Chemical Engineering world March 2019

CHRONICLING PROCESS INDUSTRY INNOVATIONS SINCE 1966

CHEMICAL ENGINEERING WORLD MARCH 2019

Engineering Procurement and Construction

VOL.54 | ISSUE 03 | MARCH 2019 | TOTAL PAGES 62 | US $ 10 | ` 150

VOL.54 ISSUE 03 Mumbai ` 150

CHRONICLING PROCESS INDUSTRY INNOVATIONS SINCE 1966

Heat & Mass Transfer

ChemTECH SOUTH WORLD EXPO 2019

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Chemical Engineering World

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

EDITORIAL

Editor Deputy Editor Editorial Advisory Board Contributing Editors

Maulik Jasubhai Shah Hemant K. Shetty Hemant K. Shetty

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

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NEWS Industry News

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NEWS FEATURES CHEMTECH World Expo 2019: Taking a step ahead to Global Chemical Processing Industry 22

FEATURES Double Tubesheet Heat Exchangers – Necessity and Challenges Purushottam M. Misal

26

An anti-fouling and corrosion resistant ceramic coating for heat exchanger tubes Article Courtesy: Tubacex

31

Solution To Steam Reforming Natural Gas Process Equations For Primary Reformer Vishwas V Deshpande, Jamnagar Engineering Centre, Reliance Industries Limited

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Proper Design of Shell and Tube Heat Exchangers Atul Choudhari, General Manager, TATA Consulting Engineers Ltd

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Water in Oil Meter and Oil in Water Meter Analysers Sunil P Agarwal, Senior General Manager, (Instrumentation & Controls) and Abhinav Prasad, Manager, (Instrumentation & Controls)

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PRODUCTS

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EVENTS

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PROJECT UPDATE

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

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Chemical Engineering World

CEW Industry News HRS India at ChemTECH 2019: Heat transfer technology with competitive advantage HRS Process Systems Ltd, (HRS PSL) recently displayed their range of heat exchangers and systems at ChemTECH 2019, organized by Jasubhai Media, at Mumbai from 20th – 23rd February 2019. The exhibition primarily gives an opportunity to connect with process industry and technology experts, to share latest information and developments by the company.

HRS is synonymous with offering innovative heat transfer technology to processing sectors. Our heat exchangers are successfully running at various chemical, agrochem, fertilizers, pharma, specialty chemicals and other process plants. At ChemTECH, HRS showcased their flagship ECOFLUX* corrugated tube heat exchangers (CTHE), HRS FUNKE Plate Heat Exchangers (PHE) and range of Heat Exchanger-based Systems.

HRS is the pioneer in corrugated technology, backed up with extensive research. ECOFLUX* CTHE is one of the most widely accepted heat exchangers in the market today. Some of the key process concerns of customers of chemical, agrochem, fertilizers, oil & gas, petrochemicals, specialty chemicals, paint, dyes, textiles, resin, polymers, etc, have been addressed in our stall by our technical team at the exhibition. Many of our esteemed customers like Atul Ltd, Pidilite Industries, Piramal Enterprises, Multiorganics, Aarti Industries, VVF India, Gujarat Organics, Aurobindo, Hetero Drugs, Matrix Life Sciences, Everest Blowers, UPL, Meghmani LLP, Bayer, etc, visited the event.

These delegates from prestigious companies were informed of the advantages of our range of products. Customized design, application engineering and consistent heat exchanger performance is why customers continue to prefer HRS. Our expertise to understand the customer requirement and supply heat exchangers in a range of regular and exotic material of construction such as SS, Hastelloy, Inconel, Monel, Titanium, Tantalum, Duplex, Super Duplex, etc, give HRS the advantage as a competitive heat exchanger supplier to the industry.

Devan Chemicals joins Consortium for Recycling Project The EU-funded Project, in which Devan Chemicals is a key partner, held a kick-off meeting on 20-21 February 2019 at the EU Commission in Brussels, Belgium. The project consortium, led by Belgian R&D centre CENTEXBEL, consists of 17 European partners from across the value chain including design, manufacturing, NGOs, and research and innovation. The focus of the consortium is on coated and painted textiles and plastic materials which are currently not recyclable. Ambitious plastic recycling targets of 50 per cent have been set by the European Plastics Industry, and to meet these targets, smart solutions to enable the circular use of textile and plastic parts with multi-layer coatings must be considered.

DECOAT has therefore been established to investigate triggerable smart polymer material systems and appropriate recycling processes. The solutions will be based on smart additives (like microcapsules or microwave triggered additives) that will enable the efficient of coatings and other finishes, activated by a specific trigger (heat, humidity, microwave, chemical) to permit recycling.

10 • March 2019

Devan’s specific role is in the development of microcapsules that will release its active core on application of a certain trigger (e g, heat) at the end of life of the article. This active core material may be something that, for example, will promote the detachment of different coating layers (by separating them), opening the possibility for recyclability/re-use of the base materials. Different active core ingredients will be evaluated, and Devan will develop processes for each type of core ingredient and for each type of coating layer/matrix.

The bold aim of the four-year project is to decrease landfill by 75 per cent of coated articles that are presently difficult to recycle, such as clothing, electronic goods and automotive components. A reduction in the carbon footprint by at least 30 per cent for the considered products is aimed for. By enabling the recycling of such materials, DECOAT is expected to generate in the medium term a new market valued at over 150 million Euros in Europe.

Pankaj Kumar takes over as the CEO for Sterlite Copper Sterlite Copper today announced the formal appointment of Pankaj Kumar as the new Chief Executive Officer of its operations. In addition to the unit’s copper operations, he will also oversee operations at Malco Energy Limited (MEL) and Fujairah Gold (FZH).

Kumar has nearly 29 years of rich industry experience and has previously served as Chief Operating Officer & Director - Smelters at Hindustan Zinc.

Prior to that, he worked in various conglomerates such as Tata Steel, Adani Ports and Mittal Steel. P Ramnath, who led Sterlite copper for the past 8 years has retired from the role of Chief Executive Officer and will now be staying on in the capacity of a Senior Advisor to the organization.

Talking about his vision for the company, Pankaj Kumar shared “it is an honour to be back in a place that feels like home. Having already worked in Sterlite Copper before, I can positively say Sterlite Copper is a people-first organization and nothing has changed in that regard. I have come at a time when many interesting projects for the development of the region as well as its people are in the pipeline, and I am very excited to serve our community in any way I can.” Pankaj Kumar has worked with Sterlite Copper in the past as the Chief Operating Officer. He takes on the helm of affairs at Sterlite Copper at a critical juncture in the company’s journey in Thoothukudi.

Süd-West-Chemie Develops Replacement Product The Swabian chemicals company SWC develops replacement products for hazardous substances and actively engages in projects to save resources.

The conservation of resources and protection of the environment is growing increasingly more important in many fields of industry and the company seeks to contribute to environmental protection through investments as well as the use of more sustainable products and raw materials. A new development to replace hazardous substances in line with this ambition, SWC has developed a new product, Supraplast 3616. This special lowmolecular phenol novolak is synthesised in an extremely narrow molecular weight distribution. This tremendously improves its properties in most high-performance applications. The free-monomer content approaches zero, which means that Supraplast 3616 does not require labelling as a hazardous substance.

Chemical Engineering World

CEW Industry News India Ranks 15th Globally in Indo-German trade in Engineering Sector

of this testing, as well as the critical quality assurance requirements needed in the medical device design and manufacturing community and are proud to be a trusted and leading supplier to them’. All Epoxy Technology MED datasheets are available online and contain information on specific applications, testing methodology, extensive product data, as well as sterilisation compatibility.

SABIC and hte extended plans for collaboration

Germany is known globally for its engineering technology. The German manufacturers are internationally well positioned with their broad range of sectors: In 23 out of 31 comparable sectors, they are among the global top three; in 14 of which, they are in first place.

India ranks 15th globally, in the list of top 50 destinations for the German Mechanical Engineering exports. In 2018, the total import of machinery from Germany reached a volume of € 3.40 billion. This was an increase by 9.3 per cent compared with the same period of time in the previous year. On the other hand, in 2017, India imported machinery of the value

€ 18.37 bn globally. Germany is the 2nd most important supplier to India globally, share of around 16.7 per cent, behind China (34.2 per cent) and ahead of Japan (10.3 per cent) and Italy (7.4 per cent).

Among the machinery sectors, major demand of German equipment was for Power Transmission (10.8 per cent), Textile Machinery (without dryers) (7.05 per cent), Machine Tools (6.76 per cent), Valves & Fittings (5.38per cent) and Construction Equipment and Building Material Machinery (5.29 per cent). There are other sectors like air handling technology, fluid power equipments, plastic and rubber Machinery and food processing & packaging, which are growing steadily in India.

Out of the total export of German Mechanical Engineering to Asia of

€ 41.9 billion, India is the second largest sales market in Asia for the German engineering industry, with a share of 8 per cent, after China (45.5 per cent).

Epoxy Technology Expands the Product Basket Epoxy Technology Inc a leading manufacturer of high-performance speciality adhesives for over 52 years, is pleased to announce an expanded range of ISO-10993 medically approved adhesives now totaling 23 products. To date, 14 epoxies have undergone ISO-10993-5 Cytotoxicity testing, an excellent screening test for biocompatibility, and 9 additional products have undergone even more screening, passing all ISO-10993 -4,5,6,10,11 testing. Included in testing for EPO-TEK MED-301 was an extended implantation test, from the normal 2 weeks to 12 weeks, which it passed. This specific optically clear epoxy adhesive is one of the most popular and well-proven materials often used for moulding header systems on many types of devices including pacemakers, ICDs and neurostimulators.

Joan Bramer, Global Sales and Marketing Director of Epoxy Technology Inc said ‘We are committed to testing all of our MED adhesives to the industry’s most comprehensive ISO-10993 biocompatibility standards and will continue to perform this level of testing, adding more adhesives to this important line of products in the coming year. We recognise the importance 12 • March 2019

SABIC and hte have deepened partnership in innovation t h r o u g h digitalization and high throughput technologies in petrochemicals research and technology. The companies have extended plans for collaboration for five more years to increase efficiency through digitalization and high throughput technologies in catalysis research and development (R&D) in petrochemicals.

The agreement stipulates that SABIC and hte will maintain the operation of SABIC’s satellite laboratory for high throughput experimentation in Heidelberg, Germany and will install and operate a new high throughput experimentation laboratory at SABIC’s Corporate R&D (CRD) site at King Abdullah University of Science and Technology (KAUST). With this partnership, hte will also support SABIC in digitalization in R&D. Building on the previous successful collaboration, SABIC and hte are extending their strategic partnership to include fast-track catalysis R&D. Under the agreement, SABIC will continue operation of the SABIC satellite High Throughput Experimentation Lab, established in 2015 at hte’s facilities in Heidelberg. In addition, SABIC will have the opportunity to transfer hte’s institutional knowledge to its own corporate R&D center at KAUST in Saudi Arabia.

SABIC and hte will also set up a new high throughput experimentation laboratory based on the established satellite laboratory in Heidelberg.

This center will provide access to the latest technology and expertise to accelerate innovation in petrochemicals. Its close proximity to commercial plants will enable SABIC to support and optimize plant operation and productivity more efficiently. The overall aim is to decrease time and costs for the development of new catalysts and petrochemical processes considerably, and ultimately, to reduce their time-to-market. Commenting on the umbrella agreement, Dr. Al-Sherehy, confirmed that the partnership is in line with SABIC’s 2025 vision, addressing future R&D needs and local access to high-end solutions and technology. He stated, “We are happy to continue our collaboration with hte, a leading provider of modern R&D solutions and technology. By introducing hte’s comprehensive, webenabled data management solution myhte™ we also will address our goal to introduce digitalization in catalysis R&D. An innovative partner like hte will add value to our business in the long term, and this will significantly enhance our pace of innovation.”

Dr. Wolfram Stichert, CEO at hte said, “The commitment for further cooperation with SABIC will take our relationship to the next level. We are proud to be SABIC’s preferred R&D collaboration partner and to extend the footprint of our partnership into Saudi Arabia for the first time.”

SABIC considers research and innovation to be a key pillar in the achievement of sustainable growth and competitiveness while considering the highest standards of safety, health, and environment, which set the groundwork for enabling Saudi Vision 2030.

Chemical Engineering World

CEW Industry News Finder Pompe Opens New Pump-Testing Facility Finder Pompe, par t of PSG®, a Dover company, is excited to announce the opening of its new pump-testing facility at its headquarters in Merate, Italy. Finder Pompe has been a leader in the design and manufacture of APIengineered centrifugal and plunger pumps, and liquid ring vacuum pumps and systems for more than 65 years. The creation of the new test building, which covers 1,500 square meters (5,000 square feet) – making it six times larger than Finder’s previous testing facility – was driven by the growth in size and complexity of its pump models, along with expanding customer expectations regarding pump performance. These stricter performance requirements demand more rigorous tests that verify a pump’s capacity, as well as its net positive suction head (NPSH) behavior, vibration and noise levels, and overall operational efficiency.

“As our product offering has become more expansive and our client base more diverse, we felt this was the perfect time to add this new pumptesting facility to the list of service offerings that we can provide for our channel partners,” said Luca Farris, General Manager of Finder Pompe.

“When providing products for use in very demanding fields like oil-andgas production and power generation, it is imperative that our clients have access to the best, most reliable and, yes, most exhaustively tested pumping equipment possible, and this new testing facility will help us satisfy those critical requirements.”

The facility’s larger footprint makes it more suitable for testing pumps with higher capacities and at higher pressures. It features three stiff platforms that can accommodate horizontal pump and skid installations. These platforms allow for extremely precise vibration tests, while two independent areas with three tanks that are 13 meters (43 feet) deep possess the capability to test vertical pumps with shaft lengths up to 12 meters (40 feet). Additionally, the facility is equipped with a testing circuit for lube oil pumps and another one that is dedicated to the testing of liquid ring vacuum pumps. This design enables up to four pumps to be tested at the same time.

To enable the handling of very big and heavy pumps, the testing bench features cranes that are capable of lifting pumps that weigh up to 20 tons (20,000 kilograms/44,000 pounds). The facility is also capable of producing maximum electrical power of 4 megawatts (MW), which further allows it to test very large pumping units. The facility features motor-tension rates that range from low tension (0-690 volts) to medium tension (0-13,900 volts), which also attests to its ability to accommodate the needs of large pumps. Finally, a closed-loop system enables the accurate and reliable NPSH testing with water of both vertical and horizontal pumps.

Nouryon Launches Improved Vanishing Red peroxide for Composites Market Nouryon , formerly AkzoNobel Specialty Chemicals unveiled a new version of its Butanox M-50 Vanishing Red peroxide at JEC World, a leading trade event for the composites market. The new version contains a lesshazardous dye solvent that makes it safer for customers to handle and reduces its environmental impact while maintaining its industry-leading 14 • March 2019

performance. Vanishing Red is widely used by customers in the composites market as part of the curing process for unsaturated resins. Its red colour gradually vanishes as resins cure, allowing customers to better monitor the dosing, mixing, and curing progress. Vanishing Red is especially useful for automated processes used to make products such as wind turbine blades and boats. “Customers using automated dosing equipment may face problems if peroxide doesn’t properly flow through the dosing line, leading to under-cured or uncured end products,” said Raymond ten Broeke, Polymer Chemistry Customer Support Engineer at Nouryon. “This can be very costly to manufacturers if moulds need to be cleaned. Using Vanishing Red peroxides helps prevent such failures without leaving a trace that any indicator was used.”

Johan Landfors, Managing Director, Polymer Chemistry at Nouryon, added: “We are proud that Vanishing Red offers our customers in the composites market a safer and more sustainable solution for curing unsaturated polyester resins. This is the latest in a series of products we have introduced to better serve and grow with our customers in this important market.” Nouryon recently expanded its peroxides offering in North America with the launch of its Butanox-branded product line of methyl ethyl ketone peroxide (MEKP) and the launch of emulsion-based organic peroxides. The company has also expanded capacity in Mexico and the United States. Another expansion project in Mexico is due to be completed this year and additional capacity is also scheduled to come online in Brazil, China, and India.

Ravindra-Heraeus sets up first pyrometallurgy smelter in India for precious metal catalyst recycling Ravindra-Heraeus, India’s leading precious metals service provider, has set up the first pyrometallurgical smelter (Plasma Metal Recovery System) in India. The Indo- German joint venture is notably investing to satisfy Indian customer request by expanding its precious metals recycling capacity. The new technology, featuring a capacity of about 1,500 tonnes per year of auto catalysts and equivalent, will allow Ravindra-Heraeus to recycle Platinum Group Metals from the growing number of spent automotive emission, insoluble aluminia-based catalysts and a wide range of diverse high-melting oxides-based catalysts per year.

Platinum Group Metals are used in homogeneous and heterogeneous catalysts in a wide range of applications, such as production of chemicals, gas purification and chemical processes. India has no natural resources in Platinum Group Metals and thus relies either on imports or recycling specialists, such as Ravindra-Heraeus. The investment in the new technology will complement Ravindra-Heraeus’ chemical-based hydrometallurgy processes and allows the company to create ten new high-tech jobs in the region.

“Our new plasma facility underlines our market leadership in India in precious metals processing. We will be the only fully integrated Precious Metals refiner in India, offering pyro- and hydrometallurgy in our facility.

This will allow us to offer new services to our customers in the whole country,” said Shailesh Choksi, Managing Director, Ravindra-Heraeus Pvt Ltd. The new Plasma Metal Recovery System will be one of the most efficient recycling systems worldwide. The less valuable material is free of hazardous material and can be used in the cement and construction industry, thus saving other resources and energy, while the refined precious metals will be available for new industry products.

Chemical Engineering World

CEW Industry News Akzo Nobel Opens Ground-breaking Innovation Campus A trailblazing lab complex which can test new products in conditions that mimic the world's most extreme environments has been officially opened today by AkzoNobel in the UK. Located in Felling, the €12.6 million R&D innovation campus fuses the site's 115year history of product development with state-of-the-art facilities designed to keep AkzoNobel at the forefront of the coatings industry.

A creative nerve center for the foremost scientists and technical experts in the world of coatings, the focus will be on continuing to deliver cuttingedge innovations and products for the marine and oil and gas industries.

It brings the total investment in the Felling site since 2011 to €31.6 million.

"The new laboratories will enable our technical experts to partner more closely with our customers and deliver innovative products and solutions that meet the most demanding specifications in our industry," says Jean-Michel Gauthier, Managing Director of the company's Marine and Protective Coatings business. One of the key features of the campus is a new application and testing laboratory. It will be used to test new products in extreme conditions such as temperature resistance, fire and high pressure. The facilities will also enable scientists to expose products to chemicals and corrosion.

A comprehensive sustainability plan was at the heart of the design and development of the new complex. The new facility in Felling is located around 25 miles away from AkzoNobel's €100 million paint manufacturing plant in Ashington, which opened in 2017.

BASF Expands Innovation Scope in Asia Pacific BASF is enhancing its regional innovation capabilities with new facilities at the Innovation Campus Shanghai, to further strengthen collaboration with the automotive industry and to offer new process catalysts to the chemical industry. With an investment of approximately € 34 million, the new 5,000-square-meter facilities include the Automotive Application Center and the Process Catalysis Research & Development (R&D) Center.

During the inauguration of the facility in Shanghai earlier this month, the company also presented a range of locally-developed innovations which support customers in industries like automotive, construction and consumer goods, and which address important market trends to reduce emissions, increase energy efficiency and enhance performance. BASF launched an innovative waterborne coating system on the same occasion.

“China’s most important growth industries can benefit enormously from innovations in chemistry. Thanks to continuous investment in research and development over the past several years, we are able to support our customers in China and the entire Asia Pacific region as they strive to improve consumers’ quality of life, address the challenges of rapid development and meet their sustainability goals,” said Dr. Stephan Kothrade, 16 • March 2019

President Functions Asia Pacific, President and Chairman Greater China, BASF. “At the Innovation Campus Shanghai, we are continuously enhancing our R&D capabilities in advanced materials, chemical process engineering and catalysts by integrating new technologies and building our teams,” said Dr. Harald Lauke, President, Advanced Materials & Systems Research and Research Representative Asia Pacific, BASF. “We have invested nearly €180 million here since 2012. More importantly, our R&D experts work closely with our business teams and customers, so as to shorten the time-to-market of innovative products.”

Equipped with a state-of-the-art spray booth for electrostatic applications, a physical testing lab, and a 3D robot, the BASF Automotive Application Center, Asia Pacific is designed to enable customer-oriented R&D activities.

The 3D robot can simulate nearly any situation on a paint line, anywhere in the world; enabling the new center to optimize application processes and products. Located at the same premises, the new Process Catalysis R&D Center will focus on the development of new process catalysts to meet the specific needs of BASF customers in Asia Pacific.

ExxonMobil to Fund Polypropylene Unit to Expand Baton Rouge Operations ExxonMobil will fund the construction of a new polypropylene production unit in Baton Rouge that will expand production capacity along the Gulf Coast by up to 450,000 tons per year. Construction will begin in 2019 and startup is anticipated by 2021. The project is expected to create up to 600 jobs during construction and 65 permanent jobs once completed.

“Growth in feedstock supply along with the increase in global demand for chemical products continues to drive our strategic investments and expansion along the Gulf Coast,” said John Verity, president of ExxonMobil Chemical Company. “We’re well positioned to meet the demand for these high performance products and investing further in Baton Rouge enhances our facility’s competitiveness.”

Polypropylene is a versatile material that can help improve the safety and performance of everyday consumer products and help improve vehicle fuel efficiency when used to manufacture lighter-weight Nauto parts.

The engineering, procurement and construction contract for has been awarded to Baton Rouge-based Turner Industries and Jacobs Engineering. The companies will use local workers to design and construct the new facility.

This new project is in addition to ExxonMobil’s previously announced plans to invest USD 20 billion to build and expand manufacturing facilities in the U.S. Gulf region as part of its ‘Growing the Gulf’ initiative, which is expected to create more than 45,000 high-paying jobs across the region.

Growing the Gulf projects include a new state-of-the-art aviation lubricants blending, packaging and distribution facility in the Baton Rouge area as well as refining and chemical expansions at ExxonMobil’s Beaumont and Baytown facilities. ExxonMobil and SABIC have also created a new joint venture to advance development of the Gulf Coast Growth Ventures project, a 1.8 million metric ton ethane cracker currently planned for construction in San Patricio County, Texas. And, earlier this month, ExxonMobil and Qatar Petroleum announced a decision to proceed with the development of the Golden Pass LNG export project in Sabine Pass, Texas. ExxonMobil’s integrated operations in Baton Rouge include a 502,000 barrel-per-day refinery, as well as chemical, lubricants and polyethylene plants.

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CEW Industry News Haldor Topsoe launches breakthrough connected service for optimal plant performance Haldor Topsoe, a world leader in high-performance catalysts and proprietary technologies, and the connected plant leader Honeywell announced a technology alliance to expand the benefits of connected services to a broader range of the chemical and refining industries. As a product of this alliance, Topsoe has launched ClearView – a breakthrough service to maximize plant output, save energy, and improve reliability. Using Honeywell’s cloud-based software platform, the ClearView service gathers operating data from the plant, cleanses the data, applies Haldor Topsoe’s tools and experience, and delivers performance-enhancing insights straight to the plant’s process engineers and managers.

“As a global market leader in catalysts and technology, we are thrilled to offer our customers a service that puts our decades of experience at their fingertips every hour of every day. Using Honeywell’s proven software platform and tools, ClearView applies Topsoe’s unique insights and allows our experts to work more closely with plant engineers to meet critical performance targets and reduce the risk of unplanned shutdowns,” says Bjerne S. Clausen, CEO, Haldor Topsoe. Company’s proprietary modelling and simulation tools have been constantly updated and refined to design increasingly energy-efficient and reliable plants and help customers optimize existing production and catalyst utilization. Now, the ClearView service gives Topsoe customers continuous access to these tools to increase the profitability of their plants. As part of the service, Topsoe engineers follow plant performance and proactively guide the customers’ plant engineers in optimizing performance and quickly addressing operational issues based on output from the new service. The first service has been developed specifically to boost ammonia production, services for other segments in the chemical and refining industries will follow. For Honeywell, the ClearView Service is a great addition to the Honeywell Connected Plan partner ecosystem, as it meets a growing need in a broader area of the chemicals and refining processes.

