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Contents CHEMICAL ENGINEERING WORLD RNI REGISTRATION NO. 11403/66 Chairman Publisher & Printer Chief Executive Officer
EDITORIAL
Editor Editorial Advisory Board Contributing Editors
Maulik Jasubhai Shah Hemant K. Shetty Hemant K. Shetty
Sub Editor
Mittravinda Ranjan (mittra_ranjan@jasubhai.com) D P Misra, N G Ashar, Prof. M C Dwivedi P V Satyanarayana, Dr S R Srinivasan, R B Darji, R P Sharma Bernard Rapose (bernard_rapose@jasubhai.com)
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Place of Publication: Jasubhai Media Pvt Ltd
VOL. 52 | ISSUE NO. 03 | MARCH 2017 | MUMBAI | ` 150
NEWS Industry News
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Technology News
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CFD Simulation in Chemical Reaction Engineering - Ravindra Aglave & Thomas Eppinger - Siemens PLM
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Tubesheet Design Algorithm as per ASME Sec. VIII-Div.1 / Part UHX - Rupesh M Ubale & Saji George, GS E&C Mumbai Pvt Ltd
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4 • March 2017
Small-Scale CO from CO2 using Electrolysis - Chetan Mittal, Casper Hadsbjerg & Peter Blennow, Haldor Topsoe India Pvt. Ltd., Use of Heat Integration and Column Sequencing in the Design of Optimum Small Scale Distillation - Avinash Patil & Manish Sharma, Synergy Process Systems,
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MARKETING INITIATIVE Innovative Vacuum Solutions in Pharmaceutical Industry: The Right Solution from Toshniwal
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Pick Heaters Inc.’s Jet Cookers: Unique Concept of Direct Steam Injection Heating
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PRODUCTS
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EVENTS
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PROJECT UPDATE
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BOOK SHELF
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AD INDEX
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INTERVIEW “Heavy Engineering Industry to Witness Opportunities in Nuclear Power, Defence and Process Sector” - Mr. S N Roy, Member of Board & Whole-time Director, L&T (Power, Heavy Engineering & Defence)
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Chemical Engineering World
CEW Press Release BASF Group Inaugurates New Innovation Campus Asia-Pacific in Mumbai Mumbai, India and Ludwigshafen, Germany: BASF Group has announced that it has inaugurated its new Innovation Campus Asia Pacific, located in Mumbai, India. The project will involve a total expected investment of up to € 50 million from BASF Group, and marks the Group’s largest research and development (R&D) investment in South Asia. All global research operations at BASF Innovation Campus Asia Pacific (Mumbai) will be housed under BASF Chemicals India Private Limited, a 100 per cent subsidiary of BASF SE. The new innovation campus will expand the company’s existing R&D activities in India to include global and regional research on a wide range of specialty chemicals. Topics will cover personal and home care, process development, organic synthesis, crop protection and many more. “A growing need for energy, food and clean water, limited resources, and a rising world population pose huge challenges. Innovations based on chemistry will enable new solutions,” said Dr. Martin Brudermueller, Vice Chairman of the Board of Executive Directors, BASF SE and Chief Technology Officer. “As a consequence, BASF is expanding its research and development network, especially to emerging markets in Asia, as we want to drive innovation addressing customer and market needs at an early stage. Mumbai will be another powerful regional innovation hub for BASF, with proximity to the dynamically growing Indian market.” The Innovation Campus significantly expands BASF’s research capacities in India, which were established in 2005 and expanded in 2014 to cover agricultural research, organic synthesis, molecular modelling and advanced process research. The new Innovation Campus includes state-of-the-ar t laboratories for chemical synthesis, application and process development, as well as analytics. It brings all new and existing research and development activities by BASF in Mumbai under one roof. Combined with the broad range of current development activities, Innovation Campus Asia Pacific (Mumbai) will enable global know-how exchange and foster collaboration with customers, industrial and academic partners. The campus can accommodate up to 300 scientists and will bring together top scientists from India and other parts of the world. “We see the demand for innovative solutions in many industries in India, including automotive as well as food and nutrition. Moreover, India is now home to a wide range of high caliber scientists and excellent domestic research capabilities,” said Mr. Sanjeev Gandhi, Member of the Board of Executive Directors, BASF SE, responsible for Asia Pacific. BASF has expanded its presence in India during the past several years, both in terms of local manufacturing as well as in providing tailored solutions for the challenges of mobility, housing, environmental protection and hygiene. Through its local subsidiaries, namely BASF India Limited, BASF Chemicals India Private Limited and BASF Catalysts India Private Limited, BASF 6 • March 2017
Group has invested actively in India to realize these opportunities, with approximately €300 million investment over the past four years in manufacturing and R&D. The approximately 20,000 square-meter campus is a collaborative space housing scientific and technical laboratories, modern offices, a full-scale auditorium, cafeteria and employee amenities. The building features a secondary façade to minimize overheating from direct sunlight, energy efficient LED lights, rainwater harvesting, a reflective roof with photovoltaic panels and a windmill to generate renewable energy. Over 50 percent of the lighting in the building will be generated from renewable sources, supported by many innovative solutions from BASF. It is designed to meet the silver standards of LEED (Leadership in Energy and Environmental Design), the world’s most widely used third-party verification for green buildings. In 2016, BASF Group’s research pipeline encompassed around 3,000 projects, and spending on research and development was €1.863 billion. Around 10,000 employees work in research and development worldwide. Globally, BASF maintains a collaboration network of around 600 excellent universities, research institutions and companies around the world. One of BASF’s three central technology platforms, Advanced Materials & Systems Research, has been headquar tered at the Innovation Campus Asia Pacific (Shanghai) since January 2016, headed by Dr. Harald Lauke, President of the technology platform and Regional Research Representative for Asia Pacific. The other two technology platforms, Chemical Engineering & Process Research and Bioscience Research, are respectively headquartered in Europe and North America. Innovation Campus Asia Pacific (Mumbai) will house research activities from all these platforms. Through its local subsidiary, BASF India Limited, BASF Group has also been operating an Agricultural Research Station in Pune since 2015, and an R&D Center in Mangalore since 2014, focusing on offering technical and product development support to local and global automotive coatings customers. These R&D facilities form a strong network to drive and support both regional and global innovation projects. Chemical Engineering World
CEW Press Release Rockwell Automation Enables Smart Manufacturing through the Connected Enterprise Mumbai, India: Rockwell Automation has announced it has recently concluded Rockwell Automation On The Move, the largest exposition of automation technologies, solutions and services showcased by Rockwell Automation and its Par tnerNetwor k members. With the theme ‘Operationalizing the Mr. Dilip Sawhney Connected Enterprise’ the event, Managing Director-India Rockwell Automation India organized in the city, was a huge success adorned with the presence of more than 20 partners and over 1000 customers across industries. The event offered more than 20 exhibits from the company and its Par tnerNetwork outlining the enabling technologies and approach towards achieving The Connected Enterprise that drives transformational value in manufacturing productivity, sustainability and global competitiveness. Highlighting the role of Connected Enterprises in smar t manufacturing, Mr. Dana Burch, Director – OEM Business, Rockwell Automation Asia-Pacific said, “The Connected Enterprise is an important pillar in helping the manufacturers capitalize on the promise of a more than ever connected world in the form of higher manufacturing velocity, reduced costs and risks and agility to the changing conditions. Rockwell Automation technology solutions enable Manufacturers and OEMs leverage their automation investments to achieve their business goals.” Communicating the company’s focused efforts on enabling smart manufacturing, Mr. Dilip Sawhney, Managing Director – India, Rockwell Automation India Pvt. Ltd. said, “Smart manufacturing allows for a highly connected, knowledge- enabled industrial enterprise where devices and processes are connected, monitored and optimized to enhance productivity, sustainability and economic performance. Rockwell Automation has a portfolio of products and services that help manufacturers incorporate smart strategies through a phased approach. This also allows them to leverage their existing automation assets while preparing for the next generation of integrated control and information innovations.” Concurrent to the technology showcase, the event hosted Executive Forums where Industry thought leaders, analysts, and Rockwell with its strategic alliance partners shared their views on industry drivers, trends and how Connected Enterprise enables to achieve Plant wide optimization and transformation. Various Technology Sessions and Hands-on labs covered a myriad of topics such as Enabling Industry 4.0 through The Connected Enterprise, Developing Machines for the Fourth Industrial Revolution, New Technology Innovations to Operationalize The Connected Enterprise, Innovative Network Infrastructure and Security Solutions for The Connected Enterprise, and many more. 8 • March 2017
American Process Inc. & Birla Carbon Announce Joint Development Agreement for Combining Nanocellulose & Carbon Black in Tires Atlanta, GA - American Process Inc. and Aditya Birla Group’s, Birla Carbon has announced that it has signed a Joint Development Agreement to further explore the technical and business potential of combining carbon black and nanocellulose to improve the performance and sustainability profile of tires. Initial evaluations suggest synergies between the companies’ Birla Carbon® and BioPlus® nanocellulose products to significantly lower the rolling resistance of tires. Research indicates that up to 20% of a vehicle’s fuel efficiency is impacted by the rolling resistance of tir e s. In c r e a s e d commercialization of low rolling resistance tread material is a key technology development focus area identified in Birla Carbon’s 2016 Sustainability Report. Over 70% of the world’s carbon black is consumed by the tire industry, with carbon black constituting 25% of the tire weight. Within the tire industry, there are ever-increasing demands to improve rolling resistance, traction and fuel economy while maintaining tire safety and affordability. In addition, with growing populations, economies, and mobility throughout the world, the industry must ensure that technology developments are sustainable and environmentally friendly. Charles Herd, PhD, Director of Birla Carbon’s Rubber Black Technology, comments, “Low rolling resistance has been and has become an ever increasing area of investment and technological development for tire manufacturers in all aspects of tire technology including design, construction and materials. The synergies between carbon black and nanocellulose offer an exciting opportunity to meet the performance and environmental demands placed on us as a responsible manufacturing entity in a global society.” According to Theodora Retsina, PhD, CEO of American Process Inc., “In addition to its exceptional sustainability profile, nanocellulose offers tremendous performance improvements for a variety of materials applications including rubber. With strength equivalent to carbon fiber, nanocellulose can improve the strength, durability, and toughness of composites. It also shows unique synergistic effects with other filler materials like carbon black in improving composite performance.” Kim Nelson, PhD, API’s VP of Nanocellulose remarks, “This partnership has many synergies including Birla Carbon’s technical expertise, rigorous and disciplined development program, and world-class research facility in Marietta, Georgia. Our ability to offer large-scale quantities of a variety of nanocellulose products with various particle sizes and surface chemistries also enhances the development process.” Chemical Engineering World
CEW Press Release NORD Drivesystems Receives “Udyog Rattan Award” for Outstanding Performance in the Field of Industrial Development
Honeywell Technology Is Helping To Keep Phones Cool New Delhi, India: Honeywell has announced the availability of Thermal Interface Materials (TIM) solution to help smartphone manufacturers and designers effectively manages heat dissipation in their phones. The worldwide smartphone market is expected to reach more than 1.9 billion units by 2020, according to a study from IDC Research. In addition, data needs are growing at unprecedented rates. To meet this challenge, the smartphone industry is leveraging technology that enables phones to provide optimal processing performance without overheating.
