Consent to Establish' for the proposed capacity of 1.875-MTPA prior to enhancing the production capacity. With regard to transportation of coal, the company has been asked to carry out by covered trucks and take mitigative measures to control dust and other fugitive emissions all along the roads by providing sufficient numbers of water sprinklers. The company has been informed to adopt controlled blasting techniques to control ground vibration and flying rocks. It has also been told to implement a progressive afforestation plan covering an area of 376.04-hectare at the end of mining. Of the total quarry area of 231.73-hectare (on floor) and 291.21-hectare (on surface), the backfilled quarry area of 115.39-hectare should be reclaimed with plantation and there will be no void left at the end of the mining operations. The land after mining should be restored for agriculture purpose. Chemical Engineering World
Book Shelf CEW Chemical Process: Design and Integration Author: Robin Smith Price: USD 68.64 No. of Pages: 896 Publisher: John Wiley and Sons Limited About the book: Author Robin Smith is a highly regarded personality with a prolific length of industrial and academic experience. This book provides a practical guidance for Chemical Engineering students and researchers. The book discourses in length about the process economies, optimization, separation, chemical reactors, distillation, heat exchange, batch processes, heat integration, steam system and cogeneration, environmental design for atmospheric emission, environmental sustainability in chemical production, process safety and many other associated topics. The book also includes a companion website for students which provides worked out solutions for problems and also the Excel spreadsheets to enable students to carry out complex calculations.
Value Creation: Strategies for the Chemical Industry Editors: Dr Florian Budde, Prof Dr Utz-Hellmuth Felcht, Dr Heiner Frankemölle Price: USD 107.52 No. of Pages: 467 Publishers: Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim About
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the in
industry
in adequate length and breadth. Starting from drawing on extensive first-hand management experience, to several hundred consulting engagements, and in-depth
Bow Ties in Risk Management: A Concept Book for Process Safety
research projects, the book is structured with the
Author: Centre for Chemical Process Safety (CCPS)
key ingredients of managing chemical companies
Price: USD 104.62
successfully with a detailed addressing in key
Number of Pages: 180
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Publisher: A joint publication of the American Institute of Chemical Engineers and John Wiley & Sons, Inc.
best practice in the core functions of chemical
About the Book: This book is a joint effort of Centre for Chemical Process Safety (CCPS) and Energy Institute (EI); and explains the effectiveness as well as the implementation of Bow Tie analysis, a qualitative risk management and barrier management methodology. Bow Ties in Risk Management clearly shows how bow tie analysis and diagrams fit into an overall process safety and risk management framework across an organization and across the industry. The book explains the proven concept of bow tie barrier analysis for preventing and mitigating the incident pathways, especially related to major accidents; shows how to avoid common pitfalls and is filled with real-world examples. The book caters to all involved in process safety, environmental and enterprise risk management applications. It covers a wide audience – both the beginners and the experienced professionals.
many more. The book treatises share-holder
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business system, post-merger management, and value orientation, structural drivers of value creation, driving innovation, today’s challenges and strategic choices, determining approach of commodity chemical business, opportunities and challenges of emerging global petrochemical hub in the Middle-East, special perspectives on specialty chemicals, prospects for agribusiness, and many more associated topics. The book mainly caters to the executives and managers belong to the chemical industry. However, the comprehensive knowledge will also benefit scientists, engineers, investors, students, and anyone else dealing with management issues in this sector.