Ammonia can Become the CO2-free Fuel of the Future Today, ammonia is mostly known as an indispensable fertilizer ingredient.

A new research project will now explore ammonia’s potential, both as a sustainable fuel and a good solution for “storing” green power from wind and sun. Ammonia has the potential of playing a central role in a more sustainable future. It can be used as a CO2 free fuel instead of gasoline, diesel and fuel oil.

Moreover, the highly energy-consuming production of ammonia for fertilizer and other purposes can be based on green power instead of natural gas.

That will save large amounts of CO2 – and at the same time efficiently “store” excess power from wind turbines and solar cells.

A new research project, SOC4NH3 (Solid Oxide Cell based production and use of ammonia) with a number of strong partners will over the next years develop and demonstrate the technology and thereby bring it a big step closer a commercial breakthrough. “We expect that ammonia can be used for transportation and efficient storage of energy. The greatest advantage of ammonia is that it has a high energy density which makes it an effective fuel and energy storage option – and it can thereby solve some of the most important challenges of creating a sustainable energy system of the future,” says project leader, Senior Principal Scientist, John Bøgild Hansen, Haldor Topsoe A/S. “In the Foulum research facility we will demonstrate an especially efficient technology which will enable us to produce ammonia solely by using 18 • March 2019

certified wind mill power, water and air. The method is much more climate friendly than conventional ammonia production which today makes up as much as one per cent of the world’s total energy consumption and CO2 emissions,” says Lars D.M. Ottosen, Head of Biological and Chemical Engineering, University of Aarhus. When ammonia is produced with power from sustainable sources, it is more or less CO2 neutral. And the ammonia has a lot more applications besides storage of green power. Ammonia today is indispensable in artificial fertilizer, which is a necessary prerequisite for feeding the world’s population. Moreover, ammonia can be used as clean fuel in e g, trains and ships which will then only emit harmless nitrogen and steam after a simple emissions treatment. The fluctuating production of green power from wind turbines and solar cells leads to variations in price and availability of green power. That is why it is necessary to develop efficient solutions to store power to reach the target of 100 per cent renewable energy. The project will examine how excess power can be stored in the form of ammonia. When there is a need for power, the electricity originally used to produce the ammonia can be regenerated.

This takes place by using the ammonia as fuel in fuel cells which then produce electricity without harmful emissions. That way ammonia can be used to level the fluctuations in the renewable/sustainable power supply and make it more economical, stable and flexible. ”We see an interesting potential in using ammonia for creating a more stable green energy production and one that can be stored, and at the same time start electrifying heavy transport and the chemical industry. With more than 100 GW wind energy installed all over the world, Vestas has demonstrated that wind energy can deliver the large amounts of energy necessary to convert other sectors to a sustainable future,” says Bo Svoldgaard, Senior Vice President, Innovation & Concepts, Vestas. Hopefully the project can contribute to the next big step in the green transition and thereby strengthen the international leading position of Danish industry within sustainable technology and green solutions. This will create the foundation for future growth, export and jobs.

Haldor Topsøe, who is world-leading within electrolysis and production of ammonia, is heading the project and cooperates with the University of Aarhus, Technical University of Denmark, Energinet, Vestas, Equinor and Ørsted Wind Power. The Danish Energy Technology Development and Demonstration Program (EUDP) supports the project with DKK 15,9 million out of a total budget of DKK 26,8 million.

Grundfos wins the ‘Energy Efficiency’ award Grundfos India, a leader in advanced pumping solutions and trendsetter in pump technology won the ACREX Awards of Excellence under the ‘Energy Efficiency’ category for its highly efficient and intelligent pump solution ‘Magna3’. Grundfos was also the only pump company to be awarded under any of the three categories - ‘Energy Efficiency’, ‘Indoor air quality’ and ‘Innovation’. The MAGNA3 circulator is the most efficient circulator pump range for commercial buildings on the market today. Its Smart “Control Modes” and “FLOWLIMIT feature” uses built-in intelligence to gather information about operation data, conditions and resets operating parameters automatically if required. “The award is a testimony to Grundfos’ commitment to provide the most energy-efficient pumping solutions. The MAGNA3 is not only energy-efficient but is combined with the renowned Grundfos reliability, this makes this pump a very attractive proposition for anyone interested in quick return on investment and low Life Cycle Costs”, said Gaurav Mathur, Head – Business Development (Building Services), Grundfos.

Chemical Engineering World

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CEW Industry News BIO4PRODUCTS Unlocks the Potential of Biomass In a drive to replace fossil material in a wide variety of end products, BIO4PRODUCTS is creating four bio-based products for which at least 30 per cent of the original fossil-based stream is substituted with sustainable resources, and which deliver a 75 per cent reduction in greenhouse gas emissions. The project’s technological developments will help the industry unlock the potential of the bioeconomy.

The EU-funded project Bio4Products is showing how bio-resources such as straw, bark, forest residue and sunflower husks can hold the key to a more environmentally-friendly future for Europe’s process industry through correct exploitation and move away from the fossil-based materials processing steams. Bio4Products will demonstrate the integration of these sustainable resources into four end products: roofing material, phenolic resins, sand moulding resins, and engineered wood and natural fibre reinforced products.

The bio-resources have been targeted because they are unsuitable for food production and do not stimulate indirect land use change and there is no commercially viable technology for industry to exploit these resources.

BIO4PRODUCTS aims to target their long-term sustainability by carrying out in-depth assessments of each resource. Treatment by a state-of-the-art technique called fast pyrolysis will first convert the solid biomass into a bio-oil, while largely preserving the original functionalities. The next step sees the functional groups present in the bio-oil separated by fractionation, obtaining a sugar stream and a lignin stream.

The project will carry out an environmental impact assessment and conduct a detailed economic and market study to develop a strong business case for the four products.

BIO4PRODUCTS is currently a member of the platform, BioWatch – the onestop-shop for the latest research breakthroughs, news and upcoming events in the bioeconomy sector. As a member of BioWatch, BIO4PRODUCTS can communicate directly with the research projects they are interested in and receive alerts in response, they are also part of BioWatch’s growing community of stakeholders (policy makers, industry experts, media) within this sector and have open opportunities for future collaborations.

Nuberg sets up a Nitrogen generation unit in M/s Homs Refinery Ltd. In Homs City – Syria Pulling off an incredible feat, Nuberg Engineering Limited has commissioned its PSA Nitrogen Generator of flow rate 500 NM3/Hr, with 99.99 per cent purity, installed in the complex of M/s Homs Refinery Ltd in Homs City – Syria. The unit will produce Nitrogen gas in service to ensure the need for gasoline production units. The Complete Design, Engineering, Manufacturing, Supply and Commissioning has been conducted by engineers of Nuberg Engineering Limited.

With a distinguished global expertise and continuous efforts of the Nuberg team, the production unit has been put in service to ensure the need of Nitrogen, which is a basic unit for Gasoline production where the product is obtained within half an hour of starting the operation. “It was ambitious project given the various challenges involved in executing a project in war-torn country like Syria. It is to the credit of our engineering team that overcame all challenges and completed the project successfully. In the past, Nuberg has successfully commissioned more than 900 projects in more than 32-countries worldwide, including conflict zones like Iraq.

20 • March 2019

The complete execution of the project has been done within six months from the date of finalization. We would also like to extend our regards to our partners Unico Petroleum and Homs Refinery for their support and cooperation in this project,” said V.K.Gupta, MD, Nuberg Engineering Ltd. The importance of this unit lies in the generation and storage of Nitrogen.

Necessary, especially for the Gasoline production, particularly during the start-up of these units. In addition, also, for the protection of units during pressurized suspension, which is done by Nitrogen purging. It is significant to clean up these units during the reconstruction of these compressors. This flushing of the system is performed by Nitrogen gas.

There are various stages to these units. The first one is Air Compression and the second one is Filtration of moisture and Nitrogen Adsorption

by PSA technology and final stage is storage of Nitrogen. The additions of new units contributes to the prosperity of oil industries in Syria and strengthens the national economy.

Fluorescent Biosensors as Tools for Drug Therapeutics Researchers in the School of Pharmacy at the University of Nottingham have been using Dolomite Microfluidic’s chips to enhance their work on drug encapsulation and therapeutic delivery. Dr Veeren Chauhan, Research Fellow in the Advanced Materials and Healthcare Technologies (AMHT) group, working with Dr Jonathan Aylott and Dr Amjad Selo, explained: “We have been using Dolomite chips since the end of 2017 and, since then, have continuously manufactured an array of uniformly-sized PLGA particles. We can fine-tune the system set-up, depending on the downstream requirements, to provide a consistent particle shape and size, as well as control drug release parameters. These attributes are key to ensuring the correct dose of drug is maintained, achieving maximum therapeutic benefit without unwanted side-effects.”

Amjad added: “We are optimizing conditions to produce fluorescent PLGA to act as a biosensor, storing and releasing biological medicines dependant on environmental changes. These novel particles can detect and monitor specific analytes in the body and, due to their fluorescent properties, can be used to assess biochemical interactions and processes within cells.”

“Using Dolomite’s microfluidic chips has significantly enhanced the innovative work we are able to perform. The beauty of using such small chips means we can produce vast quantities of particles, while occupying very little lab space, and can ensure a continuous flow of homogeneous, reproducible particle batches,” Veeren concluded.

Ineos Styrosolution Introduces Polypropylene based Composite Stylight INEOS Styrolution, the global leader in styrenics, announces today the expansion of its family of StyLight composites. The broadened portfolio will include a new PP (polypropylene) based composites specifically designed for aesthetic applications. The new composite based on a modified INEOS PP matrix rounds up the portfolio of INEOS Styrolution’s composites giving customers a choice to select the material offering the best properties for their respective needs. The StyLight portfolio now ranges from a “standard” PP or SAN glass fiber composite suitable for non-visible structural applications to an aesthetic composite based on a modified PP, up to a SAN based carbon composite for premium aesthetic surfaces.

Chemical Engineering World

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CEW News Features

CHEMTECH World Expo 2019: Taking a step ahead to Global Chemical Processing Industry The 29 th edition of CHEMTECH World Expo 2019 on February 20, 2019 at Bombay Exhibition Centre, Goregaon (East), Mumbai, India, was overwhelmed by the responses from Industries across EPC, Specialty Chemicals, Water & Wastewater, Refining & Petrochemicals, Industry Automation & Control, Pumps Valves & Fittings, and allied industries. While over 600 exhibitors from 18 countries displayed their technologies & equipment in the 3-day mega show, around 19,000 industry professionals visited the expo. The technical conferences touched upon various issues and technology trends pertaining to these industries and witnessed over 1,000 industry delegates from different sectors. The key attractions of the global mega show were Digital Pavilion, State Pavilion of Odisha Industrial Promotion Board, and the Icon Lecture at Student Outreach Programme 2019, which had witnessed around 2,000 students from chemical engineering and biotechnology. Excerpt..

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HEMTECH, the world’s 2nd largest platform for the chemical processing industry, organised the 29th edition of CHEMTECH World Expo 2019, focusing on industries - EPC, Specialty Chemicals, Water & Wastewater, Refining & Petrochemicals, Industry Automation & Control, and Pumps Valves & Fittings on February 20, 2019 at Bombay Exhibition Centre, Goregaon (East), Mumbai, India. Ministry of Chemicals & Fertilizers, and Ministry of Water Resources, Government of India, extended their supports to the mega show. The Expo was rolled out in 3 components – Technical Conferences, Expo, and Recognition of Excellence.

The inauguration ceremony of CHEMTECH + EPC World Expo 2019 had witnessed over 400 CXOs and inaugurated by Sanjeev Chopra (IAS), Principal Secretary, Industries Department, Government of Odisha & Chairman, Industrial Promotion & Investment Corporation of Odisha Ltd (IPICOL) as Guest of Honour. Around 600 exhibitors from 18 countries displayed their technologies & equipment at the 3-day expo and over 19,000 industry professionals visited the expo during the days. The technical conferences - EPC, Specialty Chemicals, Refining & Petrochemicals, Industry Automation & Control, and Pumps Valves & Fittings World Expo - witnessed over 1,000 industry delegates to discuss and network with industry luminaries across the 3 days.

The Grand Expo also created a platform for NextGen to interact, discuss and brainstorm with industry captains through Student Outreach Program, which is a flagship initiative of CHEMTECH in aiming to develop the future leaders.

22 • March 2019

Inauguration of CHEMTECH + EPC World Expo 2019

The latest edition of CHEMTECH had taken three important initiatives this year - launch of ‘Digital Pavilion’, Introduction of a focused forum to encourage ‘Women in Manufacturing’ and expansion of scope of Student Outreach Programme to Biotechnology with the aim to make the programme more comprehensive.

Digital Transformation across EPC Industry The Technical conference of EPC World Expo 2019 was based on the theme “Digital Transformation across Functional Value Chain in EPC Industry” and guided and conceptualised under the Chairmanship of B Narayan, Group President - Procurement & Projects, Reliance Industries Ltd. In his address, B Narayan emphasised on the need for project owners, EPC services providers and the equipment manufacturers to open up to the use of digital technologies.

The conference concluded with the panel discussion on ‘Blue print for digital success of

all value chain partners in the EPC industry’.

B Narayan moderated the discussion with Vinayak Pai, President – Energy, Chemicals and Resources, Jacobs; Sunder Kalyanam, Group Managing Director, Engineering & Construction Growth and Chairman Petrofac India; and Akilur Rahman, Chief Technology Officer, ABB India on the panel.

Sustainability, Digitalisation & Innovation are Key Drivers in Specialty Chemicals Making the most of digital technologies and innovations to leverage sustainability in Specialty Chemicals Sector to push the ‘Ease of Doing Business’ initiative, Specialty Chemicals World Expo 2019 was a deliberation of “Ease of Doing Business: Leveraging Sustainability, Digitalisation & Innovation”.

Dr Raman Ramachandran, Head South Asia & CMD BASF India Ltd & Chairman Specialty Chemicals World Expo 2019, Omer Chemical Engineering World

CEW News Features

Attendees at CHEMTECH World Expo 2019

Dormen, Managing Director, Castrol India Ltd, Dr Sanjay Mishra, Chief Technology Officer, SABIC, Gurpreet Kohli, Global Program Director (R&D), Unilever India Ltd and Ashish Dwivedi, President Specialty Chemicals & Business Strategy, Aditya Birla Group – Chemicals Business, presided over during the inauguration and touched upon the issues of using digitisation to enable business model innovation for sustainability in the sector.

Over 200 delegates from specialty chemicals industry and multiple end-user industries attended the technical sessions on Circular Economy, Building Innovation Ecosystem, Leveraging Digitalization followed by the CEO Roundtable on Ease of Doing Business during the day long conference.

projects and potential opportunities for the industry.

business

S M Hussain, CMD, Central Water Commission, Chairman WaterEX World Expo 2019 and Ashish Mathur, Managing D, TATA SEZ Ltd & Technical Chairman WaterEX World Expo 2019 attended the inauguration. The program had case study presentations on Projects and New Technology Interventions around the theme of the conference.

Refining & Petrochemicals and Industry Automation go Hand on Hand B Ashok, CEO, Ratnagiri Refinery & Petrochemicals Ltd presented the Keynote Address during the joint inauguration

of Refining & Petrochemicals, Industry Automation & Control and Pumps Valves & Fittings conference. Also present were, M S Patke, Executive Director HSSE and Advance Liquid Biofuels - Bharat Petroleum Corporation Ltd, P D Samudra, Managing Director, thyssenkrupp India Ltd, Anil Bhatia, Managing Director, Emerson Automation India Ltd and Rajat Kishore, Managing Director, Schneider Electric India Ltd. Yatinder Pal Singh Suri, Country Manager & Managing Director, Outokumpu India Ltd presented the concluding remarks.

Developing Future Leaders Student Outreach Program has evolved as one of the largest student engagement platforms for interaction with the industry

Smart Water Management for Urban Overhaul Looking at the urban overhaul in India since last few years, WaterEX Conference 2019 technical sessions discussed on the best practices and technology innovations in smart water management for urban sustainability.

T Rajeshwari, Additional Secretary, Ministry of Water Resources RD & GR, Government of India and H. E. Carlos Pereira Marques, Ambassador of Portugal in India, Embassy of Portugal were the Guest of Honours for the inauguration of WaterEX Conference 2019 “Urban Sustainability through Smart Water Management”. H.E. Dr. Rashid Alleem, Chairman - Sharjah Electricity & Water Authority presented the Keynote Address and talked about the upcoming 24 • March 2019

Students at Student Outreach Program 2019

Chemical Engineering World

News Features CEW

Award Recipients of CHEMTECH Leadership & Excellence Awards 2019

and had over 2,000 students from chemical engineering and biotechnology attended the Icon Lectures at Student Outreach Program 2019, and presented ideas as posters and prototypes, and participated in workshops for biopolymers and bio-plastics and Internship Program to seek internships in the industry.

Adnan Ahmad, Managing Director, Clariant Chemicals (India) Ltd & Chairman SOP 2019, Dr Mahesh Gupta, Founder Chairman, Kent RO Systems Ltd and Gurcharan Das, renowned author & former CEO, Procter & Gamble addressed the students.

The students overwhelmed interact with Ann Ollestad, Consul General, Royal Norwegian Consulate General Mumbai, Ashima Sushilchandran, Head of large Capital Projects, BASF Chemicals India Ltd, Roma Shah, CEO, Eastmen Chemicals and Upasana Wadhwani, Process Engineer BASF Chemicals India Pvt Ltd during the session on Women in Manufacturing. Harshwardhan Zala, CEO & CTO, Aerobotics7 & Prateek Sharma, CEO, Director, Nanoclean Global Pvt Ltd shared their entrepreneurial journey with the students and encouraged them to pursue the dreams in the session Entrepreneurship & Innovation.

U Shekhar, MD, Galaxy Surfactants Ltd, engaged with the students along with Chemical Engineering World

Tej Dialani, Head of Strategic Projects & Convener, Specialty Chemicals World Expo 2019 to guide them for the future course that they should take.

Students presented 97 innovative ideas across the categories of 82 projects in the categories of: Automation and Trends in Chemical Technology; Non-Conventional and Clean Sources of Energy; Environmental and Green Chemistry; Novel Engineering Materials and Corrosion Mitigation and Biotechnology during CHEMTECH World Expo 2019.

The jury comprising of academicians and experts from the industry evaluated the projects across the parameters of originality & effort, scope and industrial applications to select the winners. Students also visited the exhibition to understand the latest trends in chemical processing equipment & technologies.

Recognizing Excellence: CHEMTECH Leadership & Excellence Awards 2019 CHEMTECH bestowed upon ‘Recognition in Excellence’ to commemorate the contribution of leaders from the industry and presented CHEMTECH CEW Leadership & Excellence Awards 2019.

An independent jury under the Chairmanship of Dr R A Mashelkar selected the winners for the awards.

• Hall of Fame: Gurcharan Das, Former CEO, Procter & Gamble India • Lifetime Achievement: Dilip Shanghvi, MD, Sun Pharmaceuticals Pvt Ltd • Best Initiative by State: State of Odisha • Business Leader of the Year - Water Management : Dr Mahesh Gupta, Founder Chairman, Kent RO Systems Ltd • Business Leader of the Year - Specialty Chemicals : Ramakant Tibrewala, CMD, Rohadyechem Pvt Ltd • Business Leader of Year - Chemicals & Petrochemicals: Prasad K Panicker, ED – BPCL, Kochi Refinery • Business Leader of the Year Engineering Services: Vinayak Deshpande , MD, TATA Projects Ltd • Business Leader of the Year - Plant & Machinery: Sanjay Kirloskar, CMD, Kirloskar Brothers Ltd • Outstanding Achievement - R&D Excellence (Individual) : Prof Dr A B Pandit • Outstanding Achievement - R&D Excellence (Corporate) : Praj Industries Ltd • Outstanding Achievement - Start-Up: Devang Shah, Gaurang Shah, Bulk MRO Industrial Supply Ltd

March 2019 • 25

CEW Features

Double Tubesheet Heat Exchangers – Necessity and Challenges Among all types of heat exchangers shell and tube types are in huge demand for industrial applications. This paper specifically talk about double tubesheet exchangers with covered connected shroud shell arrangement and it presents special precautions, guidelines for manufacturers during fabrication, testing and assembly of double tubesheet heat exchangers. It also presents two different assembly sequences which by implementing manufacturer can get a quality product.

T

hese shell and tube heat exchangers are suitable for highly corrosive operating fluids and also stand for wide-spread of pressure and temperature conditions. However, all these heat exchangers are equipped with single partition between shell side and tube side fluid which is popularly known as tubesheet.

Typically, there can be leakage through tube-to-tubesheet joint which are generally the weakest points in heat exchangers. This leakage can contaminate the other side with lower operating pressure adversely affecting the process parameters. These leakages can not be avoided even after properly designing the tube-to-tubesheet joint by using a strength welded and light expanded joint with appropriate mock up in the fabrication stage.

Applications Double tubesheet heat exchangers are used for applications wherein mixing of tube side and shell side fluid must be avoided.

For instance, Chlorosilanes, while being either on shell/tube side leaks through tubeto-tubesheet joint and mixes with water. It readily reacts with water to form corrosive hydrogen chloride gas and hydrochloric

Figure 1. Shroud with expansion bellow

26 • March 2019

acid along with heat. Many Chlorosilanes evolve flammable gaseous hydrogen gas during exposure to water. Such scenario demand for non-mixing of shell side and tube side fluids.

Another example can be, Condensers in power plants. In the condenser application, water is used as a cooling medium. The cooling water (raw water) can be sea water, river water, tank or pond water. As many a times, cooling water is brackish with lot of contaminants and since the steam side is under vacuum, this water can find a way into the steam condensed water through tubeto-tubesheet joint. Potential for leakage of cooling water arises from tube failures caused by a variety of factors. Mixing of cooling water contaminates the feed water, leading to its unacceptable chemistry.

Since, this condensate further goes to the hot well and from hot well the water is again pumped to the boiler with the help of boiler feed pump. The cooling water mixing with condenser water leads to many problems on the boiler side. The conductivity and pH level of the boiler water gets affected affecting the performance of boiler.

Thus, the primary concern is prevention of contamination of treated and demineralized water due to the leakage of circulating cooling water into the condenser steam space. To overcome this possibility, provision of double tubesheet construction has been made mandatory in couple of countries for power station Condensers.

So far, there is not any known method of joining tube-to-tubesheet which completely eliminates the possibility of leakage. With double tubesheet type construction, any leaks occurring through tube-to-tubesheet joint will accumulate in the space between two tubesheets instead of leaking and contaminating the fluid on the other side.

Therefore, even though double tubesheets will not nullify the leakage, they will eliminate mixing of shell side fluid with tube side or vice-a-versa.

Construction The conventional double tubesheet exchanger has two tubesheets at both ends of tubes. In general scenario, adjacent tubesheets are connected with each other with the help of tubes. Alternatively, shroud shells can be used to cover the gap between

Figure 2. Integral type double tubesheet construction

Chemical Engineering World

Features CEW

Figure 3. Connected type double tubesheet construction

two tubesheets. In this case, leaked fluid from either side is collected in shroud shell.

Shell side tubesheet of double tubesheet U-tube unit, can be constructed with any of the attachment method suitable for removable bundle construction. In case of fixed-tubesheet arrangement, shell side tubesheet is welded with shell, whereas tube side tubesheet may be bolted or welded with channel. In case of drastic difference in Mean Metal Temperature of shell side and tube side and different metallurgy used for shell side, tube side tubesheet, shroud may be provided with expansion bellow as shown in Figure 1 Typically Tubular Exchangers Manufacturers Association (TEMA) covers three types of double tubesheet constructions. Integral (Figure 2), Connected (Figure 3) and Separate (Figure 4) double tubesheet type constructions.