New Delhi, India: NORD Drivesystems Pvt. Ltd has announced that its Managing Director, Mr. Palaniappan Muthusekkar received ‘Udyog Rattan Award’ for outstanding performance in the field of Industrial Development of the country at the Economic Development Seminar organized by the Institute of Economic Studies (IES). The Company also received the Excellence Award from IES. Joining the ranks of other leading Indian Industrialists who have received these honours is one of the grateful achievements of NORD. We had to go through many hurdles before it could reach where we are today. NORD equally thankful to our customers, family & friends, and every member of our organization who stood firmly behind us during this whole journey. NORD received many awards some of them are IPF (industrial product finder) award, Times of India accent best HR practices award, best decentralized technology award from MDA & VDMA, Leadership Excellence in Industrial Technologies award from Frost & Sullivan, skill development award from manufacturing today etc. The Udyog Rattan Award and Award for Excellence is conferred by the Institute of Economic Studies every year. The Institute of Economic Studies was established in 1980 by a group of economists, parliamentarians and industrialists. The organization works on studying various aspects of economy and economic development. The centers of the institute are in Delhi, Mumbai, Hyderabad and Bangalore. The patrons of the institute include several leaders in economic studies, politics and business. The previous recipients of this prestigious award include R Krishna Bajaj, H S Singhania, Chairman JK Tyre and Industries, Dr B K Modi, Chairman & President, Modi Group of Industries, eminent dignitaries from social and industrial fields, including S.D. Shibulal (MD – Infosys), Anoop Kumar Mittal (MD – NBCC), Naresh Goyal (Chairman – Jet Airways), Sunita Sharma (MD – LIC Housing Finance), Netmagic, an NTT Communications Company’s MD & CEO Sharad Sanghi etc. 10 • March 2017
Honeywell’s TIM technology is based on phase change materials (PCMs). The technology transfers thermal energy from phone chips to a heat sink or spreader, where it is dissipated into the surrounding environment. This functionality keeps the chips cool, so the phone can perform reliably even during the most data-intense processes or during heat spikes. Honeywell’s solution is available worldwide and is already being used by some of the largest smartphone makers to upgrade the thermal designs of their latest phone models. Customers consistently choose Honeywell’s technology because it provides the best combination of performance and reliability to maximize the lifecycles of their devices, and is optimized to meet new and unexpected challenges. “Honeywell’s innovative TIM technology provides customers with the ideal solution to optimize their phones’ performances,” said Olivier Biebuyck, vice president and general manager of Honeywell Electronic Materials. “As demand for smartphones grows around the world, these breakthrough designs help provide optimal user experience throughout the entire lifecycle of their devices.” Honeywell is a recognized leader in developing thermal management solutions. Honeywell’s proven PCM series of thermal management materials are based on sophisticated phase-change chemistry and advanced filler technology that was developed specifically for highperforming electronic devices. TIM products are designed to optimize thermal impedance across the entire thermal path, providing an end-to-end solution for best-in-class thermal performance. The PCM design can be customized to fit diverse product applications and end uses, providing customers with precisely what they need, when they need it. Honeywell supplies microelectronic polymers, electronic chemicals, and other advanced materials along with an extensive set of product offerings under its metals business segment, including physical vapor deposition (PVD) targets and coil sets, precious metal thermocouples, and low alpha emissivity plating anodes and advanced heat spreader materials used during back-end packaging processes for thermal management and electrical interconnect. Chemical Engineering World
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CEW Press Release Covestro Showcases Products #PushBoundaries at PU Tech 2017 Mumbai, India: Covestro has announced that it has showcased its innovative and eco-sensitive solutions at the 5th edition of PU Tech recently held at Greater Noida, New Delhi. Organised by The Indian Polyurethane Association (IPuA), PU Tech was a 3-day exhibition and conference that featured over 200 exhibitors under one roof to provide a platform for polyurethane material producers, equipment suppliers, end-users and the industry at large for a comprehensive growth of technology and markets. At the show, Covestro exhibited an array of innovative products under the theme #PushingBoundaries at its Booth A03 in Hall A. This theme was adopted by Covestro at K16 Fair which concluded in October. It highlights Covestro’s vision and determination in using material sciences to aid not just industry needs but social issues as well. Covestro’s versatile products offer a wide range of applications for automotive, construction and consumer industries. The company also hosted a live 3D printing demonstration every day utilising Covestro’s materials as well as highlight its Do-It-Yourself (DIY) home construction panels. Being a knowledge-driven company, Covestro will further its endeavour to help the industry stay abreast with latest trends through a series of expert sessions in which ‘Elite Speakers’ will elucidate how polyurethanes have been successful in bringing about disruptive innovation. In addition to showcasing of products, Covestro has also made organised a visit to two key projects— The Eco-Commercial Building is India’s first net-zero-energy building, as well as an affordable energy-efficient housing project—which highlight the benefits of eco-sensitive products from Covestro. “Polyurethanes form an important part of our business strategy and driven by innovation, Covestro has utilised the versatility of polyurethanes to ensure application across multiple sectors like automotive, construction and home-furnishing. We aim to strengthen our presence in core markets such as construction and align our activities with our motto, #PushingBoundaries by developing the segment in under-explored application areas such wind energy. With a vision to create a better and brighter tomorrow we aim to provide solution to the challenges of our time. This is visible in the current edition of the PU TECH, where we will highlight how we have been pushing boundaries through talented materials globally.” said, Ajay Durrani, Managing Director – Indian Subcontinent, Covestro (India) Private Limited. Adding to it, Dr. Yogendra Chauhan, Head – Commercial Operations (Polyurethanes), Indian Subcontinent, said, “This time, Covestro elastomers will be highlighting material systems, machine technologies and proven cast polyurethane elastomers in the same space. We are 12 • March 2017
committed to addressing the requirements of the polyurethane industry. We look forward to interacting with all the stakeholders to nurture our relationship and make the world a brighter place.” The polyurethane Industry is one of the rapidly growing industries in India which has registered double-digit growth during the past five years and is expected to double every four years in the coming decade. PU TECH Exhibition and Conference provides a unique opportunity for the user industry and technology players in the polyurethane space to establish their presence in this dynamic, growing polyurethane market in India.