June 2019 • 69
Exclusive Interview CEW Interview
‘Drive towards Automation reduces Cost of Manufacturing and offers Huge Opportunity to Develop Technologies’ Andy Postlethwaite Senior Vice President - Performance Materials, BASF Asia Pacific; Chairman & Director on the Board of Directors, BASF South East Asia Pte Ltd
Industry 4.0 and the exponential growth of disruptive technology means that manufacturers, suppliers, distributors, and retailers are looking more and more into digital solutions to improve visibility E2E, operational efficiency, and overall customer experience. In this exclusive interview to CEW, Andy Postlethwaite threw light on various success factorials of the present and future of the Performance Materials Business through his experiential insight. He has also shared his acumen on various aspects viz. sustaining the momentum of innovation, investment for the internationalization of research and development network, leverage of differentiating factors e g innovative power, global footprint, and strong team. 70 • June 2019
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Interview CEW You have started your journey with BASF way back in Yr 1986 and have seen BASF growing from very close quarter by being associated with various regions and functions. Please acquaint our readers with this journey; and how BASF grew over this time frame. I started my journey with BASF in 1986. Through my growth at BASF, I had the opportunity to live and experience different cultures across countries like New Zealand, Australia, Singapore, Hong Kong, Malaysia, and China in various units including Life Sciences & Functional Polymers, Fine Chemicals, Nutrition & Health, and Engineering Plastics. During 1990s, BASF had started aggressively focusing on the growing markets in Southern and Eastern Asia for opportunities, and by building verbund sites at Kuantan in Malaysia as well as Nanjing in China. We saw the expansion of our business in the region and built a regional headquarter based out of Singapore in 1989. In 1996, we
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inaugurated our plant in Mangalore which is the largest plant in South Asia. With the inauguration of the Dahej plant for BASF, we made an investment of over Rs. 1000 cr., our largest ever in India. Over a period of five years since 2014, BASF has invested approx ` 3000 cr in India. As per NASSCOM’s Industry Performance report for Yr 2018-19, Global Economy has grown by 3.7 percent and Indian GDP grew by 7.3 percent. Even the Ease of Doing Business ranking comes at 77 for Indian Economy. In contrast to this, in Yr 2018, global sales figure for Performance Materials division was down by Euro 52 million compared to the previous year. Asia Pacific Region has contributed to total sales by 28 percent. With this backdrop, – a. How is the Performance Materials sector contributing to Global, Asian, as well as Indian economy? b. What are the major challenges and trends being experienced, as well as foreseen by this sector?
c. And how has BASF positioned itself in the market compared to its competitors? Contribution of Performance Materials team: The Performance Materials team which is composed of Engineering Plastics, Polyurethanes, Thermoplastics, and Foams businesses had sales of approx Euro 7.65 bn in 2018. BASF Group registered overall sales of Euro 63 bn in 2018. The Asia Pacific contributed overall 28 percent of sales by region for the Performance Materials Business in 2018. Major challenges-and-trends and Positioning of BASF: Globally, cost is a major factor. Hence, we have to combine innovation with the cost factor. However, we also have to ensure that the end solution comes with the right price so that the brand and the OEM have the right positioning in the market. The macroeconomic situation remains unpredictable and that is a key challenge for the business. On the brighter side, Indian consumers are now looking for higher
June 2019 • 71
CEW Interview In consumer electronics, we are working on number of applications around 5G, for example- different surfaces for consumer electronics like mobile phone surfaces, miniaturization of electronic devices and interior parts. We have the capability to adapt to the materials in demand from our consumers. quality, higher performance products and we expect that to level out with other major economies in Asia Pacific. We at BASF try to adapt our business focus and innovation as per the industry demands. One of the largest markets for our performance materials in APAC is the automotive segment. The trend driving the technological development and innovation in this industry, particularly in China and Japan, is clearly the electrification. For instance, while the Indian automotive industry is still working on turbo combustion engine, we are also expecting a growth in the manufacturing of electric vehicles which will give rise to the development of new materials. In footwear manufacturing, there is a big drive towards automation to reduce the cost of manufacturing. This offers a huge opportunity to develop technologies around automation. All these trends are also expected to come to India in a couple of years. The footwear industry is moving from a disorganized to an organized market in India, and we are expecting automation to be the next big growth driver for the industry. In footwear, there is a big trend towards lighter and more durable shoes and soles especially in athletic shoes. Our portfolio of polyurethanes and thermoplastic polyurethanes in particular, offers unique solutions to the footwear industry. In consumer electronics, we are working on number of applications around 5G, for example- different surfaces for consumer electronics like mobile phone surfaces, miniaturization of electronic devices and interior parts. We have the capability to 72 • June 2019