In all three types of constructions care should be taken while designing the tube-totubesheet joint. Primarily, tube side tube-totubesheet joint needs to be strength welded with light expansion (Figure 5). This is to nullify the possibility of leaking the tube side fluid through tube-to-tubesheet joint. On the other side shell side tube-to-tubesheet joint shall be grooved with minimum two grooves and expanded to the full length (Figure 6). This grooved expansion joint need to be selected considering the fact that, on shell side tube-to-tubesheet joint welding is practically impossible.

DESIGN: In connected (Figure 3) and integral (Figure 2) double tubesheets, axial load distribution is taken care by interconnecting element/shroud shell (in case of connected double tubesheet) or integral portion of Chemical Engineering World

Figure 4. Seperate type double tubesheet construction

the tubesheet (in case of integral double tubesshet). In the integral double tubesheet construction, interconnecting element is so rigid that it distributes thermal and mechanical radial loads between the tubesheets and prevents the individual radial growth of tubesheets. For both constructions, tubes can mutually transfer all mechanical and thermal axial loads between the tubesheets.

In general, various types of stresses originated in the construction can be listed as: • Differential pressure stresses due to difference in operating pressures between tube and shell side fluids.

• Axial stresses resulted due to tension or compression of the tubes. Differential thermal expansion between shell and tubes is another parameter that induces axial stresses.

• Shear stresses induced due to differential thermal expansion between the tubes and tubesheet in radial direction.

• Thermal and pressure stresses induced due to upset conditions.

Interconnecting element and tubes between tubesheets of the connected double tubesheet needs to be designed for below listed parameters: • Interconnecting element - Radial shear stress at the junctions due to differential thermal expansion of the tubesheets.

• Interconnecting element - The combined stresses due to bending and axial tension induced due to differential thermal expansion of tubesheets and thermal expansion of tubes respectively.

• Tubes – Axial tensile or compressive/ buckling stresses acting because of operating pressure and thermal expansion.

Fabrication & Testing Tube-to-tubesheet leak tightness is directly affected by how the double tubesheet exchangers are manufactured.

A good quality of tubesheets, baffles and tube supports are produced by drilling the holes with the help of CNC Machines (Computerized Numerically Controlled) either individually or in stack. The CNC machines assures that holes in tubesheets, baffles and support plates are concentric and precise enough to allow them to be occupied by tubes easily. If tubesheets and baffles/support plates are stacked and drilled on conventional radial drilling machines, there is drift as drill penetrates the stack.

During assembly, hole-to-hole positions may also be displaced if tubesheet main center lines are not maintained congruently. Additionally, major difficulties may also be created, if tubesheets are not kept parallel with each other. For the above cited reasons, it is highly important for purchaser to review manufacturer’s equipment/tools and techniques used for drilling and assembly.

Below are couple of guidelines for manufacturers to assure proper assembly: • Tube side and shell side faces of tubesheet shall be machined flat and perpendicular to tube (and bolt) holes. Adjacent faces of tubesheets shall also be machined in the similar fashion from just outside of OTL till tubesheet periphery.

• Suitable number of Spacers either made from pipe, rod or plate shall be prepared preciously machined to the March 2019 • 27

CEW Features

Figure 5. Tube to tubesheet (tube side) Joint

Since non concentric holes in adjacent double tubesheets induce bending and shear forces on tubes and tubesheet ligaments, their concentricity is ensured with this GO gauge.

During tube expansion care should be taken in such a way that the expanded portion should never extend beyond the shell-side face of the tubesheet, since removal of such a tube is extremely difficult.

• Tubesheet ligament tolerances shall be strictly ensured as per TEMA Table RCB 7.22 or RCB 7.22M. Since we are dealing with double Tubesheet constructions, these tolerances can be further made tighter based on manufacturer’s capability and confidence.

In addition to this, tube expansion for inner tubesheets shall be done before welding to outer tubesheets.

Careful selection of type of tube-to-tubesheet joint, sequence of welding and expansion within the tubesheet is of utmost importance.

Displaced holes and ligament distortions make it very difficult to produce tight expanded joints. The outer tubesheet joints can be made tight by welding. However, problem remains at the inner tubesheet, where joints can be only made by process of expanding as there is no access for welding.

Figure 6. Tube to Tubesheet (shell side) joint

specified gap distance between the tubesheets.

• Match marking/punching on tubesheet shall be done.

• Align these match marking points on both tubesheets of each pair.

• The spacers shall be placed equally on the periphery between the pair of tubesheets. Clamping of these aligned tubesheet pair shall be done. These clamping shall be kept in place until all tubing, tube-to-tubesheet joining, tubesheet to shell/channel assembly has been completed.

• A GO gauge machined from a rod for a length somewhat longer than the distance between outer faces of tubesheets shall be prepared. Diameter of gauge shall be 0.05 mm less than the recommended TEMA standard drilled hole size with over tolerance of 0.00 mm and under tolerance of TEMA permitted hole under tolerance. The GO gauge is to ensure free entry of tubes in tube holes of both tubesheets.

Before tubing the assembly, check randomly in each quadrant of tubesheet layout that the gauge is entering freely.

28 • March 2019

In general, tube end rolling (expansion) within tubesheet shall always be done after welding of tube-to-tubesheet joint. This is mainly because of below reasons – • Tube expansion (rolling) before welding may leave lubricant from the tube expander in the tube holes. Lot of other fabrication impurities also gets accumulated at tube ends. Satisfactory welds are rarely possible under absence of extreme cleanliness.

• During tube expansion before welding, expander pushes tubes against inside surface of tubesheet in the tube holes creating uneven gap between outer periphery of tube and tube hole within tubesheet. Successful welding with uneven weld gap is very difficult.

• Tube-to-tubesheet joint welding after expansion creates uneven tube movement within tubesheet because of tube thermal expansion. This leads to non-uniform tube tightness with tubesheet surface within tube holes which was already achieved by rolling operation.

• Tube-to-tubesheet joint welding after expansion will trap the welding gases in the space between outer tube surface and tubesheet hole.

Consequently, correct sequence of assembly and testing is very important while fabricating the double tubesheet construction. Especially in fixed tubesheet like TEMA L, M, N and outside-packed floating head (P type rear heads) where number of tubesheets become 4 considering double tubesheet arrangement. In such cases, insertion of tubes through all 4 tubesheets becomes very critical and many a times becomes a challenge. In the factory.

U tube double tubesheet constructions are relatively easy in assembly.

Fabrication and assembly sequences has been presented below for fixed double tubesheet heat exchanger: Method 1: • In case of small diameter shells tubesheet/baffle/tie rod/spacer skeleton shall be made outside the shell considering inaccessible shell inside area. The same can be made inside Shell in case of bigger diameter Shell where operator can enter inside and work.

• First bundle skeleton shall be made with tie-rod end tubesheet pair in place along with spacers and clamping as discussed in above paragraph. (see Figure A ) • Insert above skeleton into the main shell. Nontie rod end tubesheet pair (along with spacers and clamping) shall also be kept in line. Tack welding of shell with shell side tubesheets shall be carried out. (see Figure B).

• Tubes shall be inserted from tie rod end tubesheet pair through the skeleton and guided through the holes of nontie rod end tubesheet pair. Guiding rod typically very small diameter (less than tube inside diameter) shall be used from the opposite end (non-tie rod end) for enabling tube entry through holes in tubesheets and baffles/support plate. (see Figure C) Chemical Engineering World

Features CEW • Tubesheets to main shell welding and NDE shall be carried out. (see Figure C) • Both ends shell side tube-to-tubesheet joint expansion in grooves shall be carried out. Length of mandrel shall be suitable for tube expansion inside the tubesheet. (see Figure D) • Both ends channel side tube-totubesheet joint strength welding and light expansion shall be carried out. (see Figure D) Method 1_Figure A

• Tube to shell side tubesheet joint leak testing (with helium or air) shall be carried based on project specific requirements. (see Figure D) • Tube-to-tubesheet joint on shell side shall be tested for shell side hydrotest pressure. Any leakage can be found out with necked eyes from the free space between pair of tubesheets. (see Figure D) • Channel assembly which has been made ready in parallel shall be connected and bolted with main shell assembly. (see Figure E)

Method 1_Figure B

• Tube-to-tubesheet joint along with other tubeside joints shall be tested for tube side hydrotest pressure and any leaks can be cited from the free space between pair of tubesheets. (see Figure E) • Shroud shell shall be rolled separately in two pieces and match fitted to ensure perfect roundness.

• After completion of all the tests, tubesheet spacers and clamping arrangement shall be removed. Shroud shell shall be inserted in the space between pair of tubesheets in two different parts. It shall be then welded along the length with root run by TIG. Shroud shell shall then be welded with tubesheets. (see Figure F) • Shroud shell hydrotest is not required.

Basically, in Method-1, shroud shell is fitted at the very end. This gives the scope for visibility through the space between pair of tubesheet especially during hydrotest.

Method 2 Method-1 may have difficulty in inserting the shroud shell in two parts, welding along Chemical Engineering World

Method 1_Figure C

the length and then with tubesheet. To overcome this difficulty, Method-2 has been presented below. All the steps in Method-1 shall be followed except below: • Shroud Shell shall be first made ready and it shall be tack welded with one of the tubesheet on tie-rod end side and pair of tubesheet shall be made ready. In this arrangement tubesheet clamping is still required however, tubesheet spacers can be avoided as shroud shell will now act as spacers.

In the similar fashion Non-Tie rod end

tubesheet pair shall also be made ready.

• Tube-to-tubesheet joint on shell side shall be tested for shell side hydrotest pressure.

Any leakage can be detected with drop in pressure, as now with presence of shroud shell there is no visibility in the space between pair of tubesheets.

Manufacturer can alter the intermediate fabrication and testing sequences based on shop facilities, experience and individual technical capability.

March 2019 • 29

CEW Features Demerits of Double Tubesheet Heat Exchangers • Although exchanger total surface area is more, effective surface area reduces significantly due to the fact that effective tube length is measured between inside faces of shell side tubesheet. Tube length surface area in the shroud area is not considered as a heat transfer area. This increases required tube length and in turn overall length of exchanger, further increasing cost of the heat exchanger.

Method 1_Figure D

• Addition of two more tubesheets in double tubesheet construction increases the cost further.

• As discussed in previous sections there are many criticalities and difficulties involved in tubesheet/ baffle/support plate drilling and machining specially to achieve tube hole concentricity and tubesheet surface parallelism. In addition to this, there are challenges in correct sequence of assembly which makes it difficult to produce quality product.

Method 1_Figure E

• Maintenance of these heat exchangers can be very difficult especially tube removal since the tube has been fixed with tubesheets at 4 places.

• The arrangement is only possible in fixed tubesheet, U tube and outside-packed floating head.

Conclusion A well planned fabrication and assembly sequences can be useful while manufacturing double tubesheet heat exchangers.

Method 1_Figure F

Apart from Power Plants, these heat exchangers are also required in Pharmaceutical Industry for Sanitary applications and are designed to meet high quality requirements and hygienic standards of Pharmaceutical industry.

These types are also required in Polysilicon manufacturing plants which then used in Solar Power Plants.

and shroud shell, fabrication, assembly sequences and testing methodologies.

Out of two proposed assembly sequence methods, any one method can be adopted by the manufacturer.

This paper presents reasons for selection of such type of heat exchangers, various types of stresses in tubes, tubesheet

2. Perry’s Chemical Engineers Handbook, Seventh Edition, Mc-Graw Hill Publications

30 • March 2019

References 1. Standards of the Tubular Exchanger Manufacturers Association (TEMA), 9 th Edition, New York

3. A Working Guide to Shell and Tube Heat Exchangers, Stanley Yokell, Mc-Graw Hill, 1990.

Author Details

Purushottam M Misal E-mail: Purushottam.m.misal@fluor.com Chemical Engineering World

Features CEW

An anti-fouling and corrosion resistant ceramic coating for heat exchanger tubes Corrosion of boiler tubes remains an operational and economic constraint for example in Waste-to-Energy (WtE) facilities. This article presents an innovative anti-fouling and highly corrosion resistant ceramic coating that has been developed by the Tubacex Group for application to the external and internal surfaces of tubes frequently used in the heat process industries.

C

orrosion and fouling of boilers or heat exchange systems can cause significant economic penalties and it is estimated that those problems cost industries billions of dollars per year.

Therefore, minimizing operating costs and maintaining equipment reliability are primary goals in today’s difficult economic climate. Heat exchangers are used to recover sensible heat from process streams (reactors, distillation columns etc.) to preheat the feedstock and minimize the external energy demand to provide the required heat for the process. Fouling in the exchanger train and the related reduction of heat transfer can cause significant energy loss and increase operating costs. Fouling can also become so severe that unit capacity and production limits are reached. Typically, units are then shutdown incurring high maintenance costs and production losses, as well as increased environmental and safety concerns.

Similarly, corrosion of boiler tubes remains an operational and economic constraint for example in Waste-to-Energy (WtE) facilities. The formation of low melting temperature salts of chloride and sulphate mixture react and dissolve the protective oxide films on the metal surface of the equipment (e.g. tubes). Current methods

of protection remain costly: refractory lining of waterwall tubes, highly alloyed corrosion resistant materials or use of surfaces coating such as weld overlays of nickel-chromium based alloys have become popular.

Among the various corrosion resistant and anti-fouling materials and coating systems used in the industries, ceramic coatings have the advantages of chemical inertness, high temperature stability, and superior mechanical properties compared to the other ones.

Additionally, they can demonstrate a strong bonding to the substrate they are deposited onto and be applied in thin layers that will minimize the thermal insulating effect. Finally, glass-based ceramic coatings show very smooth surface states (roughness Ra <0.04 um), which play an important role against the formation of scale (e.g. adherence of ashes or coke).

The Tubacoat concept is based on the utilization of a silica-based ceramic coating that can be applied inside and outside of long and narrow metallic tubes of different substrate types (preferentially stainless steel). The process is comparable to a sintering process that has to be carried out under controlled temperature and atmosphere in a furnace.

The major Tubacoat properties are: 1. Microstructure, Morphology & Surface state A ceramic slurry (suspension) is applied on the tube inner and/or outer surface before the sintering process. Suspension parameters and rheological properties are controlled to ensure a continuous and well spread on the steel surface. As a result, a very low coating roughness prevents from the settlement of particles onto the coating surface (fouling).

2. Thermal conductivity, Adhesion and Thermal Shock Properties Thermal conductivity measurements and thermal shocks tests has been performed.

No cracks in the coating, coating detachment or interlayer at the coatingsteel interface was observed, which suggests that the coating has a thermal expansion coefficient similar to that of the steel and had a strong chemical bond with the steel. Furthermore, and due to the thin ceramic layer applied the heat transfer is marginally affected through the ceramic coating.

3.Corrosion resistance The glass-ceramic coatings possess superior coating properties as compared to conventional vitreous enamel.

Figure 1. Tubacoat ceramic coating applied on tube size ranging from 20 to 150 mm diameter

Chemical Engineering World

March 2019 â&#x20AC;˘ 31

CEW Features WTE, where the tube temperature is at its maximum.

Figure 2. Tubacoat typical thickness range: 100-150 µm and surface roughness Ra<0.04 µm

Table 1 shows some of the corrosion resistance properties of the coating: Therefore, Tubacoat can be recommended as a highly corrosion resistant vitreous coating on steel tubes to transform it into a superior material of construction for power generation, chemical, oil, gas and allied industries.

Industrial Applications •Energy from Waste Energy conservation and environmental protection are currently very important issues worldwide.

Municipal solid waste (MSW) can be converted to an eco-friendly renewable resource that not only produces energy but

also significantly reduces the greenhouse gas emissions from landfills. A wasteto-energy (WTE) incineration plant recovers energy from MSW and produces electricity and/or steam for heating. For a WTE plant, the energy efficiency can be improved and CO2 emissions be reduced by improving the heat efficiency of the boiler system because this is the main method for heat transfer. The variability in the heating value of the MSW and the high content of chlorine and light metals contribute to a highly corrosive atmosphere that shorten the life of the heat exchangers tubes used. For example, in the waterwall section, where water is evaporated and, especially in the steam superheater sections of the

As the hot combustion gas flow over the heat transfer surfaces, such as membrane water tubes (waterwall) superheater tube bundles, evaporator tubes and economizer tubes, heat is transferred from the gases to the water vapor within the tubes. The efficiency of conversion steam energy to electricity increases with higher steam temperatures. However, with increasing steam temperature, the heat transfer surfaces are subjected to severe high temperature corrosion, caused by both the metal chlorides in the ash particles deposited on the gas tubes and by the high concentration of HCl in the process. Fig. 4 shows the corrosion and fouling sensitive areas in a WTE facility. The typical working conditions are: T Steam: 300 OC, P = 170 bar, T Fumes: 850 OC, inner media: Steam, Outer media: Alkaline ashes Loss of heat transfer and subsequent charge outlet temperature decrease is a result of the low thermal conductivity of the fouling layer or layers which is generally lower than the thermal conductivity of the fluids or conduction wall. As a result of this lower thermal conductivity, the overall thermal resistance to heat transfer is increased and the effectiveness and thermal efficiency of heat exchangers are reduced.

The mechanism for corrosion is mainly determined by the most abundant deposits observed on the metal after corrosion, i.e. oxidation by metal oxides, sulfidation by metal sulphides, sulfidation/ oxidation by mixtures of sulphides and

Figure 3. Thermal cycling (450ºC / 10 min) + Rapid water cooling (15ºC) test on Tubacoat samples

32 • March 2019

Chemical Engineering World

Features CEW Type of corrosion

Pitting

Corrosion Test

Result

JIS G-0577: 2005 5% NaCl @ 25OC, 2 hrs

no alteration

ASTM G48, Method A Ferric-Chloride 10% FeCl

ca. 0 g/m2²

Crevice

10% FeCl3 @ 22°C

Sea Water

3.5% NaCl @ 22oC, 2000 hrs

HCl Test

10% HCl @ 22oC, 2000 hrs

only loss of coating brightness

HNO3 and H2SO4

HNO3 60%, 6 hrs H2SO4 30%, 18 hrs

0.06 g/m@ 0.23 g/m2²

Molten Salts Test

NaNO3 + KNO3 (60/40), 46 cycles heating (8h @400OC) + cooling (air)

No visible corrosion

no visible corrosion

Table 1: Some of the typical Corrosion Resistance properties of Tubacoat

oxides, carburization by metal carbides and chlorination of metals to metal chlorides. In general, there are two principal mechanisms of high temperature corrosion: active oxidation (above 450 oC) and corrosion due to deposits by sulphation and by molten salts.

The Tubacoat ceramic coating was applied to the heating surfaces of boiler waterwall tubes of a Waste to Energy Plant in Spain. The effect of the ceramic coating on fouling resistance and energy efficiency was evaluated after 6 months, 1, 3 and 5 years of operation of the boiler. As seen in Fig. 5 a significant difference in the coated and uncoated areas of the boiler surfaces was observed.

The coated surfaces were relatively clean with only small amount of unwanted matters attached on a small part of boiler surface.

The thermal efficiency of boilers was calculated before and after applying the composite ceramic coating and the amount of produced steam (production amount). It has been demonstrated that the developed ceramic coating has great potential to be applied in real boiler systems to improve their overall thermal efficiency.

•Refinery In a crude preheat exchanger system, the hot preheat section is usually the area of greatest concern. The hottest exchangers or exchangers with the highest heatflux Chemical Engineering World

typically show the highest fouling rates.

This is also the case for the hydrotreater feed/effluent exchangers and the slurry exchangers. fouling can lead to local hot spots resulting ultimately in mechanical failure of the heat transfer surface. Major detrimental effects of fouling include loss of heat transfer as indicated by charge outlet temperature decrease and pressure drop increase.

Other detrimental effects of fouling may also include blocked process pipes, under-deposit corrosion and pollution.

In addition, increased surface roughness due to fouling will increase frictional resistance to flow. Such effects inevitably lead to an increase in the pressure drop across the heat exchanger, which is required to maintain the flow rate through the exchanger, and may even lead to flow blocks.

Intermediate cleanings represent significant economic penalties, if not planned in the normal refinery operation. increases the fouling or coking tendency of the furnace. Both effects further increase fuel demand and energy costs. Mechanical cleaning, using high pressure jetting, is typical.

Opening the equipment also increases the risk of damage and additional repair costs, as well as safety and environmental concerns.

Different fouling deposit structures can lead to under-deposit corrosion of the substrate material such as localised fouling, deposit tubercles and sludge piles. The factors that are most likely to influence the probability of under-deposit corrosion include deposit composition and its porosity and permeability. Even minor components of the deposits can sometimes cause severe corrosion of the underlying metal such as the hot corrosion caused by vanadium in the deposits of fired boilers.

Conclusion The use of glass-ceramic coated equipment may be of primary importance to their producers, suppliers and consumers as this results in lowering of production costs , increasing productivity , improving reliability and waste reduction.

The coatings can be successfully used for various challenging applications across wide specytrum of industries such as: Power generation boilers (Coal, Biomass, Urban garbage): water walls, steam re-

Figure 4. Tubacoat typical application in Steam Reheater of a Waste-to-Energy Plant

March 2019 • 33

CEW Features

Figure 5. Tubacoat tubes after 3 years life in the superheater section

heaters, super heaters and heat recovery bundles, Tubular systems of Molten salt solar power plants , Ash corrosion and fouling in the Oil and Gas Industry (Visbreaker, Coke Unit, Coke Calciner, Heat Recovery Units…), Overhead Sulphur

Condensers , Metal dusting avoidance (Syngas, Supercritical CO 2, etc.) and Nitric Acid Condensers

2. Forming an impervious barrier, preventing corrosive products of combustion from attacking the metal tubes

As a glass-ceramic coating Tubacoat is not only new generation of coatings but also versatile engineering materials which increase the service life of different types of metallic substrates. They have a very potential and promising market.

Among various coating systems for industrial and engineering applications, Tubacoat glass–ceramic coating has advantages that can be summarized as followed:

3. Non-catalytic technology, molten ash will not sinter and adhere to the surface of the coated tube, preventing from the buildup of an insulation layer.

4. The glass-like film alloys for easy cleaning of the boiler tubes, improving heat transfer and maximizing boiler efficiency.

1. Superior adhesion designed to withstand extreme thermal, physical and chemical conditions within a boiler environment

Article Courtesy: Tubacex

FORM IV Statement about ownership and other particulars about newspaper CHEMICAL ENGINEERING WORLD to be published in the first issue every year after the last day of February 1. Place of Publication

Mumbai

2. Periodicity of its Publication

MONTHLY

3. Printer’s Name Nationality 1[(a) Whether a citizen of India? (b)If foreigner, the country of origin] Address

HEMANT K SHETTY INDIAN YES NOT APPLICABLE 406-D, Karachi Citizens CHS, Juhu-Versova Link Road Andheri (West), Mumbai 400 053.

4. Publisher’s Name Nationality 1[(a) Whether a citizen of India? (b)If a foreigner, the country of origin] Address

HEMANT K SHETTY INDIAN YES NOT APPLICABLE 406-D, Karachi Citizens CHS, Juhu-Versova Link Road Andheri (West), Mumbai 400 053.

5. Editor’s Name Nationality 1[(a) Whether a citizen of India? (b)If a foreigner, the country of origin] Address

MITTRAVINDA RANJAN INDIAN YES NOT APPLICABLE 3RD FLOOR, TAJ BLDG., D N ROAD, FORT, MUMBAI 400 001

6. Names and Addresses of individuals who own the newspaper and partners or shareholders holding more than one per cent of the total capital

JASUBHAI MEDIA PVT LTD., 26, MAKER CHAMBER VI, NARIMAN POINT, MUMBAI 400 021 Maulik Jasubhai Shah (1100, Shanudeep, 10, Altamount Road, Mumbai 400 026), Maulik Business Services Pvt. Ltd & Jasubhai Business Services P Ltd., (26, Maker Chamber VI, Nariman Point, Mumbai 400 021)

I Hemant K Shetty, hereby declare that the particulars given above are true to the best of my knowledge and belief.