LANXESS Participates in PU Tech 2017 New Delhi, India –LANXESS has announced that it will be showcasing its wide-ranging product portfolio which meets virtually all the polyurethane industry’s requirements, at PU Tech 2017 being held during 08 to 10 March 2017, at the India Expo Center, Greater Noida, New Delhi. The comprehensive product range includes flame retardants, plasticizers, crosslinking agents, catalysts and hydrolysis stabilizer for rigid and flexible foams, coatings, elastomers, sealants and adhesives. The focus will be on products such as Stabaxol® (hydrolysis stabilizers), Addonyl® (additives and catalysts for cast nylon) along with Addocat® catalysts, Addolink® crosslinkers and Addovate® stabilizers (for the production of polyurethane flexible foams). The Disflamoll® 51092 grade was primarily developed for PU flexible foam and elastomers while Levagard® TP LXS 51114 is specifically suitable for flexible foam. Both flame retardants can be used in polyester as well as in polyether flexible foams. Foams manufactured using Levagard® TP LXS 51114 even meet the German Association of the Automotive Industry’s strict VDA 278 standard for the characterization of non-metallic materials in cars. The established reactive flame retardant Levagard® 4090 N is now available in improved quality owing to process optimizations. The lower acid number and water content ensure better process ability, especially in the manufacture of rigid polyurethane foams. LANXESS will also be exhibiting its phthalate-free plasticizers from the Mesamoll® range for the first time at PUTECH. They are ideal for the production of PU sealants or for use as cleaning agents for polyurethane processing equipment. “At LANXESS, we stand for tailor-made solutions, top technical knowhow and the ultimate in additives expertise. We develop, produce and market additives, phosphorus chemicals and specialty chemicals and service products for the worldwide rubber, lubricants and plastics industries. PU Tech gives us a good opportunity to showcase our competencies and interact with our Indian customers,” said Mr. Sriganesh U. P., Head of Business Unit Rhein Chemie Additives, LANXESS India Private Limited. Chemical Engineering World
CEW Industry News The Global Refining & Petrochemicals Congress 2017: The Meeting Place for Global Downstream Industry Mumbai, India: The Global Refining & Petrochemicals Congress (GRPC) is a leading international forum for downstream industries to probe and explores winning strategies and technologies in tackling the challenges of the industry. It is designed to shed lights on business critical issues such as: market trends, partnership opportunities, margin and efficiency improvements, breakthrough process technologies, catalyst developments, and mega integration of refinery & petrochemical complexes. Attracting a diverse and eclectic mix of speakers, delegates, exhibitors and attendees, GRPC facilitates the exchange of ideas and discussions on pertinent energy-related issues, while simultaneously meeting the strategic objectives of the industry, making it the most important event for those involved in the refining and processing of hydrocarbons. The 2015 edition of GRPC showcased over 50 International Expert Speakers/Panelists, 400+ Delegates, 200+ global organizations from 25+ countries under one roof. Global Attendees included top executives from Government, Regulatory Agencies, Oil Producers, Refinery & Petrochemical Companies, EPC Contractors, and Process Technology & Service Providers etc.
P M M o d i I n a u g u r a t e s O Pa L ' s ` 3 0 , 0 0 0 - C r Petrochemical Complex New Delhi, India: Prime Minister Narendra Modi committed ONGC Petro additions Ltd (OPaL) petrochemicals complex, located at Dahej (Bharuch, Gujarat) to the nation. OPaL is a joint venture company promoted by ONGC, Gail and GSPC, implementing a grass root integrated petrochemical co mp l ex l o c a t e d in Sp e cia l Ec o n o m ic Zo n e ( SEZ ) u nde r Petroleum, Chemical and Petrochemical Investment Region (PCPIR) at Dahej, Gujarat. This is the single largest petrochemical plant in India and at full capacity, will yearly produce 14 lakh metric tonnes of polymers - viz. linear low density polyethylene (LLDPE), high density polyethylene (HDPE), polypropylene (PP) - and 5 lakh metric tonnes of chemicals such as benzene, butadiene, and pyrolysis gasoline. The product warehouse is one of the largest in India with an area of 128,250 square metres. OPaL would use ONGC’s captive feed of C2+ streams (ie, ethane, propane and butane) from C2-C3 extraction plant, and naphtha from Hazira & Uran to produce polyethylene (PE) and polypropylene (PP). Set up with an investment of ` 30,000 crore, the plant is strategically located in the petrochemicals and chemical hub of the country with excellent connectivity, creating an integrated ecosystem. 16 • March 2017
The project will further result in the growth of new downstream plastic processing industries in the country, generating further investment of ` 40,000 crore and over 20,000 indirect employment opportunities, giving major thrust to government’s Make in India programme. The increased use of polymers will also reduce burden on traditional materials like wood, paper, metal and will help in conserving natural resources like water and energy and promote food safety & food conservation. The average per capita consumption of polymers in India is 10 kg, compared to a world average of 32 kg. There is tremendous potential for growth of the sector catalysed by growth drivers such as increasing middle class, higher disposable income and urbanisation. The petrochemical sector in the country has witnessed a robust annual growth of 10-12 per cent in the last decade, and is expected to grow at a rate of 12-15 per cent in the next decade.
Clariant to Reinforce its Presence in Indian Home & Personal Care Sector Mumbai, India: Clariant has announced that it is consolidating its position in Indian home & personal care (HPC) market by concentrating on innovative ingredients intended at providing solutions for unmet needs in this market. “Clariant blooms on the capability to identify new customer needs at an early stage and develop innovative solutions. This stout por tfolio of formulation inspirations, across numerous market segments of the home & personal care industry is our pledge towards enhancing overall consumer experience,” said R. Kumaresan, Head - Industrial & Consumer Specialties (India), Clariant. With its extensive range of components, Clariant aims to support formulators, specifically home-grown brands in India, to advance innovative home & personal care products. The company has also presented the portfolio of naturally-sourced products from BioSpectrum and Beraca, which have formed strategic alliances with Clariant. While Clariant acquired 30 per cent stake in Beraca in 2015, Swiss firm had bought 17 per cent stake in BioSpectrum in 2016. A common trend towards greater natural and sustainable ingredients is gradually influencing purchase decisions in the cosmetics sector globally; this is translating into India as well. Equivalent to the trend in foodstuffs, the market for organic and natural cosmetics has transmuted from a niche segment to a flourishing segment in recent years. And it is this prospect that Clariant aims to tap into with its natural ingredients, offered by Beraca and BioSpectrum. “Clariant's sustainable and innovative beauty ingredients and trend insights will create a positive impact on people's lives through influencing the beauty products of tomorrow,” said Nicolas Lasbistes, Global Technical Marketing Manager – Personal Care, ICS, Clariant. Chemical Engineering World
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CEW Industry News Chemplast Sanmar Enters Into JV with FranceBased Kem One for Chlorinated PVC
diesel oxidation catalyst (DOC), catalysed soot filter (CSF) and selective catalytic reduction (SCR) catalyst.
Chennai, India: Chemplast Sanmar has announced that it has formed a joint venture with Kem One to set up a manufacturing facility for chlorinated polyvinyl chloride (CPVC) in Puducherry. With the JV, to be called Kem One Chemplast, will meet the increasing demand for CPVC in the country.
“Around the Asia Pacific region, and especially here in India, mobility is ever more important. At the same time, more and more vehicles are being manufactured locally in India. To meet the demands of this growth, according to BASF’s Asia Pacific strategy and in support of Make in India and other government initiatives, we are expanding our local production network in the region,” said Sanjeev Gandhi, member of the board of executive directors, BASF SE responsible for Asia Pacific. With the expansion of the manufacturing capacity and capabilities in Chennai, BASF Catalysts will be in superior position to meet the growing demand for advanced emissions control solutions in the country, with the government enforcing stricter emission norms for vehicles.
The new facility, for which sanctions are in the process of being acquired, will come up at Karaikal, Puducherry. The project, which is being set up at an estimated cost of Rs 325 crores, will have technology from Kem One and a capacity of 22,000 tonne per annum (TPA) of CPVC resins. It will also manufacture CPVC compounds. CPVC is principally used as a raw material to produce pipes and fittings for supplying water which entails heat resistance, pressure resistance and high tolerance for water treatment. In recent years, there is a switch from metal to CPVC in pipes used in buildings in India, and in parallel, overall construction demand has also been witnessed. CPVC can also be used for industrial applications which require a high level of chemical resistance and for sprinklers. The demand for CPVC is expanding significantly and will continue to grow rapidly in India. The manufacturing joint venture company will thus provide the domestic answer to the Indian customers’ needs that is currently being met through imports. The formation of the manufacturing joint venture company mentioned above as Kem One Chemplast will be subject to approval from the competent authorities. Kem One is the second largest producer of PVC in Europe. Mainly located in France, it has 1300 employees and an annual turnover of € 800 million. Its eight industrial sites manufacture a wide range of PVC resins, caustic soda and chlorine derivatives. By starting CPVC resins and compounds production in the 70’s in Europe Kem One has a strong expertise in CPVC industrial process. With this partnership with Chemplast Sanmar, Kem One is expanding its footprint in the rapidly growing Indian market.