adapt to the materials in demand from our consumers. We have had an excellent growth rate in India over the last decade and we expect that to continue and increase. With electrification of rural regions and investment in infrastructure, the use of various household appliances like refrigerators are increasing. Also, the cold chain segment in India with insulation materials is expected to witness a huge growth. Hence, with the overall development of the country, we are also finding increasing demand for our applications in various segments like consumer appliances, transportation, construction, etc. Differentiating against competitors: There are three key factors that differentiate BASF in the industry: i. Innovative power: We have global R&D capabilities. In India too, we have product development and technical capabilities. We have a very strong history in material development in simulation and that makes the difference. ii. Global footprint: We have a global footprint and a strong manufacturing footprint in Asia. iii. Strong team: We have an excellent team in place with deep understanding on the Indian requirements and strong R&D capabilities that can help cocreate with customers. We are committed to address important & unmet needs in the market and develop
solutions for that. We accelerate the pace of innovation by recognizing and fulfilling customers’ needs, in tandem with regulatory changes. We have a lot of assets on the ground to produce the products: we have an R&D Center, the Innovation Campus, and now the Creation Center here in India so we are prepared to be faster in supplying innovative products. Innovation being one of the key drivers for BASF’s Performance Materials segment, what is the going forward strategic focus for Research and Development, more specifically target industry wise viz. transportation, construction, industrial applications, and consumer goods? The Performance Materials team has always been at the forefront to utilize digital tools to create a benefit for customers and markets. Ultrasim®, our proprietary simulation technology, is our prime example. We aim to continue to be the market leader in applying digital tool across our processes and in interaction with our customers and markets. In the footwear market, we are working on various projects in collaboration with the Indian industry. In the automotive segment, a lot of the developments are transplanted from the OEM perspective. However, we are also engaging with some of the Indian brands on various R&D projects specific to engine parts. To sustain the momentum of innovation, we plan on investing over the next decades in the internationalization of research and development network, especially to emerging markets like India. To cite a few examples of innovation in Performance Materials: • Polyurethane (PU) integral foam solutions with an open cell structure offer unique performance as they are light-weight, with excellent sound insulation and flame resistance. Our Chemical Engineering World
Interview CEW Elastofoam® PU solutions help make vehicles quieter and provide riders with a better experience inside the cabin. We also launched an innovative noise, vibration and harshness (NVH) solution - Cellasto®, which contributes significantly to driving comfort and safety. • Saving manufacturing time: Some motorcycle manufacturers in India needed innovative solutions to shorten their manufacturing time, in order to remain in a competitive market. BASF provided a solution called Elastoskin™, an innovative polyurethane solution to make motorcycle seats from a single mold, saving time and resources for the customer. • Reducing energy and resources for potato farmers in India through dialogue and collaboration with potato farmers, BASF has developed and delivered polyurethane-based insulation material. This helps farmers reduce energy use and costs at warehouse storage, while at the same time reducing food waste in the value chain from the farm to the consumer end. Rapid Technological Advancement and Digitalization are something that has shaken up each industry and compelled them to move out from their comfort zone. What practices are you going to adopt with regard to this? We consider ourselves a frontrunner with digitalization being of high strategic priority and launched BASF 4.0 project in early 2015. BASF believes that digitization will help develop new digital products and services to offer enhanced value for customers, simultaneously increasing efficiency and efficacy of processes. Industry 4.0 and the exponential growth of disruptive technology means that manufacturers, suppliers, distributors and retailers are looking more and more into digital solutions to improve visibility Chemical Engineering World