Date: 30 th January 2019 34 • March 2019

Signature of Publisher Chemical Engineering World

0 CH4 +H2O â&#x2020;&#x201D; CO + 3 H2; â&#x2C6;&#x2020;đ??ťđ??ť298 = 206 kJ.mol-1

Features CEW

(R1)

Solution To Steam Reforming Natural Gas Process Equations For Primary Reformer 0 CH4 +2H2O â&#x2020;&#x201D; CO2 + 4 H2; â&#x2C6;&#x2020;đ??ťđ??ť298 = -165 kJ.mol-1 0 CH4 + CO2 â&#x2020;&#x201D; 2 CO+ 2 H2; â&#x2C6;&#x2020;đ??ťđ??ť298 = 247 kJ.mol-1

(R2)

(R3)

0 CO +H2O â&#x2020;&#x201D; CO2 + H2 ; â&#x2C6;&#x2020;đ??ťđ??ť298 = 41 kJ.mol-1 (R4) 0 CH4 +H2O â&#x2020;&#x201D; CO + 3 H2; â&#x2C6;&#x2020;đ??ťđ??ť298 = 206 kJ.mol-1 (R1) 0 CnH2m+nH2Oâ&#x2020;&#x201D;nCO+ (n+0.5m) H2; đ??ťđ??ť298 < 0 kJ.mol-1 0 equations CH for obtaining gas composition H2; â&#x2C6;&#x2020;đ??ťđ??ť298 = -165 kJ.mol-1 (R2) from primary 4 +2H 2O â&#x2020;&#x201D; CO2 + 4 outlet

Hampson(1),(2) has developed process reformers of Steam-Natural gas reforming process. A system of five equations, three related to total carbon, hydrogen, 0 CH4 + CO2 â&#x2020;&#x201D; 2 CO+ 2 H2; â&#x2C6;&#x2020;đ??ťđ??ť298 = 247 kJ.mol-1 (R3) oxygen and two for equilibrium constants for reforming and shift0 reactions-1 have been solved analytically to (R4) CO +H2O â&#x2020;&#x201D; CO2 + H2 ; â&#x2C6;&#x2020;đ??ťđ??ť298 = 41 kJ.mol obtain equilibrium gas composition at the outlet of primary reformer. In this paper Newton-Raphson method 0 < 0 kJ.mol-1 CnH2m+nH2Oâ&#x2020;&#x201D;nCO+ (n+0.5m) H2; đ??ťđ??ť298 has been used to work the process equations for estimation as it has advantage of obtaining quicker solution over analytical solution. For the sake of convenience, the equations developed, nomenclature and data used in previous work are retained.

T

he equilibrium composition of reversible reactions is obtained either by Gibbâ&#x20AC;&#x2122;s free energy minimization or by formulating and solving equilibrium constant governing equations.

The former method uses the fact that at constant temperature and pressure the Gibbs-free energy of reacting mixture reaches a minimum value to determine equilibrium composition. In the later method mass balance equations related to various species in the system are related to the equilibrium constants for reactions describing the process. Zelenik and Gordon (3) have stated that neither method can have inherent advantage in obtaining equilibrium composition.

Rao, (4) however, has mentioned that the free energy minimization method has the added advantages that knowledge of set of primary reactions and values of equilibrium constants is not necessary to determine the equilibrium composition. In the free energy minimization procedure the question of what chemical reactions are involved never enters into the any of the equations.

Smith et al (5) has illustrated the method of Gibbs-free energy minimization to obtain composition of reformed gas using MATHCAD. Finlayson (6) has illustrated â&#x20AC;&#x2DC;Goal seekâ&#x20AC;&#x2122; or â&#x20AC;&#x2DC;Solverâ&#x20AC;&#x2122; functionality of EXCEL. Constantanides Mustofi (7) and Finlayson have presented a MATLAB solution using f solve, f minsearch and f zero functions. Keith (8) has obtained solution by solving equilibrium constants and method of successive substitution using a program srzero in MATHCAD. Rostrup Chemical Engineering World

J and Nielson (9) has provided spreadsheet solution for solving equilibrium constants.

CH4 +H2O â&#x2020;&#x201D; CO + 3 H2 CO +H2O â&#x2020;&#x201D; CO2 + H2

0 â&#x2C6;&#x2020;đ??ťđ??ť298 = +206 kJ.mol-1

0 â&#x2C6;&#x2020;đ??ťđ??ť298

= - 41 kJ.mol-1

(R1) (R4)

The shift reaction reaches equilibrium quickly, however the reforming reaction does not. An allowance can be made for 0 CH4 +H2O â&#x2020;&#x201D; CO deviation + 3 H2 â&#x2C6;&#x2020;đ??ťđ??ť298 = +206 kJ.mol-1 (R1) from equilibrium by assuming 0 CH4 +H2O â&#x2020;&#x201D; CO + 3 H2; â&#x2C6;&#x2020;đ??ťđ??ť298 = 206 kJ.mol-1 (R1) (10) 0 to equilibriumâ&#x20AC;? . Thus, at the + H2 â&#x2C6;&#x2020;đ??ťđ??ť298 = - 41 kJ.mol-1 (R4) CO +H2O â&#x2020;&#x201D; CO2â&#x20AC;?approach 0 = -165 kJ.mol-1 (R2) CH4 +2H2O â&#x2020;&#x201D; CO2 + 4 H2; â&#x2C6;&#x2020;đ??ťđ??ť298 đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?2 3 . đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?gas mixture exists reformer exit equilibrium (1) K1 = đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?

4 .đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?2 đ?&#x2018;&#x201A;đ?&#x2018;&#x201A; 0 -1 containing H , CO, CO , unconverted CH 4 CH4 + CO2 â&#x2020;&#x201D; 2 CO+ 2 H2; â&#x2C6;&#x2020;đ??ťđ??ť298 = 247 kJ.mol (R3) 2 2 đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?2 .đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?2 K2 = (2) and inerts. đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?.đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?2 đ?&#x2018;&#x201A;đ?&#x2018;&#x201A; CO +H2O â&#x2020;&#x201D; CO2 + H2 ; â&#x2C6;&#x2020;đ??ťđ??ť 0 = 41 kJ.mol-1 (R4)

Complete steam reforming reaction scheme can be represented by the following set of equations :

298

0 CnH2m+nH2Oâ&#x2020;&#x201D;nCO+ (n+0.5m) H2; đ??ťđ??ť298 < 0 kJ.mol-1

(R5)

The equilibrium constants for reforming and shift reactions can be written as, đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;? 3 . đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?

2 K1 = đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?

(1)

4 .đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?2 đ?&#x2018;&#x201A;đ?&#x2018;&#x201A; The methane steam reforming reaction đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?2 .đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?2 represented by R1 and water gas K2 = đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?.đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;? đ?&#x2018;&#x201A;đ?&#x2018;&#x201A; (2) CHEMCON-2017 2 shift reaction represented by R4 are independent reactions from thermodynamic point of view. Other reactions are linear It is possible to relate product composition combinations of selected two. Reaction to total carbon, hydrogen and oxygen in R5 represents steam reforming of higher the system and also equations for K 1 and are five equations and five K 2 .Thus there 0 hydrocarbons. above 3 H2 â&#x2C6;&#x2020;đ??ťđ??ť298 =unknowns. +206 kJ.mol-1 However, (R1) CH C H EAll M Cof O Nthe 2 20O 1â&#x2020;&#x201D; 7 CO +reactions 1|P a g e 4 -+H the form of equation may describe specificCO operating conditions. makes hand calculations difficult so for K 0 -1 1 (R4) +H2O â&#x2020;&#x201D; CO2 + H2 â&#x2C6;&#x2020;đ??ťđ??ť298 = - 41 kJ.mol Thus, design of steam reforming process also the conventional iterative procedures do not converge quickly on the solution. requires solution to equations represented

by R1 and R4.

DEVELOPMENT OF EQUATIONS Material balance equations for the system Several thermodynamic process are as follows: simulators for process systems design đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?2 3 . đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;? Let A= Total moles of Carbon in the system such as ASPEN+, HYSIM, Hysis, KProsim, (1) 1= đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?4 .đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?2 đ?&#x2018;&#x201A;đ?&#x2018;&#x201A;

B= Total moles of Hydrogen in the system and VMGSim are available. However open đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?2 .đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?2 2= C= Total(2)moles of Oxygen in the system đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?.đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?2 đ?&#x2018;&#x201A;đ?&#x2018;&#x201A; source software such as DWSIM Khaving

similar capacity are widely used.

FORMULATION OF THE PROBLEM: The steam reforming process design equations require solution to two equations C H E M C O N - 2 0 1steam 7 representing methane reforming and water gas shift reaction.

Let the composition of reformed gas at the exit of the primary reformer a = kmoles of H 2 b = kmoles CO c = kmoles CO 2 d = kmoles CH 4

1|P a g e

March 2019 â&#x20AC;˘ 35

1|P a g e

CEW Features

đ?&#x2018;&#x17D;đ?&#x2018;&#x17D;2 (1-K2) + â&#x2C6;&#x2026; a- K2 (đ?&#x153;&#x192;đ?&#x153;&#x192;-4d) (B-2d) = 0

e = kmoles H 2O

a =

f = kmoles inerts

(14) Reformer outlet temperature = 800 0C

content in reformed gas â&#x20AC;&#x2DC;dâ&#x20AC;&#x2122;, solving for (15) 2(1â&#x2C6;&#x2019;đ??žđ??ž2) corresponding hydrogen content â&#x20AC;&#x2122;aâ&#x20AC;&#x2122; and reformer pressure â&#x20AC;&#x2122;Pâ&#x20AC;&#x2122;.

â&#x2C6;&#x2026; Âąâ&#x2C6;&#x161;â&#x2C6;&#x2026;2 +4K2 (1â&#x2C6;&#x2019;đ??žđ??ž2)(đ?&#x153;&#x192;đ?&#x153;&#x192;â&#x2C6;&#x2019;4d) (Bâ&#x2C6;&#x2019;2d)

â&#x2C6;&#x2018; moles = a+b+c+d+e+f

Equilibrium constants

(9)

0 đ?&#x2018;&#x192;đ?&#x2018;&#x192; â&#x2C6;&#x2019; đ?&#x2018;&#x192;đ?&#x2018;&#x192;Reforming reaction K1 = 118.2 @ 785 C

Initially two values of â&#x20AC;&#x2DC;dâ&#x20AC;&#x2122; are 2 =used đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;đ?&#x2018;&#x203A;đ?&#x2018;&#x203A; say, â&#x2C6;&#x2019; đ?&#x2018;&#x192;đ?&#x2018;&#x192;d n-1â&#x2C6;&#x2019;đ?&#x2018;&#x203A;đ?&#x2018;&#x203A; đ?&#x2018;&#x192;đ?&#x2018;&#x192; ( đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;đ?&#x2018;&#x203A;đ?&#x2018;&#x203A; â&#x2C6;&#x2019; đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;đ?&#x2018;&#x203A;đ?&#x2018;&#x203A;â&#x2C6;&#x2019;1 ) (16) đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;đ?&#x2018;&#x203A;đ?&#x2018;&#x203A;+1 đ?&#x153;&#x192;đ?&#x153;&#x192; = 2(b+c+d) (a+2d+e)-2(0.5b+c+0.5e) đ?&#x2018;&#x17D;đ?&#x2018;&#x17D;3 .đ?&#x2018;?đ?&#x2018;?material+ đ?&#x2018;&#x192;đ?&#x2018;&#x192; Writing balance for Carbon, đ?&#x2018;&#x2018;đ?&#x2018;&#x2018; â&#x2C6;&#x2019; đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;đ?&#x2018;&#x203A;đ?&#x2018;&#x203A;+115= đ?&#x2018;&#x203A;đ?&#x2018;&#x203A; đ?&#x2018;&#x203A;đ?&#x2018;&#x203A;â&#x2C6;&#x2019;1 and d to calculate corresponding reformer 0 K = ( ) (4) 1 ) + (a+2d+e)-2(0.5b+c+0.5e) n = 1.136 (Assuming C đ?&#x2018;&#x203A;đ?&#x2018;&#x203A; Shift Reaction K đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;.đ?&#x2018;&#x2019;đ?&#x2018;&#x2019; đ?&#x2018;&#x17D;đ?&#x2018;&#x17D;+đ?&#x2018;?đ?&#x2018;?+đ?&#x2018;?đ?&#x2018;?+đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;+đ?&#x2018;&#x2019;đ?&#x2018;&#x2019;+đ?&#x2018;&#x201C;đ?&#x2018;&#x201C; 2 Hydrogen and Oxygen pressures P n-1 and P n. The value of â&#x20AC;&#x2DC;d â&#x20AC;&#x2DC;to Approach to equilibrium) @800 0C = a+b+4d (8) be used in(n+1) th calculation is obtained by (8) A = b+c+d Carbon balance (1) Intermediate calculation parameter; & Ă&#x2DC; using rule: đ?&#x153;&#x192;đ?&#x153;&#x192; 2(b+c+d) + (a+2d+e)-2(0.5b+c+0.5e) b == đ?&#x153;&#x192;đ?&#x153;&#x192;-a-4d (9) Hydrogen (2) B =a+2d+e đ?&#x2018;&#x17D;đ?&#x2018;&#x17D;3 .đ?&#x2018;?đ?&#x2018;? đ?&#x2018;&#x192;đ?&#x2018;&#x192; balance 2 (9)) From equation (6) đ?&#x2018;&#x192;đ?&#x2018;&#x192; â&#x2C6;&#x2019; đ?&#x2018;&#x192;đ?&#x2018;&#x192; K1 = đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;.đ?&#x2018;&#x2019;đ?&#x2018;&#x2019; (đ?&#x2018;&#x17D;đ?&#x2018;&#x17D;+đ?&#x2018;?đ?&#x2018;?+đ?&#x2018;?đ?&#x2018;?+đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;+đ?&#x2018;&#x2019;đ?&#x2018;&#x2019;+đ?&#x2018;&#x201C;đ?&#x2018;&#x201C; â&#x2C6;&#x2019; đ?&#x2018;&#x192;đ?&#x2018;&#x192; đ?&#x2018;&#x203A;đ?&#x2018;&#x203A; ( đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;đ?&#x2018;&#x203A;đ?&#x2018;&#x203A; â&#x2C6;&#x2019; đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;đ?&#x2018;&#x203A;đ?&#x2018;&#x203A;â&#x2C6;&#x2019;1 ) (16) (16) đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;đ?&#x2018;&#x203A;đ?&#x2018;&#x203A;+1 = đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;đ?&#x2018;&#x203A;đ?&#x2018;&#x203A;(4) C =0.5b+c+0.5e Oxygen balance (3) đ?&#x2018;&#x203A;đ?&#x2018;&#x203A; â&#x2C6;&#x2019; đ?&#x2018;&#x192;đ?&#x2018;&#x192;đ?&#x2018;&#x203A;đ?&#x2018;&#x203A;â&#x2C6;&#x2019;1 = a+b+4d (8) c= A-b-d (10) đ?&#x2018;&#x17D;đ?&#x2018;&#x17D;.đ?&#x2018;?đ?&#x2018;? = A- đ?&#x153;&#x192;đ?&#x153;&#x192;+a+3d = 2 x102 +504-2 x 153 = 402 kmoles (5) K2 = đ?&#x2018;?đ?&#x2018;?.đ?&#x2018;&#x2019;đ?&#x2018;&#x2019; constant for reforming Equilibrium - đ?&#x153;&#x192;đ?&#x153;&#x192;+a+3d (10) reaction, The process is repeated till the calculated 2 đ?&#x2018;&#x17D;đ?&#x2018;&#x17D;3 .đ?&#x2018;?đ?&#x2018;? đ?&#x2018;&#x192;đ?&#x2018;&#x192; b = đ?&#x153;&#x192;đ?&#x153;&#x192;-a-4d (4) e=B-a-2d (11) pressure (9) and K1 = đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;.đ?&#x2018;&#x2019;đ?&#x2018;&#x2019; (đ?&#x2018;&#x17D;đ?&#x2018;&#x17D;+đ?&#x2018;?đ?&#x2018;?+đ?&#x2018;?đ?&#x2018;?+đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;+đ?&#x2018;&#x2019;đ?&#x2018;&#x2019;+đ?&#x2018;&#x201C;đ?&#x2018;&#x201C;) (4) reformer pressures are From equation (7) (11) equal. Once the value of d is obtained c= A-b-d = A- đ?&#x153;&#x192;đ?&#x153;&#x192;+a+3d (10) = 102 + 1.136 x504 + 3d (1-2x1.136) Equilibrium constant for water gas shift reaction, the entire outlet gas composition đ?&#x2018;&#x17D;đ?&#x2018;&#x17D;.đ?&#x2018;?đ?&#x2018;?

Ke=B-a-2d 2= đ?&#x2018;?đ?&#x2018;?.đ?&#x2018;&#x2019;đ?&#x2018;&#x2019;

(5)

can be found out. However, the hand (5) (11) calculations are time consuming. It is proposed to work the equations using

đ?&#x2018;&#x192;đ?&#x2018;&#x192;đ?&#x2018;&#x203A;đ?&#x2018;&#x203A; â&#x2C6;&#x2019;

đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;đ?&#x2018;&#x203A;đ?&#x2018;&#x203A;+1 = đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;đ?&#x2018;&#x203A;đ?&#x2018;&#x203A; â&#x2C6;&#x2019;

đ?&#x2018;&#x192;đ?&#x2018;&#x192;đ?&#x2018;&#x203A;đ?&#x2018;&#x203A; â&#x2C6;&#x2019; đ?&#x2018;&#x192;đ?&#x2018;&#x192;

đ?&#x2018;&#x192;đ?&#x2018;&#x192;đ?&#x2018;&#x203A;đ?&#x2018;&#x203A; â&#x2C6;&#x2019; đ?&#x2018;&#x192;đ?&#x2018;&#x192;

đ?&#x2018;&#x192;đ?&#x2018;&#x192;đ?&#x2018;&#x203A;đ?&#x2018;&#x203A; â&#x2C6;&#x2019; đ?&#x2018;&#x192;đ?&#x2018;&#x192;đ?&#x2018;&#x203A;đ?&#x2018;&#x203A;â&#x2C6;&#x2019;

- 402(1-1.136) = 729.22-3.816*d

Introducing intermediate calculation (729.22â&#x2C6;&#x2019;3.816đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;) â&#x20AC;&#x201C;â&#x2C6;&#x161;(72 From equation (15), đ?&#x2018;&#x17D;đ?&#x2018;&#x17D; = and Ă&#x2DC; and expressing each parameters đ?&#x2018;&#x17D;đ?&#x2018;&#x17D;.đ?&#x2018;?đ?&#x2018;?

(5) K2 = đ?&#x2018;?đ?&#x2018;?.đ?&#x2018;&#x2019;đ?&#x2018;&#x2019; (729.22â&#x2C6;&#x2019;3.816đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;) â&#x20AC;&#x201C;â&#x2C6;&#x161;(729.22â&#x2C6;&#x2019;3.816đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;)2 â&#x2C6;&#x2019;0.618(402â&#x2C6;&#x2019;4d) (504â&#x2C6;&#x2019;2d) variable in terms of â&#x20AC;&#x2DC;aâ&#x20AC;&#x2122; and â&#x20AC;&#x2DC;dâ&#x20AC;&#x2122; From equation (12), From equation (15), đ?&#x2018;&#x17D;đ?&#x2018;&#x17D; = (729.22â&#x2C6;&#x2019;3.816đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;) â&#x20AC;&#x201C;â&#x2C6;&#x161;(729.

0.272 (6) đ?&#x153;&#x192;đ?&#x153;&#x192; = 2A + B â&#x20AC;&#x201C; 2C (6) From equation (15), đ?&#x2018;&#x17D;đ?&#x2018;&#x17D; = (610â&#x2C6;&#x2019;2đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;) 118.2 đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;(504â&#x2C6;&#x2019;đ?&#x2018;&#x17D;đ?&#x2018;&#x17D;â&#x2C6;&#x2019;2đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;) From equation (12), Newton Raphson numerical 2technique.

P= equation â&#x2C6;&#x161; (12), (729.22â&#x2C6;&#x2019;3.816đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;) â&#x20AC;&#x201C;â&#x2C6;&#x161;(729.22â&#x2C6;&#x2019;3.816đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;) â&#x2C6;&#x2019;0.618(402â&#x2C6;&#x2019;4d) (504â&#x2C6;&#x2019;2d) From đ?&#x2018;&#x17D;đ?&#x2018;&#x17D; đ?&#x2018;&#x17D;đ?&#x2018;&#x17D; (402â&#x2C6;&#x2019;aâ&#x2C6;&#x2019;4d) From equation (15), đ?&#x2018;&#x17D;đ?&#x2018;&#x17D; = (1-2K2) - đ?&#x153;&#x192;đ?&#x153;&#x192;(1-K2)2 (7) (7) (P2)function 0.272 = A(B-a-2d) + BK2+3d(a+b+c+d+e+f) 3. (The objective is pressure P, = a đ?&#x153;&#x192;đ?&#x153;&#x192;-a-4d).

Kđ?&#x153;&#x192;đ?&#x153;&#x192;1â&#x2C6;&#x2026;=(d) (610â&#x2C6;&#x2019;2đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;) 118.2 đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;(504â&#x2C6;&#x2019;đ?&#x2018;&#x17D;đ?&#x2018;&#x17D;â&#x2C6;&#x2019;2đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;) 2(b+c+d) + (a+2d+e)-2(0.5b+c+0.5e) 2 = a3. ( đ?&#x153;&#x192;đ?&#x153;&#x192;-a-4d).

2) P=(12), From(P equation (610â&#x2C6;&#x2019;2đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;) 118.2 đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;(504â&#x2C6;&#x2019;đ?&#x2018;&#x17D;đ?&#x2018;&#x17D;â&#x2C6;&#x2019;2đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;) â&#x2C6;&#x161; đ?&#x2018;&#x17D;đ?&#x2018;&#x17D; (402â&#x2C6;&#x2019;aâ&#x2C6;&#x2019;4d) defined by equation (12) and variable d) (a+b+c+d+e+f) Equation (6) takes following form: đ?&#x2018;&#x17D;đ?&#x2018;&#x17D; P= đ?&#x2018;&#x17D;đ?&#x2018;&#x17D; â&#x2C6;&#x161; đ?&#x2018;&#x17D;đ?&#x2018;&#x17D; (402â&#x2C6;&#x2019;aâ&#x2C6;&#x2019;4d) (610â&#x2C6;&#x2019;2đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;) 118.2 đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;(504â&#x2C6;&#x2019;đ?&#x2018;&#x17D;đ?&#x2018;&#x17D;â&#x2C6;&#x2019;2đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;) is methane gas content in exit gas from đ?&#x153;&#x192;đ?&#x153;&#x192; = 2(b+c+d) + (a+2d+e)-2(0.5b+c+0.5e) P= â&#x2C6;&#x161; = a+b+4d đ?&#x2018;&#x17D;đ?&#x2018;&#x17D; đ?&#x2018;&#x17D;đ?&#x2018;&#x17D; (402â&#x2C6;&#x2019;aâ&#x2C6;&#x2019;4d) primary (8) reformer â&#x20AC;&#x2DC;dâ&#x20AC;&#x2122;.

2 3 = a+b+4d (8) đ?&#x153;&#x192;đ?&#x153;&#x192; = 2A + B â&#x20AC;&#x201C; 2C (P2) K1 (d) (B-a-2d) (a+b+c+d+e+f) = a . ( đ?&#x153;&#x192;đ?&#x153;&#x192;-a-4d).(6) It will be seen that, (9) For the sake b = đ?&#x153;&#x192;đ?&#x153;&#x192;-a-4d (9) of convenience, example P = P (a, d) and a = a (d) b = đ?&#x153;&#x192;đ?&#x153;&#x192;-a-4d (9) solved by Hampson is used.