BASF Expands Mobile Emissions Catalysts Capacity in India with New Facility Chennai, India: BASF Catalysts India Pvt Ltd has announced that it doubled the production capacity for mobile emissions catalysts in India with the inauguration of a new manufacturing site in Chennai. The site includes a new 47,000 sq m production plant, which replaces an existing BASF plant in Chennai and is the culmination of a three-year expansion project. The manufacturing lines are housed in the new plant, producing a full range of catalyst solutions, including light duty, heavy duty and motorcycle emissions catalysts to meet growing market demand and customer technology needs. The site produces BASF Empro emissions control solutions including the three-way catalyst (TWC), 18 • March 2017
“It (the expansion) will help our customers meet increasingly stringent requirements such as the Indian government’s decision to advance from BS IV emissions norms to BS VI norms by 2020. Furthermore, the new site will produce advanced heavy duty emissions catalysts, which will allow us to better serve the fastgrowing automotive markets in India,” said Dirk Demuth, senior vice president, mobile emissions catalysts, BASF. “With initiatives like Make in India, Smart Cities, and Swachh Bharat, India is in the forefront of rapid and sustainable development. This offers significant opportunities for the chemical industry as well as BASF. We are investing actively in India to realise these opportunities. The expansion of our mobile emissions catalysts plant in Chennai is another example of our continued focus on investing in assets for growth,” said Dr Raman Ramachandran, head of BASF operations in South Asia.
Cabinet Agrees to Sale of Indian Oil's 24 per cent stake in Lubrizol India New Delhi, India: Cabinet Committee on Economic Affairs (CCEA) has announced that it has given its sanction for the sale of Indian Oil Corporation’s 24 per cent stake in Lubrizol India Private Limited to the US-based Lubrizol Corporation. “The CCEA, chaired by the Prime Minister Narendra Modi, gave its in-principle consent to permit Indian Oil Corporation Limited (Indian Oil) to sell its 24 per cent equity in one of its joint venture companies, Lubrizol India Private Limited (LIPL) to Lubrizol Corporation, USA (LC), the other joint venture partner,” said the government in a press release. Indian Oil presently owns 50 per cent stake in Lubrizol India Pvt Ltd, which is engaged in production of lube additives. After off-loading 24 per cent, Lubrizol is anticipated to bring in latest technology to the country. “The sale will facilitate IOC to have long term association with its joint venture partner and thus LIPL to have access to the cutting-edge global additive technologies developed by Lubrizol Corporation, USA.” Chemical Engineering World
CEW Industry News Dow Polyurethanes to Raise Manufacturing Capacity By 50 per cent in India
Indian Plastics Processing Industry to Achieve 22 MMTPA by FY20: Report
Mumbai, India: Dow Polyurethanes (PU) business has announced that it will expand its manufacturing base in India with 50 percent rise in the production capacity of its PU system house at Lote Parashuram (Ratnagiri, Maharashtra). With consumer durables, infrastructure and automotive segments in India experiencing a strong growth in demand, the market for inputs materials, such as polyurethanes, is expanding at an unmatched rate. By expanding its manufacturing capacity, Dow is targeting to corner larger share of PU market pie in the country.
New Delhi, Mumbai: The government policy to push investment in infrastructure is anticipated to lead to rise in consumption of plastic products in the country, according to a knowledge paper - ‘Sustainable infrastructure with plastics’ – jointly prepared by FICCI and Tata Strategic Management Group (TSMG).
In addition to capacity expansion, Dow is also capitalizing in new technology centre in Mumbai to fast-track innovation and collaboration with its customers in the region. Speaking about the developments, Ananth Muthupandian, business leader, Dow PU India, said, “Dow Polyurethanes is launching a new strategy called Vision 2020. It’s a vision that resonates around one key theme: enabling customer success. A direct result of this is that Dow Polyurethanes increases its presence in India. From the latest strategic developments, it is clear that we are increasing our capabilities and resources to better serve our customers, starting with adding production volumes to portfolio dedicated to our Indian customers. However, a bright future requires more than just extra volumes. It is clear that with the ever increasing sustainability requirements and consumer demands, long term success will only be possible when offering smarter solutions.” Dow Polyurethanes develops and delivers a broad portfolio of performance products and tailor-made solutions to customers in a variety of industries, and applications ranging from energy-efficient residential and commercial construction, industrial solutions, infrastructure repair, to consumer comfort solutions in flooring, furniture, and footwear. The business provides key ingredients, fullyformulated systems and solutions for rigid, semi-rigid and flexible foams, adhesives, sealants, coatings, elastomers and binders.
L&T Hydrocarbon Bags EPCM Services Contract from Shell Mumbai, India: L&T Hydrocarbon Engineering (LTHE) has announced that it has signed an enterprise framework agreement (EFA) with Shell Global Solutions International BV for providing engineering, procurement and construction management (EPCM) services for Shell projects in the Middle East, South East Asia and India. The EFA is for a period of five years. For any agreements consequential from the EFA, LTHE will leverage on its core fortes of engineering and project management to deliver projects for Shell. LTHE’s engineering office in India will be its high value engineering centre.“This agreement is in line with our strategic goals and is an innovation for our newly formed engineering services business vertical. We will conglomerate our engineering expertise with project and risk management skills to provide complete solutions to the customers across the globe,” said Subramanian Sarma, MD & CEO, L&T Hydrocarbon Engineering. 20 • March 2017
“With Government's current campaign on 'Make in India' which has a special focus on the chemical industry and aims to turn the country into a global manufacturing hub, a tremendous growth in the plastic processing sector is expected especially in downstream industries. The government should not hesitate to provide better infrastructure and favourable policies. With a step already being taken in that direction, plastics are bound to find tremendous use in the infrastructure space,” said the paper. The Government of India is taking every possible initiative to boost the infrastructure sector with investments of ` 25 lakh crore over the next 3 years in roads, railways and shipping infrastructure. Investments in water and sanitation management, irrigation, building & construction, power, transport and retail have been encouraged. Plastics play an important role in these sectors through various products like pipes, wires & cables, water proofing membranes, wood PVC composites and other sectors. Consequently, higher investments in these sectors will drive the demand for plastics. The knowledge paper stated that plastics processing industry has grown at a CAGR of 10 per cent in volume terms from 8.3 MMTPA in FY10 to 13.4 MMTPA in FY15 and is expected to grow at a CAGR of 10.5 per cent from FY15 to FY20 to reach 22 MMTPA. In value terms, the plastic processing industry has grown at a CAGR of 11 per cent from ` 35,000 crore in FY ’05 to ` 100,000 crore in FY15. The Indian plastic industry is making significant contribution to the economic development and growth of various key sectors in the country which includes automotive, construction, electronics, healthcare, textiles, and FMCG. The developments in the plastic machinery sector are coupled with developments in the petrochemical sector, both of which support the plastic processing sector. This has facilitated plastic processors to build capacities for the service of both the domestic market and the markets overseas. Today, the plastic processing sector comprises over 30,000 units involved in producing a variety of items, gaining notable importance in different spheres of activity with per capita consumption increasing. The plastic processing industry has the potential to contribute in bringing foreign investments and thus India’s vision of becoming a manufacturing hub. The knowledge paper noted that in the last decade, several new applications of plastic products have emerged in several sectors boosting the industry further. For example, long fibre reinforced thermoplastic for automotive industry, fibres that can trap infra-red radiations, packaging that can increase the shelf life of products etc. have created demand for plastics which were in their nascent stage in India. Chemical Engineering World
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CEW Industry News Chemicals & Plastics Sector to accomplish 15 per cent growth in 3 years: Ananth Kumar New Delhi, India: The chemicals & petrochemicals and plastics industry has grown around 12 per cent this year, defying all claims of a slowdown in the economy post the demonetisation drive, according to Ananth Kumar, Minister for Chemicals & Fertilizers. Speaking at an awards function for technology innovation in petrochemicals and downstream plastics processing industry, the Minister said, “In the next three years, this sector would achieve 15 per cent growth. Central Institute of Plastics Engineering and Technology (CIPET) had organised the awards function in New Delhi. Ananth Kumar mentioned, “The institution is playing a pioneering role in skilling the youth of India, who in the times to come would be the torch bearers of the Skill India, Start-up India and Make in India missions of the government in this sector. The government has already increased the number of CIPETs from 23 to 39 in two and half years and is determined to take this number to 100 as per Prime Minister Narendra Modi’s vision. Due to the efforts of CIPET, for the first time in elections, the containers for electronic voting machines (EVMs) were made of plastic instead of metals, which made them light, durable and easy to carry to far flung areas.” Talking about the challenge of plastic waste management, Kumar said, “Plastic is both an opportunity as well as a challenge, which needs a special strategy and a behavioural change in the common man to sustainably use it for the advantage of the masses. Biodegradable plastic is the answer to this challenge.” He noted that the award scheme incentivises meritorious innovations and inventions in the field of polymeric materials, products, processes and other areas of national and social importance. The national awards are given for outstanding contribution to R&D leading to less energy consumption, better plastic waste management, increase in product life cycle, development of innovative new products, quality standards, recycling and other emerging areas. These awards are also intended to enhance innovative capacities to the level of international recognition. The ultimate objective is to develop and maintain the petrochemical industry as a globally competitive industry using eco-friendly processes & technologies.