E2E, operational efficiency, and overall customer experience. The Industry 4.0 applications developed at BASF have the potential to have a positive impact not only on sales and productivity, but also on safety and sustainability. To drive the digitization of BASF’s worldwide research we invested in the 65th fastest super computer on the planet- Quriosity. It is the most advanced supercomputer available in the chemical industry and this allows BASF’s research to become more and more global. Our Innovation Campus in Navi Mumbai is a key hub of BASF’s global research and development (R&D) network; and next to Shanghai, BASF is the second major R&D location in Asia Pacific. With the new creation center set up in Mumbai, we will offer the entire product portfolio of Performance Products for customers to discover, to understand, and to create; and will be happy to engage the customers from the Consumer Durables, Furniture & Footwear industry in India at every stage of product development. These rapidly growing segments develops the Indian economy further. What’s the further growth plan for BASF’s Performance Materials Sector for both, -- South East Asia, as well as for India? Our Performance Materials team aims to accelerate innovation by recognizing and fulfilling customers’ needs. We take innovation beyond product development. Through the creation center we now have an excellent platform that combines design-functionality-and-simulation and thus provides enhanced offerings to our customers. Sustainability, design, and digitalization are the key driving forces for new material innovations. Our focus continues to be on close collaboration with customers and fuelling our innovation pipeline with solutions for market needs.
engineering plastics. Apart from this, we are looking to increase capacity for our solutions in India and expanded the capacity of cellasto manufacturing at our Dahej plant in Gujarat. It will meet India’s growing demand from automotive market and has helped us strengthen our presence in India and the South Asia region. Today Internal Workforce Development has become a business-critical priority to most of the organizations to commensurate organizational talent management. What are the most critical skills for Performance Materials’ workforce? And what’s your plan for up-skilling your workforce? Retention is always the best form of hiring. One of the key elements in new BASF corporate strategy is People. Now, besides the established avenues on employee recognition, internal awards, and attractive compensation packages, people feel fulfilled in their jobs and their workplace if we allow them the room to be innovative. This comes with empowerment. Empowering the employees to differentiate their offerings to customers will result not only in higher customer impact, but also with employees feeling valued for their contribution. In PM, for technical roles, we are always on the lookout for talents with chemical backgrounds in materials science, plastics, polymers, advanced materials; however, we also look for talents who are digitally inclined and trained in what they do. To stay ahead in the competition, digital savvy talents are the key. As we step into a digital future, such talents will support with smarter solutions to the customer.
Moderator: Jayati Mukherjee
We have already announced that we are looking for the acquisition of solvay June 2019 • 73
Exclusive Interview CEW Interview
Demand for Phenol and Acetone is Growing and Finding Application Diversity Meghav Mehta Whole Time Director Deepak Phenolics Limited.
“The demand for Phenol and Acetone is growing. With the advantage of the integrated facility, in FY 2018-19, Deepak Phenolics has already captured 56 percent market for Phenol and 76 percent market for Acetone. The market share is likely to increase to 64 percent for Phenol and 88 percent for Acetone for FY 19-20,” says Meghav Mehta. Tell us some of the key highlights of the project and share insights into the operations & performance of plant. Deepak Phenolics Limited’s Phenol and Acetone plant is one of the largest, state-of-the-art, IOT enabled plant with lowest thermal foot print. We have strong systems implemented for continuous plant operations monitoring, including key performance indicators, laboratory information management system, and 74 • June 2019
real time alters configuration. With this business initiative Deepak Group aims to fulfill a substantial portion of domestic demand for Phenol and Acetone. The plant is equipped to manufacture 2 lac tons of phenol and 1.2 lac tons of acetone. It also has an integrated cumene plant of 2.6 lac tons. We cater to 65 percent of India’s demand of 3.4 lac tons as of 2018. At full capacity the supply will save the country USD 400
Million that would otherwise be spent on imports. We received all necessary statutory approvals for the project requirement on time. Our facility started trial operation in August 2018 and declared project completion in November 2018. As against our plan of ramping up capacity to 70 percent in the first year, we were above 90 percent in the first five months with on-spec products. This demonstrated Chemical Engineering World