(7) â&#x2C6;&#x2026; = A + BK2+3d (1-2K2) - đ?&#x153;&#x192;đ?&#x153;&#x192;(1-K(10) 2) c= A-b-d= A= A- đ?&#x153;&#x192;đ?&#x153;&#x192;+a+3d (10) c=đ?&#x153;&#x192;đ?&#x153;&#x192;A-b-d (10) = 2A + Bđ?&#x153;&#x192;đ?&#x153;&#x192;+a+3d â&#x20AC;&#x201C; 2C Example (2): A(6) primary reformer has natural As per chain rule of differential coefficient (11) gas feed consisting of CH 4 90% m, C 2H 6 6% m of function of a function for equations for e=B-a-2d (11) e=B-a-2d (11) â&#x2C6;&#x2026; = A + BK2+3d (1-2K2) - đ?&#x153;&#x192;đ?&#x153;&#x192;(1-K2) and N 2 4% m.(7) Using steam to carbon ratio P and â&#x20AC;&#x2DC;aâ&#x20AC;&#x2122; namely, (12) and (15).

Substituting in equation (4): as 3 an outlet temperature of 800 oC and (đ??´đ??´+đ??ľđ??ľâ&#x2C6;&#x2019;2đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;+đ?&#x2018;&#x201C;đ?&#x2018;&#x201C;) đ??žđ??ž1đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;(đ??ľđ??ľâ&#x2C6;&#x2019;đ?&#x2018;&#x17D;đ?&#x2018;&#x17D;â&#x2C6;&#x2019;2đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;) 2 dP â&#x2C6;&#x201A;P δa δP 3 K ( d ) ( B a 2 d ) ( a + b + c + d + e + f ) = a .

(12) P= â&#x2C6;&#x161; 1 = . + đ?&#x2018;&#x201C;đ?&#x2018;&#x201C;) đ??žđ??ž1đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;(đ??ľđ??ľâ&#x2C6;&#x2019;đ?&#x2018;&#x17D;đ?&#x2018;&#x17D;â&#x2C6;&#x2019;2đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;) đ?&#x2018;&#x17D;đ?&#x2018;&#x17D; 2 đ?&#x2018;&#x17D;đ?&#x2018;&#x17D; (đ?&#x153;&#x192;đ?&#x153;&#x192;â&#x2C6;&#x2019;aâ&#x2C6;&#x2019;4d) a pressure of 28 atmospheres, calculate dd â&#x2C6;&#x201A;a δd δd (12) â&#x2C6;&#x161; đ?&#x2018;&#x17D;đ?&#x2018;&#x17D; (đ?&#x153;&#x192;đ?&#x153;&#x192;â&#x2C6;&#x2019;aâ&#x2C6;&#x2019;4d) ( -a-4d). (P ) reformed gas composition dP â&#x2C6;&#x201A;P δa δP On simplification, dP 1 (θâ&#x2C6;&#x2019;B+2d) = â&#x2C6;&#x201A;a . δd + δd = { 2 â&#x2C6;&#x161;K1. d (A+B-2d+f). aâ&#x2C6;&#x2019;3/2 (Bâ&#x2C6;&#x2019;aâ&#x2C6;&#x2019;2d)1/2 dd (12) dd Solution (đ??´đ??´+đ??ľđ??ľâ&#x2C6;&#x2019;2đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;+đ?&#x2018;&#x201C;đ?&#x2018;&#x201C;) đ??žđ??ž1đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;(đ??ľđ??ľâ&#x2C6;&#x2019;đ?&#x2018;&#x17D;đ?&#x2018;&#x17D;â&#x2C6;&#x2019;2đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;)

P=

đ?&#x2018;&#x17D;đ?&#x2018;&#x17D;

â&#x2C6;&#x161;

(12)

đ?&#x2018;&#x17D;đ?&#x2018;&#x17D; (đ?&#x153;&#x192;đ?&#x153;&#x192;â&#x2C6;&#x2019;aâ&#x2C6;&#x2019;4d)

dP 100 1kmoles of feed Basis: CHEMCON-2017 = { 2 â&#x2C6;&#x161;K1. d (A+B-2d+f). aâ&#x2C6;&#x2019;3/2 Substituting in equation (5): 2 3 Reformer outlet pressure = 28.0 Atm 2) K1 (d) (B-a-2d) (a+b+c+d+e+f) = a . ( đ?&#x153;&#x192;đ?&#x153;&#x192;-a-4d). (Pdd

đ?&#x153;&#x192;đ?&#x153;&#x192;+a+3d) (13) K2 (đ?&#x153;&#x192;đ?&#x153;&#x192;-a-4d) (B-a-2d) = (a) (AEMCON-2017 B-a-2d) = (a) (A- đ?&#x153;&#x192;đ?&#x153;&#x192;+a+3d) (13) C H (13) 2 3 K1 (d) (B-a-2d) (a+b+c+d+e+f) = a . ( đ?&#x153;&#x192;đ?&#x153;&#x192;-a-4d). (P2)

N-2017

CHEMCON-2017

Expressing equation (13) as a quadratic in simplifying: (đ?&#x153;&#x192;đ?&#x153;&#x192;-a-4d) (B-a-2d) = (a) (A- đ?&#x153;&#x192;đ?&#x153;&#x192;+a+3d) Kâ&#x20AC;&#x2DC;aâ&#x20AC;&#x2122; and

Component

2

đ?&#x2018;&#x17D;đ?&#x2018;&#x17D; đ?&#x2018;&#x17D;đ?&#x2018;&#x17D;22 (1-K (1-K22))++â&#x2C6;&#x2026;â&#x2C6;&#x2026;a-a-KK22(đ?&#x153;&#x192;đ?&#x153;&#x192;-4d) (đ?&#x153;&#x192;đ?&#x153;&#x192;-4d)(B-2d) (B-2d)= =0 0

(14)

â&#x2C6;&#x2026; Âąâ&#x2C6;&#x161;â&#x2C6;&#x2026;22+4K2 (1â&#x2C6;&#x2019;đ??žđ??ž2)(đ?&#x153;&#x192;đ?&#x153;&#x192;â&#x2C6;&#x2019;4d) (Bâ&#x2C6;&#x2019;2d)

â&#x2C6;&#x2026; Âąâ&#x2C6;&#x161;â&#x2C6;&#x2026; +4K2 (1â&#x2C6;&#x2019;đ??žđ??ž2)(đ?&#x153;&#x192;đ?&#x153;&#x192;â&#x2C6;&#x2019;4d) (Bâ&#x2C6;&#x2019;2d) aa = = 2(1â&#x2C6;&#x2019;đ??žđ??ž2) (đ??´đ??´+đ??ľđ??ľâ&#x2C6;&#x2019;2đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;+đ?&#x2018;&#x201C;đ?&#x2018;&#x201C;) đ??žđ??ž1đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;(đ??ľđ??ľâ&#x2C6;&#x2019;đ?&#x2018;&#x17D;đ?&#x2018;&#x17D;â&#x2C6;&#x2019;2đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;) 2(1â&#x2C6;&#x2019;đ??žđ??ž2) (15) P= â&#x2C6;&#x161; đ?&#x2018;&#x17D;đ?&#x2018;&#x17D; (đ?&#x153;&#x192;đ?&#x153;&#x192;â&#x2C6;&#x2019;aâ&#x2C6;&#x2019;4d) đ?&#x2018;&#x17D;đ?&#x2018;&#x17D;

Equations (12) and (15) are solved for Cobtaining HEMCO N - 2 gas 0 1 7composition of outlet primary reformer by assuming methane C H(đ??´đ??´+đ??ľđ??ľâ&#x2C6;&#x2019;2đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;+đ?&#x2018;&#x201C;đ?&#x2018;&#x201C;) E M C O N - 2 đ??žđ??ž1đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;(đ??ľđ??ľâ&#x2C6;&#x2019;đ?&#x2018;&#x17D;đ?&#x2018;&#x17D;â&#x2C6;&#x2019;2đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;) 017

P=

â&#x2C6;&#x161;

đ?&#x2018;&#x17D;đ?&#x2018;&#x17D; đ?&#x2018;&#x17D;đ?&#x2018;&#x17D; (đ?&#x153;&#x192;đ?&#x153;&#x192;â&#x2C6;&#x2019;aâ&#x2C6;&#x2019;4d) 36 March K2Câ&#x20AC;˘(đ?&#x153;&#x192;đ?&#x153;&#x192;-a-4d) H E M2019 C(B-a-2d) O N - 2= 0(a)1 (A7 đ?&#x153;&#x192;đ?&#x153;&#x192;+a+3d)

CHEMCON-2017

đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;đ?&#x2018;&#x203A;đ?&#x2018;&#x203A;+1 = đ?&#x2018;&#x2018;đ?&#x2018;&#x2018;đ?&#x2018;&#x203A;đ?&#x2018;&#x203A; â&#x2C6;&#x2019;

CH4

90

90

6

12

4

0

(12)

100

102

N21

(15) (15)

Sub-total 2 â&#x2C6;&#x161;(θâ&#x2C6;&#x2019;aâ&#x2C6;&#x2019;4d) H2O

â&#x2C6;&#x2018; Total

B

.

306

0

102

(12)

(13)

a

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â&#x2C6;&#x161;(θâ&#x2C6;&#x2019;aâ&#x2C6;&#x2019;4d) } x {

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3

+â&#x2C6;&#x161;K1. d (A + B - 2d + f) . ( ) 2

K2(16dâ&#x2C6;&#x2019;2θâ&#x2C6;&#x2019;4 B)

â&#x2C6;&#x161;â&#x2C6;&#x2026;2 +4K2(1â&#x2C6;&#x2019;K2)(Bθâ&#x2C6;&#x2019;2θdâ&#x2C6;&#x2019;4

Chemical World 2 | P Engineering age

â&#x2C6;&#x161;â&#x2C6;&#x2026;2 +4K2(1â&#x2C6;&#x2019;K2)(Bθâ&#x2C6;&#x2019;2θdâ&#x2C6;&#x2019;4Bd+8d^2

(16)

Inert

C

+â&#x2C6;&#x161;K1. d (A + B - 2d + f) . ( ) 406

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C H E Moles M C O N - 2 0Moles 17 H2 | P a g e O

A

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C2H6

(14) (14)

.

Moles

Moles C

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. }

3|P a g e

.

3

1

√(θ−a−4d)2 (B−a−2d)

3

+√K1. d (A + B - 2d + f) . ( )

a(−2−1) √(θ−a−4d) } x { .

1

√(θ−a−4d)2 3

K2(16d−2θ−4 B)

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√∅2 +4K2(1−K2)(Bθ−2θd−4Bd+8d^2 3

+√K1. d (A + B - 2d + f) . ( )

(B−a−2d)

a(−2−1) √(θ−a−4d) } x { K1

2

(A+B−2 d+f)

2

. }

K2(16d−2θ−4 B)

√∅2 +4K2(1−K2)(Bθ−2θd−4Bd+8d^2

. }

(θ –a−4d) {(B−a−4d)(θ –a−4d)}+4d(B−a−2d)}

1

√ + √ [ 2 3 a (a) 2 d(B−a−2d) (θ –a−4d) (B−a−2d) K2(16d−2θ−4 B) (− −1) a 2 √(θ−a−4d) } x { 2 . } (16) √∅ +4K2(1−K2)(Bθ−2θd−4Bd+8d^2 (11)

2

d(B−a−2d)

– ( a) √ (θ –a−4d) ]

(16)

d=37.4074 after 2805 iterations starting The composition of gases from outlet of primary with initial value of ‘d = 25’. The error reformer on molar basis is, H2 = 67.58%m, (θ –a−4d) {(B−a−4d)(θ –a−4d)}+4d(B−a−2d)} 2 d(B−a−2d) CO=9.53% CO2=10.20%m, CH – ( a)m, √ ] 4=11.45%m, set was 0.0001. The number of iterations 2 a (a) 2 d(B−a−2d) (θ –a−4d) N2=1.22% m on dry(θ –a−4d) basis. decreased by 87% with 150% increase in The function is defined as: (16) the initial guess of d (from 10 to 25). This f (d) = 28.0 - P calculated (17) reduction is 97% when the initial guess The proposed method of solution developed K1 (A+B−2 d+f) 1 (θ –a−4d) {(B−a−4d)(θ –a−4d)}+4d(B−a−2d)} help 2 plantd(B−a−2d) engineers in analyzing √ was increased further (from 25 to 237) by can – ( a) √ parameters ] + √ aof‘d’[ is provided.

The major process (a) 2 d(B−a−2d) (17) (θ –a−4d) influencing the f (d) = Initially 28.0 − value P calculated (θ –a−4d) 44%.

Thus, the initial convergence is slow, algorithm calculates ‘a’ and reformer performance of the primary reformer discussed pressure ‘P’. A predefined (16) convergence however, the method converges very fast elsewhere (13). These are: parameter ‘Error’ is defined in the on the root of the equation. It was observed • Reformer outlet pressure, program. Absolute value of error, defined that the value of convergence parameter • Reformer outlet temperature, number of iterations f (d) 28.0 −between P calculated as the= difference calculated value had no effect on the(17) • Steam to carbon ratio, required for arriving at the convergence.

• Carbon lay down, of reformer pressure ’P’ and actual value Newton-Raphson method is used to estimate methane gas content in the K1 (A+B−2 d+f) 1 √ [ + √from primary output gases reformer.

is calculated. It is checked with predefined value of the parameter. The program stops when convergence is reached. In case f (d) the = 28.0 − P calculated convergence is not reached, the new value of ‘d’ is substituted by using following rule: dn+1= dn - Pn/P'n

Converged value of ‘d ‘ is 37.4074.

Corresponding values of a, b, c, e from equations (15), (9), (17) (10) and (11) are 220.951, 31.1673, 33.3624, 208.108 kmoles, respectively.

(18)

The program is written in EXCEL VBA as Annexure-I. C H E MCode C O Nand - 2is0available 17 RESULTS & DISCUSSION Program converged on final value of

CHEMCON-2017

No of Iterations at convergence

SN

Initial Guess ‘d’

1

5

∞

2

10

22217

3

15

12451

10.00

4

20

6424

5.00

5

25

2805

6

30

987

7

35

151

-5.00

8

36

73

-10.00

9

37

18

10

37.4074

Convergence achieved

15.00

f(x) = 28-Pcalcd

CHEMCON-2017 d→

0.00 20

25

30

35

40

45

-15.00 Table-2: Progress of convergence with initial

Fig.-1: Methane content in reformed gas d vs Reformer Pressure, f (P) =28.0-Pcalculated

Chemical Engineering World

guess value of ‘d ’

SN

Initial Guess ‘d’

1

5

No of Iterations at convergence ∞

• CO2 to carbon ratio, • Heat recovery

Operating the reformer at lower pressures reduces the feedstock consumption and minimizes the risk of carbon lay down. The optimum level of outlet pressure is mainly dictated by the best suited pressure level in the CO purification step

5 | P a and g e CO formation reactions Methane reforming R1 and R3 are endothermic. Operating reformer at higher temperatures will favour conversions.

However the higher temperatures are dictated by mechanical strength of the tube material.

5|P a g e The carbon lay down reduces activity of the catalyst and it reduces reformer tube life due to overheating. Similarly the catalyst life is reduced due to disintegration. The carbon formation is 5governed | P a g eby the relative rates of carbon formation due to cracking of hydrocarbons in the feed and the carbon removal through gasification reactions which occur simultaneously. In an optimal reformer both the rates are equal so that there is no net carbon lay down (12). steam to carbon ratio is one of the most important parameter influencing performance of the Steam supplied is always in excess which prevents carbon lay down. At lower ratios, the carbon lay down as well as catalyst disintegration is rapid. Similarly with the excess steam in the feed methane conversion is improved.

March 2019 • 37

CEW Features

Fig-2: Output screen

CO2 to Carbon ratio In order to maximize CO formation, CO2 is added at the inlet of the reformer. With CH4 as a feedstock, a CO/H2 ratio of 1:3 can be achieved at the outlet of reformer by recycling all CO2 formed. A further decrease in this ratio can be achieved by adding import CO2. However the carbon utilization of CO2 decreases significantly as the CO2/C ratio increases beyond a certain level. Further an excessive CO2/C ratio increases the fired heat duty of the reformer and the CO2 recovery and recycling costs, thus increasing CO manufacturing cost.

Heat Recovery In energy optimization study the design of heat recovery system is of great importance. In a CO plant the reformer is the largest energy consumer. The heat recovery has to be brought down to the minimum level by incorporation of combustion air, fuel gas and BFW preheating so as to maximize the plant overall efficiency.

Pinch technology is used for arriving at optimum heat recovery network for overall steam system.

The Newton-Raphson method sometimes faces difficulties in some situations for example, where ƒ'’ (Pn) = 0, for some ‘n’, then formula will involve division by zero, making it impossible to generate Pn+1. However, it is expected because the tangent line to y=f(x) is parallel to x axis where ƒ'’ (Pn) = 0, hence the tangent line does not cross the x axis to generate next approximation.

Other reason of failure could be because the desired root of the equation is overlooked or simply the method may not converge.

Similarly, the derivative of the function is somewhat complicated.

Initially a suitable numerical method such as interval halving, successive substitution, successive bisection or method of Golden Section is chosen to straddle the root of the 38 • March 2019

equation, which may then be sharpened by Newton-Raphson method.

CONCLUSIONS: Equilibrium composition of outlet gases from primary reformer has been calculated for a specific problem where the feed to reformer is a natural gas. The proposed method of solution should be of use to process engineers who are tackling the problem of estimating output from a primary reformer at the design stage. Although the problem has been solved using Excel VBA, the solution approach, numerical method and programming language will vary amongst the readers. Originally, Hampson had developed the equations for the process engineers who first estimate the output from primary reformer, and later are given access to the program which looks at the complete flow sheet, heat and mass balance of the entire hydrogen production plant. Although major contracting companies supplying hydrogen plants already use the proprietary software to tackle this kind of problem, the solution method will be of particular use to those who do not have access to the proprietary software. Numerous process design software are available but are highly capital intensive and access controlled.

The method can also benefit the plant operators in evaluating and analysing the performance of the plant for arriving at optimum operating conditions.

The code can be developed further to obtain equilibrium composition of output stream from primary reformer to include various feed stocks such as naphtha or mixed feed and also to include higher hydrocarbons present in natural gas. .

August/September 1979.

3. Zeleznik F J, Gordon S, Calculation of Complex Chemical Equilibria, Fourth Annual State of Art Symposium on Applied Thermodynamics sponsored by ACS & I&EC, Washington, DC, NASA Technical Memorandum NASA, TM-X52303, June 12-14, 1967 4. Rao Y V C, “Chemical Engineering Thermodynamics”, University Press Limited, Ed 1997, pp 505-514 5. Smith J M, Van Ness H C, Abbott M M, Adopted by Bhatt B I, “Introduction to Chemical Engineering Thermodynamics”, 6th Edition, pp 493-495 Appendix D Page 644 6. Finlayson B A, ’Introduction to Chemical Engineering Computation’, John Wiley Interscience 7. Constantanides A, Mostoufi N, “Numerical Methods for Chemical Engineers with MATLAB applications, Prentice Hall International Series in Physical & Chemical Engineering Sciences, 2nd Edition, 2008 8. Keith J M, Equilibrium Simulation of a Methane Steam Reformer, CACHE Modules on Energy in the Curriculum”, Fogler, 4th Edition, Sections 8.5, Appendix C, October 14, 2008 9. Rostrup-Nielsen J, Christiansen L, Concepts in Syngas Manufacture, Catalytic Science Series, Vol-10, Imperial College Press, Appendix-2, Chemical Equilibrium Constants, pp 317-322 10. Mearns A M, “Chemical Engineering Process Analysis”, Oliver & Boyd, pp 94-95 11. Carnahan B, Luther H A, Wilkes J O ‘Applied numerical methods‘, Wiley, 1969 12. Carlsson M, Matthey J, “Carbon Formation in Steam Reforming and Effect of Potassium Promotion”, Johnson Matthey Technol. Rev, 2015, 59, (4), 313-318 13. KTI Newsletter, Winter 1987, pp 12-17 14. Anderson J R, Boudart M, Catalysis Science & Technology, Springer Verlag, pp 1-118 , Vol 5, 1984 15. Bridger G W, Catalyst Handbook, Springer Verlag, NY, 1970.

Author Details

References: 1. Hampson, G, Design Procedures: A Simple Solution to Steam Reforming Equations (Part1), The Chemical Engineer, Page 523, July 1979.

2. Hampson, G, Design Procedures: A Simple Solution to Steam Reforming Equations (Part-2), The Chemical Engineer, Page 621,

Vishwas V Deshpande Jamnagar Engineering Centre Reliance Industries Limited E Mail: vishwasdeshpande1@rediffmail.com Chemical Engineering World

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Proper Design of Shell and Tube Heat Exchangers This paper provides an overview of key design parameters and recommended practical engineering tips for properly designing shell and tube heat exchangers.

S

hell and tube heat exchangers are widely used equipment for heat transfer applications. Thermal design of heat exchangers is generally carried out using specialized softwares like HTRI, HTFS, etc. While these softwares use rigorous design techniques, user needs to carefully configure the problem, optimize the solution and analyze the design outputs. A consistent design approach is required to standardize the shell and tube heat exchanger designs.

Input Data Review: Adequacy, consistency and completeness of process data for initiating the thermal design should be verified. Below are few important parameters that shall be reviewed firmly at the onset of thermal design.

Physical properties: It is crucial that the physical properties are available over the entire temperature range for both hot side and cold side. In case of presence of multiphase mixtures or for phase change cases, properties of relevant phases should be stated separately. The missing physical properties required to carry out the thermal design can be estimated using steady state simulation softwares. The thermal design software has a limited thermodynamic ability for mixture property predictions.

Temperature cross: For exchangers having a temperature cross, multiple shells in series would be required.

Heat release data: For reboilers, condensers or any other heat exchanger, wherein, phase change is taking place, heat release data is required as the enthalpy would be different at different locations in the exchanger. When only pure components are involved then the heat release will be linear and as the phase change occurs at the same temperature, heat release data is not required. For multicomponent mixtures, if the mixture is of ‘close boiling range’ type, then heat release can be assumed to be

Chemical Engineering World

linear. For multicomponent mixtures with wide boiling ranges, the heat release data impacts the heat transfer area calculations.

When the phase change is occurring over a range of pressure then heat release data at multiple pressure points would improve the thermal design accuracy. For other cases wherein the pressure range is small, heat release data at one single pressure point is adequate.

Cleaning requirements: Based on the cleaning requirements, shell type, tube layout pattern, tube diameter can be selected during thermal design. As an example, if shell side cleaning is required then use of square pitch is recommended.

Similarly, for low shell side Reynolds number, tube pattern of 45 deg is preferred and for moderate to high shell side Reynolds number pattern 90 layout is preferred. If no shellside cleaning is desired then shell type can be selected as fixed tubesheet else a floating head needs to be considered.

Fluid allocation: For fluid allocation, many times the criteria below contradict with each other but broadly serves as a screening guide while allocating hot and cold side fluids to shell side and tube side.

• High temperature streams preferred in tube side.

• High pressure fluids in tube side.

• Viscous liquids are better handled in shell side.

• High allowable pressure drop streams on tube side.

• Dirtier fluids are preferably placed in tube side.

• More corrosive fluid through tube side is preferred.

• Low flow rate streams are better handled in tube side.

Process design margins: The process margins are generally specified on heat duty and flow rates. Sometimes, the overdesign on heat duty is stated as 110% and overdesign on flowrates is specified

as say 120%. This means that the heat exchanger to be thermally designed for 110% of specified duty and at the same time, the allowable pressure drop is not exceeded at 120% flow rate. User has to provide adequate design margin on the surface area over and above the process margins specified in the process data sheet.