Henkel Submits Binding Offer to Acquire Darex Packaging Technologies for $ 1,050 Million Mumbai, India: Henkel has announced that it has submitted a binding offer for the Darex Packaging Technologies business. Darex is based in Cambridge, MA, USA and supplies high-performance sealants and coatings for the metal packaging industry around the world. It serves various global customers producing beverage, food or aerosol cans, ensuring with its solutions the highest quality standards for many best-known brands. In fiscal 2016, Darex Packaging Technologies generated sales of around $ 300 million. Darex has about 700 employees and 20 sites in 19 countries. 22 • March 2017
“The intended transaction is in line with our strategy to strengthen our portfolio through targeted acquisitions and would reinforce the position of our Adhesive Technologies business as a global market and technology leader,” said Henkel CEO Hans Van Bylen. “We are excited about the opportunity to add the high-performance Darex business to our existing Adhesives Technologies portfolio. We are glad that we are now entering into exclusive negotiations about a possible acquisition. Darex’s experience in developing innovative, high-performance sealants and coatings will underpin our commitment to provide our global customers with best-in-class solutions. This business is the perfect fit for our existing portfolio serving the metal packing industry and would therefore strengthen our position in this highly attractive and non-cyclical business. We would be happy to welcome to Henkel such a successful and experienced strong team with long-standing business expertise,” said Jan-Dirk Auris, Executive Vice President Adhesive Technologies at Henkel. In connection with this binding offer, GCP will begin a consultation process with the relevant Works Councils and Labor Unions. Upon completion of that process, it is intended to enter into a definitive purchase and sale agreement in respect of the proposed sale. The proposed transaction will also be subject to customary closing conditions, including regulatory approvals.
L&T Hydrocarbon Wins ` 1100 Crore Order for Indian Oil's Cracking Unit Mumbai, India: L&T Hydrocarbon Engineering (LTHE) has announced that it has bagged an onshore EPC contract from Indian Oil Corporation Limited (IOCL) worth around ` 1100 crores for setting up a 0.740 MMTPA fluidised cracking unit (FCC) including LPG treatment facility at its Bongaigaon Refinery, Assam. At present, IOCL's Bongaigaon refinery has a capacity of 2.35 million metric tonne per annum (MMTPA). Last year, Indian Oil Corporation had declared its plan to set up Indmax FCC unit (including LPG treatment) of 0.740 MMTPA with an investment of ` 2582 at its Bongaigaon refinery. The new unit is part of IOCL’s Hydrocarbon Vision 2030 for North-East which targets at expanding oil & gas production by 2030.Indmax technology, developed by IOCL to produce high yield of light olefins and high octane gasoline from various petroleum fractions, is more competitive and exceedingly suitable for heavy feed contaminated with metals. This process has also been enhanced to enrich propylene yield from paraffinic VGO (vacuum gas oil) feedstock. While Indmax of 0.1 MMTPA capacity was set-up at Guwahati refinery as the pilot project, IOCL commissioned 4.27-MMTPA Indmax unit at Paradip refinery in December 2015. As per the contract, LTHE’s scope of work covers extended basic engineering, detailed engineering, procurement, supply, transportation, storage, fabrication, inspection, construction, installation, testing, mechanical completion, pre-commissioning and commissioning of the unit. Chemical Engineering World
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CEW Technology News Agilent Technologies Receives 2017 Scientists’ Choice Award for Best Webinar Series Award for Agilent Biopharmaceutical Webinar Series
Pittcon 2017 International Conference and Expo in Chicago, IL. As it does each year, scientists around the world were invited to participate by nominating, voting and reviewing online.
Santa Clara, California: Agilent Technologies Inc. has announced that it received a 2017 Scientists’ Choice Award – Best Webinar Series of the Year – for its webinar series titled Solutions in Biopharmaceutical Discovery and Development, which ran for 10 episodes over the course of 2016. The award recognizes excellence in online scientific communication.
“We are much honoured to be receiving the Scientists’ Choice Award," said Stefan Schuette, Agilent vice president and general manager of the company’s Liquid Phase Separation Division. "The Agilent 1260 Infinity II LC system—a key component of our InfinityLab family—increases laboratory efficiency in three ways: delivering trusted analytical data, outstanding usability, and easy integration into existing environments.” The annual Scientists' Choice Awards celebrate the laboratory products and manufacturers that make a difference to the industry. SelectScience began the Scientists’ Choice Awards in 2007 to enable scientists to voice their opinions on the best laboratory products. Scientists are then invited to vote for their favourite products within each category, and the winners are announced at scientific conferences.
“We were delighted to present Agilent Technologies with the 2017 Scientists’ Choice Award for Best Webinar Series of the Year, for its biopharmaceuticals webinar series: Solutions in Biopharmaceutical Discovery and Development,” said the SelectScience editors. “You’ve won the award for generating the highest level of scientist-audience engagement, demonstrating that your educational content is vital to the industry and that you understand that webinars are a key communication tool that scientists need.” “We are especially gratified to receive this award,” said Tiffani Manolis, Agilent’s global pharma segment marketing manager. “It speaks to our commitment to engage with scientists on the challenges that matter most to them, and tells us that they value the content we share with them.” The 10- session series includes the following webinars: • R a p i d l y C h a ra ct e r ize An t ib o d y-D r u g C o njugates and Derive Drug-to-Antibody • Ratios Using LC/MS. • Biosimilars Workflow: Biocolumns. • Three-Par t Series: Technology Accelerating Biopharma: Analytical Workflow Solutions. • O n l i n e 2 D - L C A n a l y s i s o f C o m p l e x N - G l y c a n s i n Biopharmaceuticals. • Enhancing the Mass Spectrometr y Characterization of Antibody Drug • Conjugates (ADCs). • New Advances in Biotherapeutic Aggregate and Charge Variant Analysis. • Faster Aggregation Method Development with Cutting Edge LC Technology. • R a p i d , Po w e r f u l Te c h n o l o g i e s t o A d d r e s s Pe p t i d e Mapping Challenges • A Comprehensive Workflow Solution from Sample to Answer.