Interview CEW our ability to run the plant at such a high level and also manage logistics of 50,000 tons of material movement. The project was completed on time and within budget in spite of demonetization and GST introduction. The market for phenol and acetone are growing; and have diverse application in plywood, agrochemicals, pharmaceuticals, paints, laminates, adhesives, and resins. We hold very high standards in Health and Safety during project stage and operations. We achieved 12.6 million safe man-hours and 629 incident free work days with high compliance standards by implementing safe work culture and practices. Were there any hiccups the company had to face before and while implementation of the plant, how were these addressed? There were not major hiccups while starting the project. For implementation of such a high capacity plant with all required utilities we had significant land constraints. The challenge was addressed by various iterations of engineering and design while complying to all statutory guidelines. Integration of various contractors and handling of equipment and manpower was another aspect that needed to be addressed. Highly talented professionals and organizations have contributed in setting up and successfully commencing operations. What is the current demand supply gap of phenol and acetone in the Indian market? To what extent the production will cater to the demand of these chemicals in India and what kind of growth do you expect in the coming years? The current annual domestic demand for phenol and acetone stands at 3,60,000 tons and 1,80,000 tons respectively. Before Deepak Phenolics, there were Chemical Engineering World
only two players who collectively met 11-12 percent of both, Phenol and Acetone demand for the Indian market. Majority demand for India was met via imports. With Deepak Phenolics Limited (DPL), the equations have changed drastically. DPL will supply almost 60 percent of India’s phenol and acetone requirement. Until now, the Indian industry has been largely dependent on imports of these chemicals, how will the product flow in domestic market going to impact business dynamics? How do you intend to compete with the imports of these chemicals in the domestic market? Our customers are very happy having indigenous supply. With reducing dependency on import latency and uncertainty, customers can avail justin-time service and keep inventories low. Foreign exchange fluctuations are contained while pricing is competitive. With a nearly 50-year legacy as a key player in the chemical industry we aim to catalyze derivatives and downstream petrochemicals’ industry growth. With the absence of stable availability of phenol, an entire vertical of petrochemicals were neglected. Now, India has the potential to expand manufacturing of bisphenols, resins and polycarbonates. As a company with a long standing customer centric approach, we intend to support the domestic industry with competitive pricing, impeccable service, and better value for money. Since these chemicals are one of the most significant steps towards import substitution as well as realizing the vision Make in India, what kind of response has this project received from the Indian Government and also if there are talks about increasing the entry barriers for foreign suppliers in domestic market? Deepak Phenolics’ core inspiration is to meet India’s demand for phenol and acetone. We are playing a vital role in
strengthening and building our nation. The new government is ambitious and is taking every measure to ensure reduced dependencies on other nations. Like other countries that have introduced several trade remedy measures to safeguard the domestic industry, Indian government is continuously reviewing its fair-trade policies. The government of India is realizing the importance of DPL and similar business initiatives. DPL looks forward to offer employment opportunities, support industry growth, as well as to improve likelihood of domestic downstream applications. We are optimistic that our government shall be promoting fair trade policies to ensure the Indian economy continues to be on the growth trajectory. What are your plans for exports from the currently commissioned plant and how do you plan to leverage upon the group’s presence in the international markets? Domestic customers have been very supportive of our initiative and we look forward to servicing their needs first. While our capacity is targeted for the domestic market, we would continue to export small quantities to Europe and South-East Asia. This would help us to be in touch with international market as well as with the discerning customers. How do you plan to go about further value addition to diversify the product matrix of Deepak Phenolics? We are actively looking at increasing our support to phenol & acetone consumers. Expansion of phenol and cumene capacities through debottlenecking at the current site are under way to meet the domestic demand. We are also expanding into various solvents based on phenol and acetone through the same philosophy – import substitution and blue ocean strategies. Moderator: Mittravinda Ranjan June 2019 • 75
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