Basis of design: Generally, the basis of design is unique for each project. Preparation of basis of design is a first step during the thermal design.

Following parameters, as a minimum, are addressed in basis of design: Fouling factors: Fouling factor varies with the given service application. To maintain consistency across the thermal designs a uniform fouling factor for the given fluid should be used.

Shell type: Shell type selection is generally based on the cleaning requirements and fouling factors. Below is the generic recommended practice. Various shell types and its TEMA designations are provided in Figure 1.

• Floating head is used if both shell side and tube side fouling factors are more than 0.0002(hr-m2-OC/kcal).

• Fixed tube sheet is used if the shell side fouling factor is less than 0.0002 (hr-m2-OCkcal) and tube side fouling factor is greater than 0.0002 (hr-m2-OC/kcal).

• U bundle is used if the shell side fouling factor greater than 0.0002 (hr-m2-OC/ kcal) with tube side fouling factors less than 0.0002 (hr-m 2-OC/kcal) • For the services having both side fouling factors less than 0.0002 (hr-m 2- OC/kcal) then either a fixed tube sheet or U bundle are recommended configurations.

• For vacuum services, to keep shell side pressure drops to minimum; X shell is recommended • Horizontal thermosiphon reboilers are often employed with J, G or H type of shells.

March 2019 • 39

CEW Features

Figure 1. TShell side flow streams

• Floating head or U tube is sued to avoid the bellow otherwise required for thermal expansion.

Cooling water velocity: Salts in the cooling water starts precipitating due to reverse solubility at higher temperatures.

Due to high film temperatures in the heat exchanger, this precipitation leads to scaling and fouling of the heat exchanger.

The exchanger performance degrades due to fouling. It is thus necessary to maintain certain minimum velocity for all cooling water services. As a general practice, cooling water velocity is to be maintained at minimum 1 m/s for lowest possible steady continuous long operation flow rate. Steady and long operation flow rate does not include the start up cases but sometimes includes turndown cases. It is practically very difficult to design exchanger for minimum 1 m/s velocity when turndown is too low.

Bundle diameter: The maximum bundle diameter is limited lifting machinery (crane) specifications. In order to pull the bundle, the maximum bundle diameter restrictions are applied. The number varies from case to case basis. It is recommended that the thermal designer obtains this number before the start of the design and should be part of basis of design.

Shell Diameter: Restrictions to shell diameter apply based on maximum weight that the lifting machinery can take at the given site for erection and dismantling purpose. Thermal designer should restrict the designs within the defined constraints of maximum shell diameter. For the cases wherein the surface area requirements are larger than those defined by these 40 • March 2019

constraints, then multiple shells in parallel should be used.

Tube lengths: Tube lengths are either selected in multiples of 1000 mm or as standard TEMA lengths which are basically rounded of values in feet. Basis of design should state the tube lengths selection to maintain consistency of all exchanger designs for the given project. The basis of design should also specify the maximum tube lengths permitted by the plot and layout constraints. This is generally restricted to 6 or 9 metre.

Tube diameter, pitch and pattern: Basis of design should address the considerations for selecting tube geometry including tube wall thickness. The tube wall thickness can be considered as per BWG or it can be rounded of in multiples of 0.5 mm. Tube OD is function of fouling factors and cleaning requirements. Preferred tube ODs based on fouling factor can be standardized. As a recommended practice, if the tube side fouling factor in excess of 0.0004, minimum 1” tubes are used. Basis of design should clearly state if tube ODs are based on standard in inches or standard in mm.(eg,3/4”and 1” or 20 mm, and 25 mm) Overdesign on surface area: The design margin on surface area is required to account for inaccuracies and limitations to the empirical correlations used during rigorous thermal design. Typically, the design margins on surface area are kept at 6% to 8%.

Design Pressure and design temperature: Preferably, the low pressure side design pressure should be 10/13 times design pressure of high pressure side. The design

pressure of pumped liquids should be based on (estimated) pump shut-off pressure. All the exchangers with phase change service should also be designed for full vacuum condition. Steam-out conditions should be specified separately. Many times it is likely that the steam-out design condition turns out to be governing criteria for exchanger design. All possible alternate operations of the equipment should be considered before specifying design conditions. When cold side fluid is in tubes, its design temperature should be equal to design temperature of shell side.

TEMA class: Basis of design document should specify the applicable TEMA class (R, C or B) for the exchangers in the given project. Many design parameters like tube pitch, corrosion allowance; mechanical clearances are based on the TEMA class selected.

Data Entry: Nozzles: Nozzle size and number are required for accurate prediction of pressure drop.

Specify the vapour and liquid outlet nozzle sizes separately for partial condensers. For thermosiphon reboilers, ignoring this data entry can sometimes have large impact on the resistance calculations.

Design Pressure: Though the thermal design softwares have the ability to estimate the design pressure and tube sheet thickness, shell thickness, baffles thickness, etc, it is recommended that user specifies the design pressure so that the estimations of mechanical design from the program are closer to actual designs.

Mechanical clearances: In case of rating an existing exchanger, make sure that all the mechanical tolerances as shown on fabrication drawing are inputted to the program. For new designs, these fields can be left blank. However, after the mechanical design is carried out, it is recommended to input these clearances and re-run the thermal design program for verifying exchanger performance.

Impingement plate: To avoid tube rupture due to high velocity of fluids at bundle entrance and exit, impingement plates are required. Impingement plate occupies a significant portion of the shell. The shell Chemical Engineering World

Features CEW the possible extent by consuming most of the allowable pressure drop.

Enhancing tube side heat transfer coefficient is relatively easy. Tube diameter, tube length and number of tube passes are the variables available. Please note that velocity affects pressure drop more strongly than it affects heat transfer Coefficient. Within the permissible limits of pressure drop, try to reduce the tube count or increase the tube passes to enhance tube side Coefficient. As allowed by basis of design, reduction in tube diameter can help sometimes.

Shell style, baffle geometry, tube layout pattern and tube pitch are the variables available to enhance the shell side heat transfer co-efficient. Use multiple shells in series for a temperature cross or to increase shell velocity and heat transfer coefficient.

Multiple shells in series reduce the penalty due to temperature profile distortion.

Decrease the centre to center baffle spacing and reduction in shell diameter enhances the heat transfer coefficient. Baffle type selection also has impact on shell side coefficient as the leakage pattern changes from the selection. As an example, double segmental vs single segmental baffles, heat transfer co-efficient in the later case is generally found to be more.

Figure 2: Exchanger Shell Type and Designations as per TEMA

diameter required for given number of tube increases with presence of impingement device.

Tube Layout: As a general experience, for a given shell diameter the thermal design program accommodates more number of tubes than the actual mechanical design permits for. After mechanical design is completed, it is recommended that original run is revisited and performance of the exchanger reviewed before released for vendor enquiry or for construction.

Baffle design: Center to center baffle minimum spacing should be 1/5th of the shell diameter subject to minimum 150 mm which is mechanical fabrication limitation.

Generally, the baffle spacing is roundedoff in the multiple of 5 mm. Baffle cut Chemical Engineering World

orientation may vary based on application.

Vertical cut is provided for total condensers.

The baffle spacing and baffle cut design depend on stream analysis and vibration analysis. User to avoid baffles being placed under the nozzle. For low pressure drop and vacuum service applications, â&#x20AC;&#x153;no tubes in windowâ&#x20AC;? option can be utilized.

Review and analyze output data: Controlling coefficient: Observe the individual shell side and tube side heat transfer coefficients and the thermal resistances from the output. Enhancement in overall heat transfer coefficient can be targeted by first identifying the controlling resistance. Check if the case is fouling controlled. The side having lower heat transfer coefficient will be controlling side.

Try to enhance the governing coefficient to

Pressure drop: Try to consume as much of the allowable drop as possible. Any increase in velocity causes increase in heat transfer co-efficient. Thus increase in pressure drop increases heat transfer co-efficient and in turn lowers the required heat transfer area. Tube side pressure drop can be increased by decreasing tube dia. or increasing the tube passes. Shell side pressure drop can be increased by changing baffle configurations or putting multiple shells in series.

Velocity: Check that the velocity restrictions if any stated in the datasheet and/or design basis are satisfied. As a general rule of thumb, for liquids in the shell side, minimum velocity should be 0.2 m/s.

Design heat duty: Many times, user leaves the outlet temperatures or flow rates to be calculated by the program. For thermosiphon reboilers, make sure that the March 2019 â&#x20AC;˘ 41

CEW Features absolute quantity of vapours at reboiler outlet matches with process data sheet.

Check that heat duty multipliers if applicable for the given case are adequately added and the exchanger is designed to meet all the operating condition specified in the process datasheet.

Stream Analysis: There are 5 types of flow streams defined for a shell and tube exchanger. See Figure 2 for details. These streams are defined as below.

• ”A” stream is tube to baffle hole leakages. The magnitude of tube-tobaffle clearance affects size of the Aleakage stream. Because the ‘’ stream is thermally effective, a significant A stream does not have a large negative impact on thermal performance of the exchanger.

• ”B” stream is main cross flow. The cross flow as indicated by B-stream should be minimum 45%.

• ‘‘C” stream is bundle to shell bypass: This clearance has a strong effect on the tube count.

• “E” stream is baffle to shell leakage: Because the E-stream is not thermally effective, a large E-stream has a large negative impact on the exchanger’s thermal performance. If user specifies a fouling layer thickness, it has no effect on this clearance or on the E-stream calculation. Being thermally inactive stream, this should be always less than 20%. Very large amount of C and E streams causes temperature profile distortion due to bypass and leakage.

• ‘‘F” is pass partition line bypass. The F stream travels along tube pass partition lanes. Because these bypass streams can affect heat transfer and pressure drop performance, they must be modelled accurately. The F-stream, the leakage stream that flows through the pass lane partitions in multiple tube pass bundles, is only partially effective for heat transfer. Use F-stream seal rods to reduce the F-stream flow fraction.

• Tube Layout: The software program generally has the ability to produce a tube layout for given configuration. Ensure that the number of tubes specified does not exceed number of tubes calculated for the given shell geometry. This layout is only suggestive and indicative. Final tube layout 42 • March 2019

shall be based on mechanical design.

Based on past experience, as a general rule of thumb, specify 2% to3 % of less number of tubes than programs default count to minimize design iterations.

Percent over design: This is the margin on surface area over and above the process heat duty margins. This margin is applied to account for inaccuracies, programming limitations and empirical correlations used by the program. Maintain this margin as per the design basis.

Vibrations: Vibration analysis is integral part of thermal design. For two phase services and low pressure gas applications in particular, special user attention is required to avoid exchanger vibrations.

Thermal designer must ensure that the design is vibration-free. Parameters that affect various type of vibration includes tube thickness, baffle spacing, clearance under nozzle, nozzle size, bundle entrance and exit velocity. Flow induced tube vibrations and acoustic vibration are two common types of vibrations encountered in thermal design.

Flow induced vibrations: Tube unsupported span is the key to flow induced vibrations. It can be reduced gradually and no resonance would occur. Various shell types with different baffle configurations can be tried to get rid of flow induced vibrations. The suggested approach in the order of preference is as below.

• E shell and single segmental baffles • E shell and double segmental baffles • J shell with single segmental baffles • J shell with double segmental baffles • No tubes in window configuration • X shell • Use of rod baffles Below is the suggested approach to avoid the vibrations.

• Cross flow velocity should be less than 0.8 times critical velocity at all locations.

Higher the cross flow velocity, higher the turbulent buffeting frequency.

• Fluid elastic instability is characterized by tubes vibrating in whirling manner.

This occurs when cross flow velocity is larger than critical velocity.

• Vortex shedding frequency is described

by Strouhal number. Tube natural frequency varies inversely as the

square of tube unsupported span.

Vortex shedding and turbulent buffeting requirements to be 0.8 times natural frequency.

• Unsupported tube span is less than 0.8 times TEMA limit Acoustic vibrations: Most of the problems occur to 45 degree tube layout. The use of 60 degree layout often eliminates acoustic vibrations. Acoustic vibrations can be avoided by using de-resonating baffles.

Mean metal temperature: For fixed tube sheet type of exchangers, mean metal temperatures decide the need for a bellow to take care of thermal expansion.

Process engineer should analyze the failure scenarios to arrive at design mean metal temperature values. This includes, mean metal temperatures when one of the fluids is lost, start up conditions, upset conditions, Turndown requirements, etc.

For Floating head or U tubes, however, it is not necessary to provide mean metal temperatures.

Concluding Remarks: Shell and tube heat exchanger thermal design is generally carried out using specialized softwares. These softwares follow a rigorous design methodology and the technology provides the opportunity to select the exchanger configuration in a quicker manner. However, it is very vital that the design approach followed for the shell and tube exchangers on a given project is highly consistent. In addition to the optimized configuration, A uniform design methodology and design standardization helps in maintaining lesser inventory, better maintenance planning.

Author Details

Atul Choudhari General Manager TATA Consulting Engineers Ltd E-mail: achoudhari@tce.co.in Chemical Engineering World

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Water in Oil Meter and Oil in Water Meter Analysers Many process industries are unaware of the importance & benefits of measuring hydrocarbon and water content.

The technical document covers two such analysers which are Water in Oil Meter and Oil in Water Meter. This document would help the reader to understand and select a suitable analyser for their process industry based upon the principle of operation, components, mounting, application and benefits of these analysers.

M

easurement of water in oil and oil in water are very important for any hydrocarbon industry.

There are varieties of analysers available in market. Selecting right type of an analyser considering accuracy and reliability requirements, measurement principles and their applicability/ limitations, mounting requirement, cost, etc., for a particular application is a very complex task. The performance of the analyser may not be satisfactory if selection is not carried out properly considering all these criteria. This paper highlights all major features of ‘water in oil’ and ‘oil in water’ analysers to facilitate right selection of analyser for a particular application.

In earlier days, sampling was the only method for measuring hydrocarbon in water. These samples were taken to laboratory for analysis. This caused delays in analysis and was less accurate.

This had caused loss of production, efficiency, inaccuracy in process, deteriorated quality, etc.

Water in Oil Meter (WiOM) and Oil in Water Meter (OiWM) have addressed these issues to a large extent and have become important pieces of instrumentation in hydrocarbon industry.

These analysers use online measurement techniques which provide continuous and reliable data to the plant operator.

Introduction of Highway Addressable Remote Transducer (HART) and other digital protocols in these analysers have improved the speed of transmission of

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measured signals to the control system (DCS & PLC) and this has opened the gate for more automation in the processes.

These meters have helped the oil industry to use crude oil efficiently and reduce oil loss from the system.

A WiOM (also known as water cut meters) measures the content of water in crude oil, other hydrocarbons and low dielectric liquids. The measurement unit of WiOM is in percentage of water. WiOMs are used where accurate and drift-free determination of water content is crucial.

An OiWM measures the concentration of oil or other hydrocarbons or dissolved hydrogen sulphide in water. The measurement unit of OiWM is either in parts per million of oil or in milligram/litre.

Principle of Operations in WiOM and OiWM Principle of operation of WiOM : There are two operating principles for measuring water in oil. These principles are being used due to distinct dielectric properties of water and oil.

• Microwave resonance: The permittivity of oil and water mixture is measured. The measured permittivity of oil and water mixture is then compared with dry oil permittivity and water permittivity. The water molecules

have

positive

charged

side as two hydrogen atoms and negative charged side as one oxygen atom. When the oil and water mixture passes through the microwave, the water molecules align themselves

continuously with microwave field. This causes the microwave propagation to slow down. On the other hand, hydrocarbon molecules do not respond to changes in microwave field. Due to the symmetrical structure of hydrocarbon molecules, the propagation effect of microwaves is insignificant.

This principle uses Bruggeman equation for calculating the percentage of water. Microwave resonance can be used to measure different ranges from 0-1% to 0-100% water. The accuracy may vary from +0.05% for the range of 0-1% water and +5% for the range of 1-15% water. To measure upper limit for 15-100% water, WiOM requires density calculation giving accuracy around +5% of reading. For the measurement of full range from 0-100% water, the WiOM compensates the salt content in water by measuring the conductivity. The accuracy of full range WiOM is around +1% of water.

• Capacitance type: The sensor used in this method is capacitance type which measures the dielectric of water in oil and water mixture. Capacitance type can be used to measure ranges from 0-25%.

The accuracy may vary between +0.01% to +0.2% • Optical & Density measurements were old principles which were used in laboratory for analysis.

Principle of operation of OiWM - There are three operating principles for measuring March 2019 • 43

CEW Features oil in water. These principles typically use ultra violet (UV) light as a source and a detector which measures the wavelength of the light reaching it. The detected wavelength is compared with the chart already stored in the memory of the microcontroller.

• Ultra Violet (UV) Fluorescence: This principle uses the unique fluorescence property of crude oil when UV light passes through the water in a pipe. The fluorescence of the UV light is received on the UV detector. The change in UV light due to fluorescence of oil is measured.

The advantage of using UV Fluorescence is that the detector is tuned only to measure the fluorescence of crude oil.

The wavelength of any other impurities in the water is not measured by the detector.

This principle is mainly used in offshore and onshore oil industries having the measurement range of 0-20,000 ppm and accuracy of approximately +1%.

• UV Absorption/Photometer: Similar to UV fluorescence, UV light is used as the source. The emitted light is then passed through water in the pipe.

The oil or hydrocarbon in water absorbs/ emits UV light. The change in UV light received at the detector due to absorption /emission of UV light is measured.

UV absorption has the measurement range of 0-1,000 ppm and accuracy of approximately +1-2% as other impurities also absorb UV light.

This principle can be used in any industries involving hydrocarbons such as Breweries and Oil & Gas industries in the downstream of the process such as cooling water system, waste water treatment, oily water system, etc.

• UV Persulfate/Thermal Oxidation: This principle is used mainly in regulation of Waste Water, Chemical Oxygen Demand (COD) and Biochemical/ 44 • March 2019

Figure-1: WiOM with static mixer

Biological Oxygen Demand (BOD) where Total Organic Carbon (TOC) is measured.

In this, the sample is extracted at periodic interval from the pipe. The sample is then passed over a reactor. The organic and inorganic carbon is oxidized by dissolving all carbon bonds at 1200oC in the ceramic oven and converted into carbon dioxide (CO2).

The converted CO 2 is then measured. The organic and inorganic carbon is oxidized using carrier gas. The supply of the carrier gas may use filtered ambient air.

housed in analyser or a control panel. All wires from the transmitter, receiver and temperature transmitter are connected to the analyser or control panel.

UV Persulfate/Thermal Oxidation has the measurement range of 0-20000 ppm and accuracy of approximately +2%.

Components and Mounting of OiWM : There are two methods of mounting OiWM as mentioned below:

UV Persulfate/Thermal Oxidation can handle high salt concentrations of approximately 10 g/l.

The transmitter is mounted directly on the pipe spool whereas control panel is mounted in the field with suitable supports.

Built-in static mixers are sometimes provided in water cut meters for conditioning of oil and water mixture.

• In-line probe type: The probe of the in-line OiWM analyser (Refer Figure-2) is inserted in the process

Due to slow measurement principle (response time of 3 minutes), batch measurement and lower accuracy, UV Persulfate/Thermal Oxidation is not used in any application where continuous measurement of oil or hydrocarbon is required.

Components and Mounting Components and Mounting of WiOM : The Water cut meter (Refer Figure-1) comes with a pipe spool piece with a transmitter and a receiver or probes and temperature transmitter for temperature compensation.

These are installed on the pipe spool.

The pipe spool comes with flanges which can be fitted directly in the process line or in the bypass line. The microcontroller /micro-processor based electronics is

Figure 2. In-line type OiWM

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Features CEW which the analyser can handle. If the pressure is very low then separate pump is used to carry the sample up to the analyser.

The analyser and the electronics of the micro-controller are housed inside a control panel (Refer Figure-3). The control panel can handle one bypass line.

A suitable structural arrangement for mounting the control panel, by-pass line and pump is required.

The probe and the control panel are mounted in the by-pass line. Since, the analyser probe and the controller are housed in the same control panel, external cable is not required between the probe and the analyser.

Figure 3. By-pass type OiWM

line. The probe length may vary with process line size. The inline probes are retractable type and can also be used in high pressure lines with special accessories.

These analysers use fibre optic cable between the probe and the control panel.

The light source used is laser. The laser light is converted to UV light in the inline probe. The measured wavelength of UV light is sent from inline probe to the micro-controller in the control panel using fibre optic cables. Unlike UV light, the laser light is used for its advantages of better life and less prone to energy loss when travelling through longer distance and bends.

The micro-controller based control panel can be mounted away from the pipeline.

The size of the control panel may vary depending upon hazardous and safe area. The control panel in hazardous area is smaller in size due to which there is restriction in the number of probes handled by a controller (usually 1 to 2 Chemical Engineering World

probes). The control panel in safe area can be of larger sizes. More than one (approximately 4 nos) controller can be mounted in each control panel. Large size panels can be floor-mounted. Sometimes external cooling is also required for the control panel.

The micro-controller analyses the measured signals and indicates the concentration of hydrocarbon in water.

The light source used is either laser or UV. The laser light is converted to UV light in the probe. The measured wavelength of UV light is sent from the probe to the microcontroller for analysis of measured signal which indicates oil concentration in water.

The outlet of the bypass line is either connected back to the process line or is drained through the drain line. If the pressure in the process line is higher, then another set of pumps are used to inject the fluid from the by-pass line back to the process.

•

No loss of fluid

This arrangement of OiWM has the advantage of low initial cost which is due to: • Small fibre optic cable between the controller and analyser probes

•

Reduces piping

•

•

Low maintenance

•

Requires less space

•

Works at high pressure and temperature of up to 35 bar (g) and 200 oC, respectively

The advantages of using inline probe type are: • Continuous and immediate measurement

• Bypass type: As the name suggests, a bypass line (Refer Figure-3) of smaller size is tapped off from the process line. The size of bypass line depends upon the pressure

Since the analyser probes are not in pressurized process line, the length of the probes are shorter and are easily retractable

Other advantages of using by-pass type OiWM are: •

Continuous measurements

and

immediate

•

Works at high pressure and temperature of up to 20 bar (g) and 120 oC, respectively March 2019 • 45

CEW Features • Elimination or minimization of manual sampling for laboratory analysis using online measurement • Automatic rerouting of water back to the filters for retreatment • Detection of leakages It is very important to understand the selection criteria of Water in Oil Meter and Oil in Water Meter analysers while preparing the specifications. These analysers are costly. In order to achieve required performance, it is very important to critically consider all parameters while selecting analysers for a particular application.

Figure 4. Sample type OiWM

• Sample/Extractive type: Like any other sampling technique, Sample/Extractive type OiWM (Refer Figure-4) also requires hose pipes and pumps for bringing samples. The ceramic oven, reactor, tubes, pumps, filters, controller, etc, are mounted inside an analyser panel. The analyser panel can handle multiple samples. This arrangement has the advantage of low initial cost as the complete arrangement comes in a single analyser panel. The hose pipes and tubes need to be installed from the sampling point up to the panel. The complete set up may require maintenance and a trained operator to handle the analyser.

Applications Some of the applications of WiOM: • For the testing of the production separator • Fiscal quality measurement

and

quantity

• During loading and unloading terminals and pipelines

in

• Custody transfer Some of the applications of OiWM: • Onshore and Offshore oil platforms • After crude separators, degassers, etc.

• In water drain lines from tanks and equipment for oil detection 46 • March 2019

• In waste water treatment plants, effluent treatment plants (ETP), oily water system (OWS), boilers, cooling water and process heat exchangers.