Agilent Technologies Receives 2017 Scientists’ Choice Award for Best New Separation Product Santa Clara, California: Agilent Technologies Inc. has announced that it has received a 2017 Scientists’ Choice Award for Best New Separation Product: The Agilent 1260 Infinity II LC system. The award recognizes the product that has made the most difference to chromatography as nominated by scientists. SelectScience announced the winners of the 2017 Scientists’ Choice Awards for General Lab, Separations and Spectroscopy during a special ceremony held on March 7 at the 24 • March 2017
HPCL to use Honeywell UOP Technology to Meet rising Domestic Demand for Clean Fuels New Delhi, India: Honeywell has announced that Hindustan Petroleum Corporation Limited (HPCL) is using technologies from Honeywell UOP for the expansion and modernization of its refinery at Visakhapatnam in Andhra Pradesh on the southeast coast of India.Included in the project are licensing, basic engineering design and other associated services for a Penex™ isomerization unit, which helps make cleaner burning high-octane gasoline, and a Unicracking™ hydrocracking unit to produce cleaner burning diesel fuel. “HPCL chose these solutions from Honeywell UOP due to their superior economics and our successful track record with these technologies,” said Steve Gimre, Managing Director, Honeywell UOP India. “UOP has licensed more than 160 Penex units, and more than 220 Unicracking units – more than any other licensor in these applications.” The Penex process upgrades light naphtha feedstock to produce Isomerate, a cleaner gasoline blend-stock that does not contain benzene, aromatics or olefins. The process uses Honeywell UOP’s portfolio of proven, high-activity isomerization and benzene saturation catalysts. The Unicracking process uses highly effective catalysts, unit design and reactor internals to produce higher yields of cleaner-burning fuels from a wider range of feedstocks. The unit’s fractionation section includes an innovative configuration to more efficiently separate the products, reducing capital costs and significantly lowering utilities and operating expense. In addition, the unit’s heavy polynuclear aromatics management allows the unit to achieve near ly 100-percent conversion throughout the entire cycle length. Together, the two processes will significantly enhance HPCL’s ability to supply gasoline and diesel that meets the Indian government’s new Bharat Stage-VI clean fuels standard, and meets growing demand for those fuels. They also improve gross refining margins by converting low value feed stocks to high-value transportation fuels. Chemical Engineering World
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CEW Technology News Flux.io chooses Siemens’ Parasolid to Advance Software Interoperability in AEC Munich. Germany: Flux.io, Inc. has announced that it has selected Siemens’ Parasolid® software as the geometric modeling foundation for Flux® software, a cloud-based collaborative platform for Architecture, Engineering and Construction (AEC) professionals. Flux needed a geometric modeling kernel that would enable model geometry to be shared, interrogated and manipulated in a browser by all project stakeholders. Parasolid was chosen because of its excellent track record in cloud-based computing, as well as its broad industry adoption. “The cloud is a compelling asset for Flux users who benefit from neutral, browser-based collaboration and interoperability across dispersed teams, as well as parallel processing that supplements local computing resources,” said Jen Carlile, Co-founder and VP of Engineering, Flux. io. “Parasolid has a proven track record as a geometric modeling component with reliable functionality and strong performance in the cloud, which is critical to our users’ success. It’s the ideal solution for our needs and the needs of our customers.” Teams of architects and engineers often use different software tools for their specific tasks, creating data incompatibility issues for the broader project. Time is wasted and data may be corrupted by data translation. Flux eliminates these barriers to productivity by preserving project data integrity - pushing and pulling data seamlessly between different AEC software applications.. In addition, Flux provides realtime cloud-based collaboration and visual programming for custom data manipulation, creating more dynamic workflows that keep users and their data synchronized. “As a company that champions software interoperability, we license Parasolid to hundreds of other software vendors to give their users access to the world’s leading high-precision 3D modeler, as well as its widely adopted and openly published data format,” says Jim Rusk, Chief Technology Officer, Siemens PLM Software. “Flux.io clearly understands the benefits of interoperability in the AEC domain and we were keen to support their shared vision for empowering cross-project collaboration.” Parasolid equips Flux users with a common representation of their geometric models in the cloud. These models can be shared among different teams, regardless of their chosen AEC software application and its native file format. Users can host live, interactive reviews in the browser across disciplines, without the need for colleagues to install and learn a specific software tool. Moreover, Flux users can construct, interrogate and manipulate
B&R Presents Intelligent Conveyor Technology at Interpack Pune, India: At this year's Interpack (Booth E62, Hall 6), B&R will be showcasing SuperTrak – a versatile, intelligent con-veyor system that represents a key contribution to Packaging 4.0. These smart manufacturing revolution prom-ises CPG producers’ unprecedented levels of OEE and reduced TCO. SuperTrak is a new generation of robust, operator-friendly intelligent conveyor technology based on long-stator linear motors. Unlike similar 28 • March 2017
systems available thus far, it offers true industrial-grade reliability and easy serviceability. Its independently-controlled shuttles allow mass production of highly customized prod-ucts, while also minimizing time lost on stoppages and product changeover. Seamless connectivity B&R will also be showing how open standards like POWERLINK, OMAC PackML and OPC UA will provide seamless connectivity – the lifeblood of industrial IoT solutions. From the sensor to the cloud, across multivendor lines and value chains, this connectivity will bring a dramatic leap in operating efficiency. More about B&R's contributions to the future of the packaging industry can be found in the Packaging 4.0 white paper and the special edition of its customer magazine. Both publications will be available at Booth E62 in Hall 6 at Interpack.
Honeywell UOP Scientists Recognized By American Institute of Chemical Engineers For Development Of Methanol-To-Olefins Technology New Delhi, India: Honeywell (UOP) has announced that the American Institute of Chemical Engineers’ (AIChE) Fuels and Petrochemical Division has recognized four of its scientists with the 2016 Industrial Research & Development Award for the development and commercialization of the UOP Advanced Methanol-to-Olefins process.The award recognizes the scientists’ work on the technology that converts methanol from sources such as coal and natural gas into the olefins that are the primary components in the manufacture of plastic resins, films and fibers. This is especially critical in countries that lack domestic sources of crude oil but are rich in coal or natural gas. “Our Advanced MTO technology has played a dramatic role in petrochemicals markets in only a few short years, and it shows how innovation and the application of chemistry and chemical engineering principles can profoundly benefit society,” said Jim Rekoske, VP and chief technology officer at Honeywell UOP. While many engineers and scientists contributed the development of the Advanced MTO process, the AIChE recognized John Chen (who led the research team) John Senetar (who led modeling and process design), Paul Barger (who established the catalyst and process criteria), and Dan Kauff (who led the integration of MTO and OCP processes) as leaders in the effort. The awardees set a new benchmark for smooth, rapid, and resilient technology commercialization, overcoming many technical challenges. The award recipients will be recognized at an awards banquet at the AIChE Spring Meeting in San Antonio on March 27. Honeywell UOP and Atofina (now part of Total) developed the Olefin Cracking Process (OCP), which converts heavier olefin byproducts from the MTO process into even more light olefins. OCP was integrated with MTO to create the Advanced MTO process, which is covered by more than 50 patents, and has been licensed to nine customers. Chemical Engineering World
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CEW Features Technical Article
CFD Simulation in Chemical Reaction Engineering Reaction engineering is a branch of chemical engineering that deals with the design and optimization of chemical reactors. The goal is to optimize the transport processes (heat transfer, mass transfer and mixing) in order to improve yield/conversion of desired products and safe operation of the reactor. This means maximizing yield while minimizing costs. These costs could be related to the cost of feedstock, energy input, heat removal or cooling, stirring or agitation, pumping to increase pressure, frictional pressure loss and the like. From the standpoint of computational fluid dynamics (CFD), reaction engineering is the application of transport phenomenon and chemical kinetics knowledge to industrial systems. Chemical kinetics—the study of rates of chemical processes—is founded on the experimental study of how different conditions influence the speed of a chemical reaction, its mechanism and transition states, and on the development of mathematical models of the reaction’s characteristics.
Reactor design and CFD Designing a reactor has several key facets: phase, or state of the reactants and products (solid, gas, liquid or aqueous/dissolved in water); reaction type (single, multiple, parallel series or polymerization); whether a catalyst is involved; flow distribution and mixing; transport of the species; and mode of operation - batch, semi-batch or continuous. Most crucial are the underlying transport processes - fluid flow, heat transfer, mass transfer and reactions - which is where CFD simulation can add substantial value. In reactor design, the process of taking the discovery of a new chemical with novel properties from lab to commercial production involves many steps: • •
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Conceptualization (analysis of new chemistry and the business case) Lab scale (analysis of kinetics, catalysis, thermodynamics, material properties and toxicity) Reactor se le ct io n (a n a lysis o f f l o w re g im e , h e a t re le a se , Residence Tim e D ist rib u t io n (R T D ), L i q u id H o u rly Sp a ce V e l o c i t y (L H S V ), a s w e ll a s Ga s H o u rl y S p a ce V e lo cit y (GH SV)
30 • March 2017
Figure 1: Essential aspects of chemical reactor design
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Engineering with idealized models (analysis of plug flow or Continuous Stirred Tank Reactors (CSTR), volume sizing, overall heat transfer) Preliminary configuration (analysis of vessel configuration, internals, baffles, and coils)
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Scale-up simulations (pilot scale design, scale-up parameters and design space exploration) Final design (extrapolation from scale-up rules, flow modeling, safety, risk and runaway analysis, dynamic modeling) Chemical Engineering World
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CEW Features Gas Phase: Gas phase reactions may be simple combustion reactions, or reactions that take place inside tubes such as those in cracker furnaces where heat is supplied externally. Liquid Phase: Liquid phase reactions may involve polymerization schemes or series-parallel liquid reactions with meso/micro mixing. Custom Reactions: These involve enzymatic reactions, fermentation, as well as user coding.
Table 1: List of available reaction models for gas phase reaction flows
•
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Initial engineering begins with an idealized reactor model sized to lab/bench scale and is used to predict key variables in reactor behaviour including the reaction parameters, material properties, toxicity, ideal operating conditions, catalysts best suited for the job, as well as preliminary reactor dimensions. Next comes the preliminary reactor configuration followed by scale-up and simulation of a pilot scale design. Finding the sweet spot for the pilot scale design is typically the stiffest challenge during the design process, as the affected parameters are linked nonlinearly to each other, and hence each of the sub process scales differently. Therefore if you want a larger capacity, increasing the size geometrically is sufficient, but not so for reaction, heat transfer, or mixing. If you scale the model with turbulence scales, it may result in extremely high revolutions per minute or a geometrically unfeasible design. As a result, there are many different designs that can be created depending on the scale-up rule used, and achieving the perfect scale-up model requires design space exploration to find the optimum result. Final design is accomplished through extrapolation from scale-up rules, detailed flow modeling, assessment 32 • March 2017
of safety risks and runaway reactions, and dynamic modeling of the entire system to see how the predicted reactions will work at plant scale. At each stage of the design process, illustrated in Figure 2, CFD can provide predictive capability, design exploration and optimization at better fidelity, speed and cost than experimental data alone. Reaction models Depending on the physics of the reaction, a wide range of chemical reaction models are available in STAR-CCM+®, for example whether the reaction is carried out in gas phase or liquid phase, and whether a catalyst is present. Models that are supported include:
Cases where detailed chemical kinetics of a reaction need to be developed, modified or modelled in ideal flow conditions, a dedicated tool called DARS is available. Beyond off-the-shelf support for all these, the types of reactions that can be modelled in STAR-CCM+ are virtually unlimited, thanks to the software’s field functions and user coding capabilities. Gas phase reacting flow models The most basic types of flow models are for gas phase reacting flows where the different species (feedstocks) enter the reactor non-premixed, completely mixed or partly premixed. For each category, a host of STAR-CCM+ models are available to simulate the reaction (see Table 1).
Figure 3: Eddy Break-Up model of glass furnace in STAR-CCM+ showing flame zone and region of NOx formation within overall combustion chamber. Chemical Engineering World
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CEW Features confidence and predictive capability for designing as well as operating this type of reactor safely. Also important are species concentration such as O2 mole fraction at the same location, which is shown 0.9 meters from the fuel inlet. In Figure 3, the bottom plot demonstrates a good agreement between experimental measurements and simulation results. In situations such as this, where high-temperature processes make experimental work difficult and expensive, simulation provides an easier, more cost-effective way to explore quantities of interest
Figure 4: STAR-CCM+ results for coupled 1D/3D simulation of a steam methane reformer.
Some of these are regarded as tabulated chemistry models to reduce computation times, while others make use of detailed chemistry using DARS. An example is a simple glass furnace, where air and fuel enter the domain non-premixed. The simplest model is the Eddy Break-Up model available in STAR-CCM+, an example of which is shown in Figure 3, highlighting the flame zone, the approximate region where NOx is formed, and the rest of the combustion chamber. In this case, critical considerations in design and operation of
the reactor include not only heat transfer but also production of pollutant species such as NOx. Validation studies conducted for this reactor design are summarized in Figure 3. The top plot shows the temperature profile at a location of 0.9 meters downstream from the fuel inlet. The green dots show experimental measurements, while the blue line shows simulation results from STAR-CCM+. Good agreement is visible between the two, giving the necessary
Modeling process for heaters and crackers In process heaters and naphtha crackers, reactants pass through a tube while heat is supplied by combustion outside the tube. STAR-CCM+ provides a simplified way to simulate these reactions by modeling the tubes as 1D plug flow reactors - an idealized model used to describe chemical reactions in continuous, flowing systems of cylindrical geometry - while the external combustion is modelled in 3D. This approach is much less computationally expensive than simulating the whole system in 3D.
Figure 6: STAR-CCM+ provides an automated process to model and simulate packed bed reactors. 34 • March 2017
Chemical Engineering World
CEW Features DARS: Digital Analysis of Reacting Systems
Figure 7: Schematic of the lab scale mixing vessel used in solids suspension experiments
DARS (Digital Analysis of Reacting Systems) is a standalone gas phase detailed chemical kinetics modeling tool. It can be used for simulating ideal (simplified) reactor models, to develop and import reaction mechanisms to perform sensitivity analysis, validate experimental data, and simplify the reaction mechanisms for use in CFD simulations.
On the outer tube wall, conduction, convection and radiation are modelled in 3D, while inside the tube, heat transfer via convection is modelled in 1D. Then the two simulations are coupled at the junction of the tube wall. This allows the designer to look at how mass fractions of species behave inside the tubes, and at the same time look at heat transfer and temperature profiles outside the tubes in the furnace. Figure 4 shows the STAR-CCM+ results for a coupled 1D/3D simulation of a steam methane reformer providing the axial distribution of temperature, heat flux, and species concentration.
An important class of detailed chemistry simulations is surface chemistry. These are reactions in which the reactants are initially adsorbed onto a surface medium that acts as a catalyst for the reaction; after the reaction, the products are desorbed and the surface is left unchanged. Surface chemistry can be modelled either with detailed chemistry formulations using the stiff differential equation solver in STAR-CCM+, or using just at global reaction mechanisms. One application where surface chemistry is important is designing packed bed reactors, which consist of tubes filled with a packing material impregnated with catalysts to improve contact between two phases in the reaction. Design
challenges include accurate prediction of heat transfer, which is critical for safe operation of such reactors. Modeling of such reactors provides critical insights into heat transfer if generation of representative random packing, and contact resolution in meshing can be done efficiently and accurately. STAR-CCM+ provides an automated way to model and simulate packed bed reactors. Through a graphical user interface, the designer can specify geometry conditions, particle properties, wall properties, particle-to-particle interactions as well as other fluid properties, and heat transfer simulations. Once these specifications are defined, the catalyst bed is generated using the built in Discrete Element Modeling capability in STAR-CCM+. The software creates a mesh including boundary layers, then progresses to carry out the CFD simulation, followed by post processing to look at radial and axial porosity, velocity profiles, heat transfer, and reactions if necessary. Multiphase systems Performing lab scale tests and validating them in a CFD simulation is an essential part of the scale-up operation. Such
Figure 8: Power consumption comparison of experiment, simulation and correlation: the contours plot on the right shows the solid volume fraction for the various solids loading. 36 • March 2017
Chemical Engineering World
Features CEW Results as see in Figure 8 show that simulation predictions (performed with commercial CFD code STAR-CCM+) not only accurately validate power consumption data but also predict the trend that increase in power is sub-parity. Common correlations used to predict power need a power number look up from available charts in literature. One has to match the conditions of the given system to those available in literature for geometric ratios, material properties and solid concentrations.
Figure 9: Physical configuration of reactors is critical to predicting the product of many liquid phase micro-mixing reactions.
validation gives the necessary confidence in robustness and fidelity of the model to make predictions at plant scales where measurements may not be possible. One such example of determining the power calculation for a varying solids concentration (10%, 20%, 30% and 40% by wt.) is given as follows. In this example,
a four bladed pitched bladed turbine (4PBT see Figure 7) was used to suspend sand (particle size 190 microns) in water at a speed of 600 rpm. The liquid and solid densities were 1,000 and 2,483 kg/m3 respectively. The tank had a height and diameter of 0.34 m whereas the impeller diameter was 0.19 m.
Figure 10: Comparison of predicted yield values obtained by Eddy Contact micro-mixing, and Eddy BreakUp (EBU) models with experimental measurements for liquid phase reaction Chemical Engineering World
Most of the time, it is not possible to find a good match from the geometries and material properties for cases available in literature for factor “s” to those for a given design requirement; therefore the confidence to choose the right power number is very low. This uncertainty results in inaccurate power prediction from correlation based methods, as can be seen reflected in the plot shown in Figure 9. Liquid phase reactions: micro-mixing Liquid phase reactions differ significantly from gas phase reactions because diffusivity of liquids is much lower than their viscosity. Therefore reactions can be strongly influenced by scalar gradients. The most important difference present in many liquid phase reactions is the phenomenon of micro-mixing, or mixing at the molecular scale. In the reaction shown in Figure 9, whether the reaction will preferentially form product S or whether it will preferentially form product R depends on the physical configuration of the reactor. In this schematic, for example, the location at which species B is added - at the top of the vessel, or instead close to the impeller - can make a significant difference in results. STAR-CCM+ allows accurate modeling and prediction of these micro-mixing effects by providing the eddy contact micro-mixing model, which gives higher accuracy compared to the Eddy BreakUp model (standardly used for gas phase March 2017 • 39
CEW Features
Figure 11: STAR-CCM+ provides numerous ways and capabilities to model reactors.
reactions). The Eddy Contact model calculates a reaction time scale based on scalar dissipation rate and uses this to calculate the reaction rate. Customized reaction models: fermentation and biochemical reactions Another kind of flow reaction consists of fermentation and biochemical reactions. In these, sugar is converted to acid and either gases or alcohol are produced through complex reaction chemistry. Reaction rates differ starting with a log phase followed by an exponential phase, then a deceleration phase and finally a stationary phase. Each phase has its own defined reaction rate. All of these can be defined in STAR-CCM+ using the custom reaction definitions 40 • March 2017
available through the user-defined functions or field functions. Conclusion The capabilities available in STAR-CCM+ allow reaction engineers to look at the transport processes in various reactor types including packed bed reactors, fluidization, stirred reactors, bubble columns and membrane reactors, as well as all the various high-temperature processes in gas phase reactions. Even in established processes, the underlying transport processes are crucial for reactor design and open up possibilities for improvement. For each of those transport processes, STAR-CCM+ provides numerous ways and capabilities to model and discover better reactor designs, faster.