Benefits Benefits of measuring water content in crude oil in water using WiOM: • Measurement of oil and water production simultaneously in the mixture of oil and water • Indication of effect of water and oil separation treatment which maximizes production and decreases retention time • Automatic rerouting of oil back to the process for retreatment

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• Detection of undesirable condition such as contamination • Detection of interface dewatering of storage tank

during

Benefits of measuring oil content in water using OiWM: • Improvement in productivity of water treatment systems Improvement of health and safety conditions by reducing oil level in water • Reduction of hazardous impact to environment • Improvement in cost of operation by minimizing the use of chemicals and maintenance frequency

Sunil P Agarwal Senior General Manager (Instrumentation & Controls) TATA Consulting Engineers E-mail: spagarwal@tce.co.in

Abhinav Prasad Manager (Instrumentation & Controls) TATA Consulting Engineers E-mail: abhinavp@tce.co.in Chemical Engineering World

Products CEW Robust & Intelligent Drives NORD DRIVESYSTEMS offers a wide range of drive units for more than 100 industries from intralogistics, the food and textile industries to woodworking. Product highlights include the NORDAC LINK decentralised field distributor series, smart drives with condition monitoring, ATEX products, as well as nsd tupH surface treatment. The wide range of products from NORD includes geared motors, motors, industrial gear units, as well as central and decentralised drive electronics. The latter includes the NORDAC LINK field distributor series with freely configurable frequency inverters (up to 7.5-kW) and motor starters (up to 3-kW), that include an integrated PLC. The devices can be flexibly adapted to various applications and are installed close to the motor. Thanks to their full plug-in capability as well as optional maintenance switches and manual control options, the devices enable simple commissioning, operation and maintenance.

NORD decentralised frequency inverters are equipped with multiple interfaces and are ideal for Industry 4.0 applications. The integrated PLC can reduce the load on the higher level control and enables a modular automation concept. It is freely programmable and able to process data from connected sensors and actuators and, if necessary, it directly initiates a sequence control. The drives communicate their status data via the control system or into a secure cloud. NORD drives can therefore be used for continuous condition monitoring and predictive maintenance.

The intelligently networked drives are currently in use in pilot projects for NORD Industry 4.0 applications. NORD supplies individually configured drive systems in accordance with EU Directive 2014/34/EU and IEC Ex for use in explosive atmospheres. The explosion protected drive systems can be operated in category 2D or 3D dust atmospheres (Zones 21 and 22) as well as in category 2G or 3G gas atmospheres (Zones 1 and 2).

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 01

Vacuum Concentrators The Thermo Scientific Savant SpeedVac systems achieve fast, one-click solvent evaporation. SpeedVac Vacuum Concentrators now offer preset and custom-made programs for optimal application flexibility. Chemists, chromatographers and molecular biologists can now benefit from the firstever line of vacuum concentrators offering a library of pre-programmed protocols, while also allowing users to create custom programs, for fast and reliable evaporation of a broad range of solvents. Built on Thermo Fisher’s leading vacuum concentration technology, the upgraded Thermo Scientific Savant SpeedVac systems provide users with the flexibility to choose from a selection of preset or custom-made programs to suit varying application needs. The new vacuum concentrators achieve a reduced drying time and are compatible with a large number of solvents, helping to boost laboratory efficiency and productivity across a wide array of pharma, biotechnology, academic research, industrial, agricultural and food testing applications. The Savant SpeedVac line of products consists of eight vacuum concentrators, ranging from a compact, integrated device designed for low-volume sample preparation, to medium-capacity models available in either integrated or modular designs, to large, modular systems addressing high-volume sample preparation needs.The Savant SpeedVac portfolio includes: Model DNA130 – a compact, integrated system designed for low-volume preparation of samples, including nucleic acids, polymerase chain reaction (PCR) preps and synthetic oligonucleotides, to support DNA and RNA applications; Model SPD120 – a medium-capacity, modular system, which is resistant to aggressive solvents used in DNA and biological applications, such as methanol and acetonitrile w/0.1% trifluoroacetic acid (TFA). It is also suitable for applications where freeze-drying or lyophilization is needed; Model SPD130DLX – a medium-capacity, modular system, which is resistant to aggressive solvents used in combinatorial chemistry applications, including TFA and dimethyl sulfoxide (DMSO); Model SPD140DDA – a medium-capacity, modular system, used for drying aggressive organic solvents, strong acids, bases and combinatorial chemistry solvents; Models SDP1030 and SDP2030 – a medium-capacity, fully integrated systems, combining a concentrator, a refrigerated cold trap, a diaphragm pump and a vacuum gauge in a single, compact unit; Model SPD210 – a large-capacity, modular system, suitable for drying aqueous and organic solvents in large sample volumes; and Model SPD300DDA – a large-capacity, modular system, used for drying aggressive organic solvents, strong acids, bases and combinatorial chemistry solvents in large sample volumes.

For details contact: Thermo Fisher Scientific India Pvt Ltd 102, 104, Delphi C-Wing, Hiranandani Business Park, Powai Mumbai 400 076 Tel: 022-67429494, Fax: 91-022-67429495 E-mail: sagar.chavan@thermofisher.com Circle Readers’ Service Card 24 or orCircle Readers’ Service Card 0200

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March 2019 • 47

CEW Products Dust Collector

Capture Hood

Reverse pulsing high-efficient dust collector adapts a cassette type reverse air system for energy saving and high efficient de-dusting process, which is able to install on a smaller space company to conventional machines. It is also lowcost and easy-maintenance with such system, and using servomotor for more efficient de-dusting, which gives energy savings and longer life-time of filter bag to compare with conventional systems.

It is an efficient extraction of the fumes in all phases of operation. Energy saving by an integrated furnace cover, air flow control and an optimized design for less false air, less pressure loss. Robust design, easy to maintain custommade – individually adapted to the furnace, the melting area, charging wagon, ladle, operating process, etc. Ease of operation – hydraulicallyoperated, no mechanical interlocks: the hood is moved by the operators or levers in the control booth. Good access and visibility to the melting bath and the furnace spout.

For details contact: Doo Young Eng Co, Ltd #782-18, Gomo-ro, Hanlim-myeon Gimhae-si, Gyeongsangnam-do Republic of Korea 50850 Tel: +82-55-346-5178 Fax: +82-55-346-5181 E-mail: dy1542@hanmail.net

For details contact: Doo Young Eng Co, Ltd #782-18, Gomo-ro, Hanlim-myeon Gimhae-si, Gyeongsangnam-do Republic of Korea 50850 Tel: +82-55-346-5178 Fax: +82-55-346-5181 E-mail: dy1542@hanmail.net or Circle Readers’ Service Card 03

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Corrosion-resistant Aluminium Drives The nsd tupH surface treatment offered by NORD is an outstanding anti-corrosion treatment for gear units, smooth surfaced motors, frequency inverters and motor starters in washdown-optimised cast aluminium housings. A protective layer is created which is permanently bonded with the substrate material and will not chip or flake off. In a special process, the surface of the aluminium is hardened and made similarly corrosion-resistant as SS. Also, the drives are easy to clean and largely resistant to acids and alkalis. It is even possible to use high pressure cleaners or apply aggressive media.

Thus, nsd tupH drive units are 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 motors are available as synchronous and asynchronous motors and comply with efficiency classes IE2, IE3 and IE4.

NORD demonstrates two different drive concepts for wet and dry areas of beverage container conveying by means of a bottle conveyor: Firstly, a standard-solution with an open, two-stage bevel gear unit, IE3 asynchronous motor and an attached NORDAC FLEX SK 200E frequency inverter.

Secondly, a washdown-capable solution with a closed, two-stage bevel gear unit, IE4 synchronous smooth motor and an attached NORDAC BASE SK 180E frequency inverter. The entire unit meets protection class IP 69K. The inverters are coupled with a system bus and operate synchronously; the synchronous motor as the master and asynchronous motor as the slave, with slip compensation. The IE4 synchronous technology also offers better energy efficiency for the partial load range.

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 05

48 • March 2019

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Products CEW Plunger Type Dosing & Metering Pump / Industrial Metering Pumps SRS Pumps offer qualitative range of plunger type dosing and metering pumps and industrial metering pumps. These pumps are positive displacement pumps and in each cycle of operation displace a particular amount of fluid.

The pumping action is created by the reciprocating motion of a plunger. As per the requirements of the customers, SRS Pumps offer their assortment of plunger metering pumps and industrial metering pumps in different models.

These pumps have two parts such as drive end mechanism and the liquid-end mechanism. It can be distributed in simplex, duplex or multiple heads for handling various chemicals with a common motor to facilitate the whole operation. Each head is independently connected and the capacities of each head are also independently adjustable.

It can achieve flow rates up to 10,000 LPH and delivery pressures up to 400 kg/cm2; steady state metering accuracy of +/-1% of pumps output; and handles corrosive, abrasive or viscous fluids. Flow metering accuracy is almost independent of back pressure of liquid. Discharge flow rate is linear to variation of stroke length. Heating of cooling jackets for liquid head is also available.

SRS Pumps offers different types of plunger pumps such as simplex, duplex, triplex and multiplex.

MoC (wetted parts) includes: SS-304/SS-316/Alloy 20/Hastealloy B/Hastealloy C, etc.

For details contact: SRS Pumps Chawl No: B, Pitch No: 3, Pimpal Galli, Nr Hindustan Naka Charkop, Kandivli (W), Mumbai 400 067 E-mail: info@srspumps.net / srspumps@gmail.com or Circle Readers’ Service Card 06

Dispersible Polymer Powders for Biocide-Free Wall Paints Most wall paints are produced using water-based binders or raw materials.

When used in paints, however, water provides a favourable environment for microbes and bacteria. In order to kill these organisms, the paints are typically formulated with biocides to make them last longer. According to the German Paint and Printing Inks Industry Association, one in four buckets of paint will spoil unless preservatives are added. That translates to eleven million buckets per year. There is a problem with biocide use, however: once the paint has been applied to the wall and begins to dry, liquid components evaporate, allowing biocides to escape into the air. In some people, biocides can trigger allergic reactions upon inhalation or skin contact.

By developing NEXIVA, WACKER has now created a technology for the production of biocide-free paints. The Munich chemical group will present a product line based on spray-dried polymeric binders suitable for producing interior wall paints in either liquid or powder form. Paint manufacturers can use NEXIVA to create individual paint formulations, just as they can with traditional binders in dispersion form.

Powder paints remain stable, even without the addition of preservatives. Water for redispersing the paints is not added until just prior to application, thus eliminating the need for adding biocides during production. As the paint dries, all that evaporates is water. Thanks to the polymers, the paint adheres well and has good spreading properties. In addition, paints are easier to transport and store when they are in powder form, as they weigh less and can be packaged differently from liquid paints. Unlike traditional wall paints, powdered versions do not freeze in the cold, nor do they thicken when exposed to heat.

WACKER will be unveiling the first products from its new NEXIVA line over the course of 2019.

For details contact: Wacker Chemie AG Hanns-Seidel-Platz 4 81737 München, Germany Tel: +49 89 6279 1588 E-mail: agnes.froeschl@wacker.com or Circle Readers’ Service Card 07 24

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March 2019 • 49

CEW Products Silicone Diaphragms

Wastewater Treatment Systems

Medical-grade, platinumcured silicone is widely accepted in pharma and biotech applications and is often used throughout the plant. Like all of their diaphragm materials, silicone diaphragms meet USP Class VI and FDA 21 CFR 177.2600 Standards. It is suitable for biomedical/pharma application. All diaphragms meet the standards for quality, purity, lack of toxicity, strength and consistency.

Proper treatment and reuse of wastewater generated during process of manufacturing is of utmost importance for environment protection and to reduce the burden on fresh water supply sources.

Wastewater treatment requires deep understanding of the manufacturing process in addition to subject knowledge engineering capabilities and experience. Paragon offers complete system for wastewater treatment and reuse using variety of process technologies both aerobic and anaerobic.

For details contact: Ami Polymer Pvt Ltd 319 Mahesh Indl Estate, Opp: Silver Park Mira-Bhayander Road, Mira Road (E) Thane, Maharashtra 401 104 Tel: 022-28555107, 28555631, 28555914 E-mail: mktg@amipolymer.com

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

or Circle Readers’ Service Card 08

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Dispersible Polymer Powder for Waterproofing Membranes Waterproofing membranes are barrier layers which are based on cement mortars and have a high content of polymeric binders (up to 30 per cent). They are used to protect cellar walls, terraces and bathrooms against penetrating moisture. After they have been applied, they can be covered with other, appropriate materials, eg, tile adhesives and tiles in wet rooms, and bituminous sheets on flat roofs. The binders are also highly adept at bridging cracks in masonry, as the high content of dispersible polymer powder makes the layer flexible as well as waterproof. This prevents cracks from spreading from the substrate to the surface and from allowing moisture to penetrate. In German-speaking countries, waterproofing membranes are usually applied with a notched trowel.

The ease with which the cement-polymer mixture can be trowelled depends heavily on its rheology, ie, flow properties. For, it is the rheology which determines how much the cement mortar slumps – and thus whether the ribs produced by the notches of the trowel remain standing or collapse after application.

VINNAPAS 7150 E, a new binder that has vastly improved rheological properties. It consists of a combination of vinyl acetate-ethylene polymers and vinyl esters which has been modified with newly developed protective colloids and silicon dioxide particles. As a result of this modification, spray drying of the dispersion yields a powder which, in the ready-for-use sealing compound, imparts a more stable rheology and boosts its nonslump properties. A further bonus is that the waterproofing membrane is less tacky and so does not cling as much to the trowel. Instead, it stays where it belongs – on the floor or wall. It is thus easier for the craftsman to apply it in a layer thickness of two millimeters, which is mandated in German-speaking countries by the German PG-MDS waterproofing-membrane standards. Furthermore, by virtue of their low glass transition temperature, waterproofing membranes containing the new WACKER binder are capable of bridging cracks at temperatures down to -5oC, as determined per EN 14891. As VINNAPAS 7150 E is free of solvents, plasticizers and film-forming agents, it has the added bonus of not emitting any volatile organic compounds (VOCs). With VINNAPAS 7150 E, it is possible to formulate recipes that have very low emission values (placing them in the EMICODE EC1 emissions category of the Association for the Control of Emissions in Products for Flooring Installation (GEV)); the dispersible polymer powder has even been approved by the Federal Institute for Risk Assessment for drinking water applications.

For details contact: Wacker Chemie AG Hanns-Seidel-Platz 4 81737 München, Germany Tel. +49 89 6279 1588, +49 89 6279-1639 E-mail: nancy.bechmann@wacker.com / agnes.froeschl@wacker.com or Circle Readers’ Service Card 10

50 • March 2019

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Products CEW Tanks & Vessels Plastic material has been used in numerous applications where corrosive chemicals are present.

Thermoplastics are well-known for their excellent chemical resistance and are commonly used in piping, valves, halves, hoods and linings. They unfortunately do not have sufficient mechanical strength to make them suitable for large structures such as storage vessels, towers and stacks. New generation fiberglass reinforced plastics on the other hand, have excellent mechanical properties. The combination of thermoplastic liners and FRP thermoset composites provides structures, commonly called dual-laminate with excellent chemical resistance and structural strength. Dual-laminates are now used in numerous applications replacing exotic metals and alloys lined steel (glass, stoneware or rubber).

DM Engg Co fabricates dual-laminate equipment such as scrubbers, process vessels and tanks, which have been used for years offering a cost-effective solution in highly-corrosive applications. These are commonly found in the anodizing, electroplating, chemical process industry, pulp and paper, and metal refining where chemicals such as chlorine and chloro-alkali products, strong acids, strong bases, organic compounds and others are present.

For details contact: D M Engg Co Unit 4, Bldg 5A, Rajprabha Mohan Indl Estate Off W E Highway, Naikpada Vasai (E), Dist: Thane, Maharashtra 401 208 Tel: 0250-3217484 Telefax: 91-0250-2456877 E-mail: sales@dmenggco.com / dmenggco@gmail.com or Circle Readers’ Service Card 11

Flexible Binder for Protecting Mineral Flooring SILRES BS 6921 is based on alpha-silane technology. The low-viscosity alpha-silane-terminated polyether cures rapidly upon contact with atmospheric moisture to yield a comparatively soft, flexible coating that affords outstanding protection against soiling and staining. The main purpose of the new binder is to flexibilize the chemically related SILRES BS 6920, which is already being used for transparent, extremely hard-wearing concrete floors, but which is too brittle for use with flexible substrates. Its hardness creates a risk of cracking, should the floor experience mechanical stress or deform in response to large temperature fluctuations. With SILRES BS 6921, it is now possible to formulate much more flexible coatings that can also withstand thermal expansion and mechanical deformation. Tests show that 20 to 30 per cent SILRES BS 6921 is enough to adapt the binder to the properties of the intended substrate.

Such formulations bond very strongly not only to cementitious floors, but also to epoxy and polyurethane substrates.

The bond is in fact so strong that the formulations are suitable for manufacturing repair sets for damaged epoxy or polyurethane flooring, pervious systems and stone carpets. SILRES BS 6921 is a crystal-clear formulation and remains transparent after curing. Yellowing induced by exposure to the sun or other light sources is reliably prevented by the addition of light stabilizers. The binder combination is formulated to yield one-part end products which can be applied with a mop, roller or spray gun. The coating is generally applied in two thin layers, at an average rate of 100 gram/m2. The first coat strengthens the floor. The second produces a more homogeneous finish that increases stain, scratch and scrub resistance and makes the floor polishable. Coatings based on blends of SILRES BS 6921 and SILRES BS 6920 are equally at home in multistory car parks, automotive workshops, railway station buildings and logistics centers as they are in display and sales rooms, bistros, halls where events and exhibitions are held, and museums and private dwellings. The treated floor is easier to maintain and stain resistant as a result of the treatment. Abraded material, dirt and liquid spills can be removed with ease.

For details contact: Wacker Chemie AG Hanns-Seidel-Platz 4 81737 München, Germany Tel: +49 89 6279 1588 E-mail: agnes.froeschl@wacker.com Circle Readers’ Service Card 24 or orCircle Readers’ Service Card 1200

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March 2019 • 51

CEW Products Dust Disposer System

Dust Disposal System Dust and other particles can be produced as part of casting and steel manufacturing and such process required dust collectors at different locations, and it can be hard to process with clean condition at dust collecting sites. The dust disposal system can solve such problems with closed on-line system using central dust suction, dust mixer and discharging units.

For details contact: Doo Young Eng Co, Ltd #782-18, Gomo-ro, Hanlim-myeon Gimhae-si, Gyeongsangnam-do Republic of Korea 50850 Tel: +82-55-346-5178 Fax: +82-55-346-5181 E-mail: dy1542@hanmail.net

Sand dust or other dust materials can be produced as part of casting manufacturing, and each process required dust collectors at different positions, and it can be hard to process with clean condition of dust collecting site. The dust disposal system can solve such problems with closed on-line system at each dust collecting points.

For details contact: Doo Young Eng Co, Ltd #782-18, Gomo-ro, Hanlim-myeon Gimhae-si, Gyeongsangnam-do Republic of Korea 50850 Tel: +82-55-346-5178 Fax: +82-55-346-5181 E-mail: dy1542@hanmail.net

or Circle Readers’ Service Card 13

or Circle Readers’ Service Card 14

Flexibility for Intralogistics NORD DRIVESYSTEMS provides an extensive modular system of decentralised drive technology with frequency inverters which are mounted directly on the motor or in its immediate vicinity. NORD drives are networked, autonomous and scalable – and therefore form the basis for intelligent intralogistics. The drive components have a power range of up to 22 kW and a PLC which is integrated as standard, and can be supplied with all commercially 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. This allows a plant design with production groups and production islands. 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. As well as intelligent networking, economical drive technology solutions are required, which can be achieved for example with a tried and tested method for reducing the number of variants. With its LogiDrive systems, NORD offers service and maintenance friendly plug & play technology, which features ultimate efficiency and reliability. LogiDrive drive units consist of energy-efficient IE4 geared motors, 2-stage helical bevel gear units and decentralised frequency inverters to ensure optimised processes and costs.

NORD provides fail-safe communication and safe movement functions according to IEC 61800-5 with the SK TU4-PNS PROFIsafe module.

Functions such as SLS (Safety Limited Speed), SSR (Safe Speed Range), SDI (Safe Direction), SOS (Safe Operation Stop) and SSM (Safe Speed Monitor) can be integrated and expand the drive units’ safety stop functions.

With the NORDCON APP and the corresponding Bluetooth stick “NORDAC ACCESS BT”, the company has created a mobile commissioning and service solution for all NORD drives. The dashboard-based visualisation is useful for drive monitoring and fault diagnosis. Parametrisation of drives is easily feasible with a Help function and rapid access to parameters. The app also offers other convenient functions such as backup, recovery and oscilloscope.

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 or Circle Readers’ Service Card 15

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Chemical Engineering World

Products CEW Direct Drive Electronic Elesa+Ganter wide range of standard machine elements has recently extended its range of electronic position indicators by introducing the new DD52R-E that joins the DD51-E model.

Elesa+Ganter electronic position indicators are characterized for their wide orientable display (DD51-E – 5 digit of 8,0 mm height and DD52R-E – 6 digit of 12,0 mm height) that ensures excellent readability even from a distance and from different viewing angles.

The AISI 304 stainless steel bushing ensures a high corrosion resistance. Diameter: DD51-E – 14 mm and DD52R-E – 20 mm. The internal lithium battery ensures a long life: DD51-E of over 5 years and DD52R-E of over 8 years. The battery replacement can be performed easily, without disassembly of the indicator from the control shaft and without the loss of parameter configuration.

The window in transparent technopolymer moulded over the case protects the LCD display against accidental shocks. The ultrasonic welding between the base and the case avoids dust and liquids penetration offering a high IP protection class (IP65 or IP67). For this reason the electronic position indicators are suitable for applications that require frequent washing, even with water jets.

Thanks to the available functions and the programmable parameters, one item can be used for many applications.

For details contact: Elesa and Ganter India Pvt Ltd A-54, Sector-83 Noida, Uttar Pradesh 201 305 Tel: 0120-4726666 Fax: 91-0120-4726600 E-mail: info@elesaganter-india.com or Circle Readers’ Service Card 16

Dispersible Polymer Powder for Tile Adhesives The new dispersible polymer powder VINNAPAS 8812 T rounds out WACKER’s existing VINNAPAS product portfolio for tile adhesives and wall trowelling compounds.

Developed from VINNAPAS 8620 E, it is ideal for sophisticated tile adhesives that have to bond to large-format, high-quality tiles or to difficult surfaces, such as natural stone.

Like VINNAPAS 8620 E, VINNAPAS 8812 T features excellent adhesion – even after critical exposure to moisture and freeze/thaw cycles – as well as a long open time and high flexibility. VINNAPAS 8812 T also offers very good non-slump properties. It is therefore eminently suitable for formulating tile adhesives in categories C2TE, C2TES1 and C2TES2 of DIN EN 12004.

For tilers, this means that the tile will not slip in the fresh bed of adhesive and can be readily adjusted. After application, the trowelling compound can be smoothed or the tiles adjusted for at least 30 minutes (a minimum requirement for C2E adhesives under DIN EN 12004) before it begins to dry. The high flexibility conferred by the WACKER product evens out stresses between tile and substrate while the high water resistance makes it ideal for use in wet areas.

VINNAPAS 8812 T is based on a terpolymer of vinyl acetate, vinyl chloride and ethylene. Produced without the use of either plasticizer or film-forming additive, the dispersible polymer powder is also suitable for formulating low-emission products that must comply with ecolabels such as EMICODE EC1 PLUS and the Blue Angel.

For details contact: Wacker Chemie AG Hanns-Seidel-Platz 4 81737 München, Germany Tel. +49 89 6279 1588, +49 89 6279-1639 E-mail: nancy.bechmann@wacker.com / agnes.froeschl@wacker.com Circle Readers’ Service Card 00 24 or orCircle Readers’ Service Card 3117

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CEW Products Compressors Sauer Compressors offers wide range of compressors. The solutions meet all compressed air requirements on ships, ranging from starting and working air to SCR-systems for exhaust gas purification. A new state-of-the-art compressor control and various accessories round out the manufacturer’s impressive line-up.

The new MLC 4.0 presents a new high-end addition to Sauer Compressors’ range of controls.

Given its easy integration into higher-level systems, the new MLC 4.0 control enables the high connectivity required to meet the demands of tomorrow’s vessels © Sauer Compressors.

With its 7” touchscreen and its intuitive operation it provides excellent usability. Given its easy integration into higher-level systems, the new control enables the high connectivity required to meet the demands of tomorrow’s vessels.

For details contact: J P Sauer & Sohn Maschinenbau GmbH Brauner Berg 15 24159 Kiel, Germany Tel: +49 431 3940-0 E-mail: William.koester@sauercompressors.de or Circle Readers’ Service Card 18

TwinCAT IoT Communicator The TwinCAT IoT Communicator makes it easy for PLCs to communicate with mobile devices by connecting the TwinCAT controller directly and securely to a messaging service through TLS encryption. For smartphone and tablet users, the associated IoT Communicator App ensures that process data can be represented on all mobile devices in a clear overview. Alarms are sent to the device as push messages.

The TwinCAT 3 IoT Communicator exchanges data using a publish/subscribe mechanism. Since no special firewall settings are needed, integration into an existing IT network is easy. Information is exchanged via a message broker that uses the standardised MQTT protocol and acts as a central messaging service in a cloud or local network. A high level of communication security is guaranteed by proven TLS encryption (up to Version 1.2).

Transmitted process data can be displayed on mobile devices using the IoT Communicator App, which is available for both Android and iOS operating systems. The IoT Communicator App also incorporates an integrated QR code scanner to facilitate entry of access data for communication between the broker and individual users.

The TwinCAT IoT Communicator simplifies the transmission of push messages. It offers a number of advantages over conventional e-mail and SMS messages by visualizing live data, variables and status values. This makes the IoT Communicator an ideal addition to the related TwinCAT IoT and TwinCAT Analytics software products.

For details contact: BECKHOFF Automation Pvt Ltd Suite 4, Level 6, Muttha Towers Don Bosco Marg, Yerwada Pune, Maharashtra 411 006 Tel: 020-40004802 Fax: 91-020-40004999 E-mail: a.phatak@beckhoff.com or Circle Readers’ Service Card 19 24

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Chemical Engineering World

CEW

NATIONAL Chemspec India

ENGIMACH

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

Dates: 04-08 December 2019 Venue: The Exhibition Centre, Gandhinagar, Gujarat Event: ENGIMACH is a leading engineering and machine tools show and

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

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

showcase engineering products and services, heavy and light machines, machinery equipment and accessories, tools and parts, 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 partnership 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

Expo Paint &Coatings

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

the coating industry right from raw materials, formulation, application, technology, finishing, quality assurance, recycling and disposal.

The exhibition will feature a wide range of products, raw materials, application systems, machines, tools, current trends, development and innovations shaping the future of coating industry. This expo will bring together leading local and international manufacturers, formulators, buyers, industry professionals, consultants, enthusiasts and prospective entrants from the paint and coatings, surface finishing and allied industry presenting unrivaled opportunities to network, exchange best practices, do business, unveil new products and source cutting-edge product and technologies.

For details contact: Toredo Fairs India Pvt Ltd 16/1, 1st Floor, 2nd Cross Mission Rd Srinivasa Colony Bengaluru Karnataka 560 027 Pharma Tech Expo

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

Event: PharmaTech Expo 2018 & LabTech Expo 2018 is an

International Exhibition on pharma machinery, lab, analytical, pharma formulations, nutraceutical and packaging equipment.

This will give oppor tunities to suppliers, manufacturers, industrialists, entrepreneurs, buyers and consultants to assemble at this common platform. The focus will be on the Pharmaceutical Formulations, Nutraceuticals, APIâ&#x20AC;&#x2122;s, Cosmetic and Ayurveda sector.

For details contact: PharmaTechnologyIndex.com Pvt Ltd 701-702 Corporate House Nr Dinesh Hall, Income Tax Ashram Rd Ahmedabad, Gujarat Chemical Engineering World

INTERNATIONAL ACHEMA

Dates: 14-18 June 2021 Venue: Frankfurt Fair, Frankfurt, Germany Event: This five day event showcases products like engineering products, abrasives, chemicals and compounds, chemical machineries, equipment, manufacturing technologies, chemical engineering compounds, laboratory compounds and other similar range of products and services.

For details contact: Messe Frankfurt Exhibition GmbH Ludwig-Erhard-Anlage 1 Frankfurt, Germany International Exhibition of Chemical Industry and Science

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

CEW

Project Update New Contracts/Expansions/Revamps

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

CHEMICALS Shalimar Paints lays down the foundation of its Nashik manufacturing plant with a planned monthly capacity of 2,180-kilo-litres. Set to commence operations by April 2019 with a planned production capacity of 2,180-kilolitres per month, Shalimar's state-of-the-art Nashik facility will increase the brand's overall production capacity by 65 per cent. It is also expected to stimulate the local economy by creating around 200+ employment opportunities for prospective jobseekers in the region. The newest Shalimar plant hints at the brand's aggressive push to capitalise on the growing market demand for its high-quality, high-performance paint and coating products, as well as to further consolidate its position as one of the fastest growing paints companies in the country. Shalimar has also pledged further investment into its Nashik plant and aims to establish it as a key component within its regional distribution network, as well as its pan-India supply chain. The paint industry has been growing at a rapid rate in India and measures between 1.5 to 2 times GDP growths. Rapid urbanization, better transparency and consumer evolvement has been leading the growth of the industry.

Songwon Industrial Co Ltd a specialty chemicals company of South Korea has launched its new pilot plant in Panoli (Gujarat), thereby strengthening the organisation’s overall specialty chemicals development capability. Built on Songwon’s Indian site with all the necessary main unit operations, the new plant is equipped with the most up-to-date technologies and materials for producing a wide range of chemicals for a broad spectrum of applications - from one kilo up to several hundred kilo samples. To reinforce the organisation’s position in existing areas of business and enhance its ability to enter new areas, the new pilot plant will be supported by the Songwon’s strong local R&D team in Panoli, as well as its central technology innovation center located in Maeam, Korea.

Insecticides (India) Ltd has announced a ` 200-crore expansion plan to increase its capacity in the next three years. In the first two years, it would spend about ` 100-crore, followed by an investment of ` 100-crore in 2020. The firm is planning to set up an Export Oriented Unit in Gujarat with an eye on increasing export component of the business. Exports contributed about ` 35-crore in the total turnover of `1,109-crore in 2017-18. The firm has a share of about 5 per cent in the ` 18,000-crore crop protection market in the country.

MINING Coal India (CIL) is expected to put another 25-30 million tonnes (MT) of coal under the hammer in the ongoing quarter. This comes after e-auction volumes dipped following the decision to pump more coal into the coalstarved power sector through fuel-supply agreements (FSAs). The coal behemoth has been able to book 54-MT of coal through e-auction till December (first three quarters) as against 79-MT in the similar period of the last fiscal year, registering a 31.65 per cent dip. On the other hand, its offtake via the FSA route to power plants increased by over 12 per cent. As more coal gets routed via the FSA route, e-auction volume will be low. Production in January-March was expected to be substantial, which will leave Coal India with more to offer in auctions. It is expected that another 25-30 MT of coal will be offered this quarter on the auction platform. Coal consumers in the non-power sector have long been 56 • March 2019

complaining about scarcity because most of this fossil fuel is being routed to feed coal-starved thermal power plants. Coal India’s production, as well as offtake, was hit in December owing to industrial unrest in its key production zones in Jharkhand and Odisha and cyclones, which disrupted production and supply lines. Besides, the availability of rakes from the Railways also constrained the company from supplying coal. South Eastern Coalfields (SECL), its most important subsidiary, registered a 13.1 per cent fall in production in December at 12.52 MT while Mahanadi Coalfields, the second-largest subsidiary, registered a 3.2 per cent dip at 13.05 MT. These two subsidiaries account for more than 45 per cent of Coal India’s production. Sales were low at 52.77-MT, which is a 1.2 per cent fall compared to December 2017-18. However, in the next fiscal year, the e-auction volumes are expected to dip further. E-auctions directly add to Coal India’s bottom line because the prices are often higher by at least 60 per cent over the notified price. Thus, effectively while the miner spends the same amount of money to mine the coal which is either sold as linkage or put under the hammer, it earns 20 per cent higher in auctions.

Prices in the e-auction, however, are expected to remain stagnant in the ` 2,400 a tonne level backed by muted global coal prices. According to S&P Global Platts, the price of FOB Kalimantan 4,200 kilo calorie per kilogram GAR (gross as received) — which is imported in huge volumes by both India and China — has declined almost 22 per cent since October 1, given the sagging demand in China and improving supply in Indonesia.

NTPC Ltd hopes its captive coal production will reach 100 million tonne as soon as its five coal blocks commence operations, aided by faster regulatory clearances and the part-privatization model of Mine Development and Operator (MDO). The success of the plan would determine fuel security of the operations of India's largest power producer.

Coal India aims to raise output from its troubled Rajmahal mine in Jharkhand to 60,000 tonnes a day by March 2019, having resolved land-acquisition related problems which had crimped production to 20,000 tonnes per day. Coal from the Rajmahal mine helps NTPC run close to 4,200-MW of power generation plants in eastern India, which supply power to Bihar, Jharkhand and West Bengal, and also to northern India including Delhi and Uttar Pradesh. NTPC’s generation capacities were faced with depleting coal stocks and lower power generation as supplies from Rajmahal dwindled. Reserves at Rajmahal within the land acquired by Coal India were almost exhausted and required expansion to keep production levels intact. However, land acquisition at two villages - Bansbiha and Taljhari - spanning 160 hectares, adjacent to the existing project turned out to be a lengthy process, as sorting out ownership issues resulted in inordinate delay. It led to drastic fall in supplies and stocks at the coalfield, as well as at two critical power plants in the region - at Farakka and Kahalgaon. At present, Coal India is using 15 goods trains to transport coal from the Rajmahal mine to power stations in the region.

One goods train can load up to 3,500 tonnes of coal. Coal India is also sending five loaded goods trains from West Bengal’s Ranigunj coalfields to augment supplies at power stations. At present, the entire production from Rajmahal is getting delivered to power plants and there has been no stock buildup yet.

CIL, ONGC to produce coal-bed methane from 10 new mines: support SAIL in one more. The Coal Ministry has identified 11 mines to produce Chemical Engineering World

Project Update coal bed methane (CBM). Of these, 10 will be worked on jointly by ONGC and Coal India Ltd (CIL). The two entities will also work on one mine with SAIL. Initially, ONGC will harness the gas and then CIL will extract coal from them. In addition to the mines with CIL, the two (ONGC and CIL) will also help develop Steel Authority of India Ltd’s Parbatpur coal block (Jharkhand). Here too, ONGC will first harness the CBM. SAIL had surrendered the Sitanala and Parbatpur coal mines. In its representations while surrendering the Parbatpur mine, SAIL had said there was a reduction in the area available for coal mining due to overlapping of mining area.

SAIL had engaged MECON to prepare a techno commercial viability report, which declared the project unviable. The SAIL board had then decided to return the Parbatpur mine to the Coal Ministry.

JSW Energy, part of the Sajjan Jindal-led JSW Group, is believed to be in the race for buying out the thermal power assets of Monnet Power and Jindal India Thermal Power Ltd (JITPL) in Odisha. Monnet Power’s 1,050-MW coal-based power plant near Angul was in advanced stage of commissioning. Monnet Power’s parent company, Monnet Ispat & Energy had won the Mandakini coal block in Odisha in competitive bidding, it surrendered the block later on grounds of economic unviability. Monnet Power had accumulated debt in excess of ` 5,000-crore. Though lenders had earlier denied a haircut in JSW Energy’s prospective deal to acquire majority equity in Monnet Power, the Sajjan Jindal-owned firm is still believed to be in the hunt for the asset. Besides Monnet Power, JSW Energy is also eyeing takeover of BC Jindal controlled JITPL’s 1,200-MW coal-based plant at Derang near Angul. The first unit (600-MW) of the 1,200-MW plant had begun commercial operations and started power supplies to the Odisha grid. This project has been completed at a cost of ` 7,537-crore which includes a debt component of ` 5,900-crore.

JITPL has power purchase agreements (PPAs) with Odisha’s Gridco Ltd, Kerala State Electricity Board and Tata Power Trading Corporation.

Apart from JSW Energy, JITPL also had competing offers from Adani Power and Singapore’s SembCorp. The valuation of the prospective deal is not known. JSW Energy refused a comment on the status of its takeover plans of Monnet Power and JITPL. NLC India (formerly Neyveli Lignite Corporation) which is in the hunt for buying out power assets, is understood to have shown interest in the 700-MW Odisha plant of Hyderabad-based Ind-Barath Power Infra Ltd (IBPIL). The power plant located at Sahajbahal, near Jharsuguda, has commenced commercial operations. Though the exact size of the potential deal is not known, the valuation could be anywhere in the range of ` 5,000-5,500-crore.

In August last year, NLC India had floated an Expression of Interest (EoI) from companies owning coal and lignite-based power projects, for a possible acquisition. NLC India’s installed thermal power capacity is 3,240-MW. It runs a 10-MW solar power unit and wind power assets with a capacity totalling 37.5-MW. Western Coalfields has received the environment clearance for its ` 263-crore expansion project in Nagpur district, Maharashtra. The proposal is to enhance the production capacity of the Gokul open-cast mine to 1.875-million tonnes per annum (MTPA) from the existing 1-MTPA. The mine, located in 767.17-hectare, has a mineable reserve of 14.50-million tonnes. The clearance to the project is subject to certain conditions. Total cost is estimated to be ` 263-crore. Among the conditions specified, the company has been asked to get 'Consent to Operate' certificate from the State Pollution Control Board for the existing production capacity of 1-MTPA and also the 'Consent to Establish' for the proposed capacity of 1.875-MTPA prior to enhancing the production capacity. With regard Chemical Engineering World

to transportation of coal, the company has been asked to carry out by covered trucks and take mitigative measures to control dust and other fugitive emissions all along the roads by providing sufficient numbers of water sprinklers. The company has been informed to adopt controlled blasting techniques to control ground vibration and flying rocks. It has also been told to implement a progressive afforestation plan covering an area of 376.04-hectare at the end of mining. Of the total quarry area of 231.73-hectare (on floor) and 291.21-hectare (on surface), the backfilled quarry area of 115.39-hectare should be reclaimed with plantation and there will be no void left at the end of the mining operations. The land after mining should be restored for agriculture purpose.

OIL & GAS Chennai Petroleum Corpn Ltd (CPCL), Indian Oil Corpn's (IOC's) group company is planning to set up a greenfield refinery at Nagapattinam in Tamil Nadu, at a cost of ` 27,460 crore. The products, including motor spirit (MS) and high speed diesel (HSD), which will be produced from the refinery will help meet the latest BS-VI specification in the southern States. The new refinery will be part of the Govt of India's plan to set up a petroleum, chemicals and petrochemicals investment region (PCPIR) in this region. The boards of CPCL and IOC have accorded in-principle approval for the 9 million metric tonne per annum (MMTPA) refinery at CBR at an estimated investment of ` 27,460 crore, plus or minus 30 per cent.The investment includes ` 2,800 crore for setting up a polypropylene unit of around 500,000 metric tonne (TMT) per annum capacity. Detailed feasibility report (DFR) preparation is underway and is expected to be completed by April 2019. The refinery is expected to be operational by 2023-24. The products from the refinery will meet the latest BS-VI specifications. CPCL's new refinery complex will come up with the latest technology and it will include a polypropylene unit to maximise value addition from the complex. It will produce valuable products, including liquefied petroleum gas, petrol, diesel, aviation turbine fuel, polypropylene, etc, besides petrochemical feed stocks. The petrochemical complex will also feed stocks to downstream industries, including pharma, paint and lacquer, printing inks, adhesives, coatings, chemicals, automobile lubricants and PVC, among others. CPCL operates two refineries with a total capacity of 11.5 MMTPA (10.5 MMTPA at Chennai and 1 MMTPA near Nagapattinam) in Tamil Nadu. The company's crude throughput increased to 10,789 TMT in 2017-18, from 10,256 TMT in 2016-17. Its profit after tax stood at ` 913 crore in 2017-18, as compared to ` 1,030 crore in 2016-17.

Reliance Industries Ltd has secured backing of the key expert appraisal committee (EAC) in the Ministry of Environment, Forest and Climate change to expand the capacity of its export-oriented refinery in the special economic zone (SEZ) at Jamnagar by 5.8 million tonnes (MT).

The planned expansion will raise the installed capacity of the SEZ refinery to 41 MT from 35.2 MT and lift the overall capacity of the Jamnagar refinery complex to 74 MT. The additional terms include prior transfer of environment clearance issued on March 30, 2010 to Reliance Jamnagar Infrastructure Ltd to Reliance Industries Ltd (the entity that applied for the environment clearance). The Jamnagar refinery processed 69.8 MT of crude in FY18, exceeding its installed capacity of 68.2 MT. Higher refinery utilisation helped the company cater to growing demand for transportation fuels. Between April and December 2018, Reliance refined 52.3 MT of crude. Reliance Petroleum Ltd, a unit of Reliance Industries, built its first refinery at Jamnagar with an installed capacity of 18 MT which was later expanded to 27 MT. March 2019 • 57

CEW

CEW

Project Update The capacity of the Jamnagar refinery and petrochemical complex was further expanded by Reliance Industries to 59.7 MT during which the production was split between Reliance Petroleum (26.7 MT) as an only for exports refinery unit and Reliance Industries (33 MT) that sold most of its products in the local market. The capacity of the SEZ refinery was further expanded by Reliance Jamnagar Infrastructure Ltd to 35.2 MT from 26.7 MT. Great Eastern Energy Corpn (GEECL) and Essar Oil are upbeat about shale gas reserves in the CBM blocks of West Bengal, as GAIL looks for more buyers as it is poised to start business with city gas distribution. H Energy is looking for opportunities to supply imported gas from Malaysia to GAIL in a bid to get a price advantage over GAIL’s supplies from Dahej.

While West Bengal finance and industry minister Amit Mitra hopes that the shale gas reserves in the state would attract ` 60,000 crore worth of investment in production, supplies and creating infrastructure, Y K Modi, executive chairman, GEECL, said that it has found proven reserves of 6.6 trillion cubic feet of shale gas in the CBM blocks of West Bengal, which would require ` 15,000 crore worth of investment for exploration. Mitra said Essar Oil has reported the same amount of reserves and it could change the state’s economic landscape by 2020. Modi said the Centre, through a notification in August 2018, has allowed exploration of shale gas in its CBM blocks. GEECL has drilled over 150 wells, which has CBM reserves of 2.6 trillion units. Essar for CBM has drilled around the same number of wells and is poised to increase CBM production to 2.3 million standard cubic metre per day from the present 1 mscm per day. Mitra said GAIL, which is steadily progressing with its construction of Haldia -Jagadishpur pipeline, is poised to start business in West Bengal with city gas distribution. S Bairagi, GAIL’s chief general manager-marketing, said out of its ` 15,000 crore investment for the 2,600 km Haldia-Jagadishpur pipeline, West Bengal would get an investment of ` 3,600 crore. The pipeline in Matrix Fertilizer, Durgapur, would reach by July this year, whereas the pipeline is expected to reach Haldia by December 2020. An official said GAIL, besides Matrix, has tied up with Bhusan Steel, Himadri Chemicals and other small players for sale of gas but it needs more buyers to utilise its pipeline capacity, which can carry 9 million metric cubic metres per day. For city gas distribution, the government has signed an agreement for supplies of 1.2 mmcd but GAIL was looking for a 2.5 mmcd market.

However, GAIL’s present focus is to build infrastructure for gas distribution for which they have formed a JV with State-run Greater Calcutta Energy Supply Corpn and incorporated the JV on January 4, Mitra said. He said the zero date for starting construction work of the 448-km pipeline in and around Kolkata is April this year, and GAIL is committed to supply to 14 lakh consumers, including the transport sector by 2020. This would entail an investment of ` 5,000-6,000 crore. The economic life of the project is for twenty years. Bairagi said the company was creating a pipeline network in Kolkata, Howrah, Hooghly, North and South 24 Paraganas and Nadia districts with compressor pressure of 14,62,101 kg per day.

For the city gas distribution, GAIL – apart from sourcing gas from Dahej – is looking at other sources. H Energy was building an LNG terminal at Kukrahati near Haldia on 47 acres, from where it was building a pipeline up to Khulna in Bangladesh. This would entail an investment of ` 1,500 crore for the terminal and another ` 2,200 crore for the pipeline, said Darshan Hiranandani, MD and CEO. He said the company would import LNG from Petronas Malaysia and is committed to supply 2 million tonne to Bangladesh and keep 1 million tonne to market domestically. GAIL 58 • March 2019

may be a potential buyer for the city gas distribution, Hiranandani said.

Indian Oil Corpn, with the final clearance from the National Green Tribunal (NGT), is all set to re-start construction activities at its ` 2,200-crore LPG import terminal-cum-pipeline project at Puthuvypeen near Kochi.

Necessary orders in this regard have been issued by the Kerala government and the work is expected to commence in January. The NGT judgment has made it amply clear that there is no environmental pollution in the Puthuvypeen project. IOCL has adopted global standards on safety measures and one-third of the cost is being spent on safety. The risk analysis study conducted by Projects & Development India Ltd has estimated the risk factor in a million chances per year.

The Kochi terminal, with the pipelines connecting the bottling plant, will eliminate the movement of bulk LPG by road, citing the removal of LPG tanker lorry movement from Mangaluru to Tamil Nadu after the commissioning of Ennore terminal. The Kochi project consists of an import terminal, multi-user liquid terminal (MULT) jetty, Kochi-Salem pipeline and the bulk LPG terminal at Palakkad with a total investment of ` 2,200-crore. Of this, the ` 225-crore jetty is ready and the company has invested another ` 160-crore for construction activities.

The physical progress of the work is only 40 per cent complete, which includes ground improvement, land development, etc. Kerala presently has an average waiting period of 15 days to receive a LPG refill. This could go up if the infrastructure expansion does not happen. Referring to LPG consumption in the State, it was 8.4 lakh tonnes in 2016-17, which would touch 13.2 lakh tonnes by 2022 and 22.7 lakh tonnes by 2028. India imports 50 per cent of its LPG requirements. With the boom in LPG requirement, imports are expected to go up. To meet the huge growth in volumes, infrastructure must be improved. LPG is imported through the major ports on the coast and there are 13 import terminals. Kochi is next on the list. The design of the terminal has been approved by regulatory agencies, which will inspect during the construction stage and prior to commissioning.

CPC Corp of Taiwan is planning to invest $6.6 bn in petrochemical project in Paradip, Odisha. In this regard, delegation led by CPC president Shun-Chin Lee met the Indian Minister for Petroleum & Natural Gas to discuss the proposal. With an annual production capacity of 15 million tonnes, the Indian Oil Corpn’s (IOC), Paradip Refinery was selected to host the new project, which will utilise the refinery’s feedstock. It will have many downstream units for the production of a wide range of end-products and petrochemical intermediates.

Indian Oil Corpn (IOC) plans to invest ` 20,000-crore in city gas distribution (CGD) projects in the next five to eight years. IOC, which owns a third of India’s oil refining capacity identifies compressed natural gas (CNG) replacing some of the petrol and diesel consumed in vehicles today and LPG replaced by piped cooking gas in households. The company plans to invest at least ` 20,000-crore for the CGD business in those projects won during the ninth round of bids. The investment will mainly include setting up of CNG dispensing stations as well as laying pipelines in cities to transport gas to households for cooking purposes and industries for commercial use. According to oil ministry figures, India needs to invest an estimated $100 billion in natural gas infrastructure by 2022, including setting up a gas grid across 228 cities, Chemical Engineering World

Book Shelf CEW Pump User’s Handbook Authors: Heinz P Bloch and Allan R Budris Price: $129.16 No of pages: 556 pages (Hardcover) Publisher: Fairmont Press (4th Edition) About the book: This text explains just how and why the best-of-class pump users are consistently achieving superior run lengths, low maintenance expenditures and unexcelled safety and reliability.

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