Ravindra Aglave Director Chemical & Process Industry Siemens PLM Thomas Eppinger Technical Specialist Reaction Engineering Siemens PLM Chemical Engineering World
Features CEW
Tubesheet Design Algorithm as per ASME Sec. VIIIDiv.1 / Part UHX Shell & Tube heat exchanger is one of the critical & complex equipment of process industry. Over the years considerable changes were observed in heat exchanger design. Primitive approach of TEMA (Tubular Exchanger Manufacturers Association) was further replaced by new analytical approach. New analytical approach was based on various technical papers published by eminent researchers, which was adopted by various pressure vessel codes (BS5500, CODAP, ASME Sec VIII-Div.1) to arrive at more realistic results. This article aims at understanding of: 1. Limitations of earlier design approach & evolution of new analytical approach on Tubesheet Design, 2. Algorithm (Analytical Methodology) of tubesheet design as per ASME Sec VIII Div.1 / Part UHX & 3.Flowchart for tubesheet design as per ASME Sec VIII Div.1 / Part UHX
Limitations of Earlier Design Approach & Evolution of New Analytical Approach on Tubesheet Design Primarily TEMA design of tubesheet was based on classical plate theory under uniform pressure which neither had any consideration of weakening of tubesheet due to holes nor strengthening (elastic modulus correction) of tubesheet due to tubes which provides stiffening effect. Later in 1988, TEMA 7th Edition tries to overcome these deficiencies in design of tubesheet. Being simplistic, TEMA rules of design were popular & served more than 40 years with satisfactory performance of exchangers in various industries. However it was later found that rules were inadequate & proven to be not conservative for big exchangers having high pressure-temperature conditions.
TEMA analysis does not taking into account the effects of: • Un-tubed area (Peripheral Rim & Untubed lanes of multipass) • Tube expansion in tubesheet • Type of channel end (cylindrical or spherical head) integral to tubesheet • Stresses developed in shell/channel integral to tubesheet • Xa, Axial rigidity of tube bundle to tubesheet bending rigidity When Xa is 1 it signifies low support to tubesheet When Xa is higher it signifies higher support to tubesheet; generally Xa varies between 2 to 8 • Rotational stiffness (restrain) of shell/ channel integral to tubesheet Z = Rotational restrain at tubesheet edges (degree of fixity), 0 when simply supported (SS)∞ when integral (Clamped)
analysis. In which weakening effect of holes was also considered by replacing tubesheet with equivalent solid plate having equivalent Elastic Modulus E* & Poisson’s Ratio v*.
However by 1952 based on studies made by Gardner & Miller, tubesheet was treated as plate on elastic foundation (of tubes) for
TEMA methodology seems to have assumption that stiffening effect of tubes is nullified by weakening effect of tubesheet
Later based on works by Gallety in 1959 effect of tubesheet elastically restrained at edges against rotation was also considered in analysis. Similar approach is then developed by ASME based on works of KP SINGH & AL SOLER in 1984. Also in 1969 Gardner, improved his method by taking into account unperforated rim. Graphical representation in figure. 2 depicts that TEMA has very discrete values for coefficient F based on tubesheet support at its edges, whereas ASME has varying analogue for such coefficients (F, Z) in tubesheet thickness calculation.
Fig.1-Analytical Model in Tubesheet Design Chemical Engineering World
March 2017 • 41
CEW Features
Fig.2-Comparision of TEMA & ASME UHX for fixed tubesheet
due to holes. However, it is observed that most of the cases stiffening effect of tubes prevails weakening effect of holes. TEMA gives over conservative output for tubesheet thickness for many cases, it shall not be always considered as desirable as this will lead towards more stresses in tubes. The reason being, thicker tubesheets are more flexural rigid which restricts axial strain (due to pressure / thermal) of tubes, imparting more stresses in tubes. This may lead to failure of tubes & requirement of bellow, making the equipment complex & uneconomical. It was also observed that TEMA calculated thickness of tubesheet becomes unconservative for large diameters with high pressure / temperature. Hence, TEMA has limitation in the form of “Pressures – Diameters Multiplier” for its applicability. Whereas in ASME-UHX design is an analytical approach which can take care of these shortcomings by taking into account of the axial rigidity of tubes, effect of tube holes, effect of tube expansion, connection of the tubesheet with shell/head and un-tubed lanes of tubesheet. Hence there is no size & design condition limitation unlike TEMA. Further paragraphs explain the methodology of UHX approach for tubesheet design. 42 • March 2017
Fig.3-Tubesheet with Shell Band
Flowchart for tubesheet design as per ASME Sec VIII Div.1 / Part UHX
Nomenclatures: σ:
Induced tubesheet stress
S:
Allowable stress for Tubesheet at design temperature
σs :
Total axial stress (membrane+bending) in channel at design temperature (at tubesheet junction)
σc :
START
# Tubesheet thickness or shell/channel thickness Integral to tubesheet
Perform Tubesheet analysis as per ASME Sec VIII Div.1 / UHX Analyse stresses
σ, σs , σc
Allowable stress for Shell at design temperature
Sc :
Allowable stress for channel at design temperature
SPSs : Allowable primary + secondary stress for shell at design temperaturemin ( 3 Ss, 2 σys ) SPSc : Allowable primary + secondary stress for channel at design temperature min ( 3 Sc, 2σyc ) σ ys :
Yield strength at design temperature for shell material
σ yc :
Yield strength at design temperature for channel material
Algorithm (Analytical Methodology) of tubesheet design as per ASME Sec VIII Div.1 / Part UHX Step-1: Induced tubesheet stress σ shall be within allowable stress limit ‘k x S’ (Primary membrane+ Primary bending) σ ≤ σ≤ k x S k : 1.5 for Fixed & Floating Tubesheet ; 2 for U-Tubesheet
Check
1
σ≤ kxS
2
Check σs > SPSs σc > SPSc
N
Y
Total axial stress (membrane+bending) in channel at design temperature (at tubesheet junction)
Ss :
Assume new Thickness #
Y
N Check σs ≤ 1.5 Ss σc ≤ 1.5 Sc
3
Tubesheet is SAFE in Bending
N
4
Perform Plastic-Elastic** Analysis as per UHX
Y
Therefore 1.5 Ss < σs < SPSs 1.5 Sc < σc < SPSc
5
6
N
Perform Simply-Supported Analysis as per UHX
Check
σ’ ≤ k x S
Tubesheet is SAFE in Bending
Flowchart for tubesheet design as per ASME Sec VIII Div.1 / Part UHX
Step-2: Determine Junction stresses in shell/ channel integral at tubesheet (σós & σóc) When σós > SPSs or σóc > SPSc, shell / channel thickness to a certain extent (as prescribed by code, shell band) integral to tubesheet shall be increased. Step-3: If Junction stresses in shell/channel integral at tubesheet is less than SPSs or SPSc, then at first Junction stresses between tubesheet & shell/channel shall be Chemical Engineering World
Features CEW studies are going in tubesheet design. Special working group of heat exchanger equipment (SWGHTE) of ASME is working on evaluating maximum stress on inner tubes. This is because; it is observed that in some cases inner tubes are stressed more than peripheral tubes. Whereas present practices of ASME/ TEMA evaluates stresses of peripheral tubes. Fig.4-Tubesheet design as per Plastic - Elastic Phenomenon
treated as primary stresses & those shall be qualified as per primary stress criteria. (1.5 x S for primary membrane + Primary bending) σ σ s ≤≤ 1.5 x Ss σ c ≤≤ 1.5 x Sc Step-4: However, if ‘1.5 Ss ≤σs ≤≤ SPSs‘ or ‘1.5 Sc≤σc ≤SPSc ‘, either of below method shall be adopted to qualify stresses. Step-5: “(Pseudo) Plastic-Elastic Analysis” shall be performed, where entire credit of shell/channel stiffening is not considered. It is assumed that shell/channel will plastically deform (beyond elastic limit) under application of loads, deformation relieves induced stresses at shell/channel junction integral to tubesheet. Once plastically deformed geometry will again follow new elastic path for further application of load i.e “shakedown to elastic path from plastic deformation”. Due to this phenomenon allowable criterion is set at higher limits. Hence analysis is termed as “Plastic-Elastic Analysis” & induced stresses near shell/ channel junction integral to tubesheet are
considered to be secondary which shall be qualified for secondary stress criteria [σs/c < SPS s/c = min(3S s/c , 2σσys/c)] This Analysis is performed by knocking down (reducing) modulus of elasticity of shell/channel to Es*. Revised tubesheet stresses (σσ’) are evaluated & checked for its qualification as per σ’ ≤σ≤ k x S. **However Plastic-Elastic analysis shall not be performed at high temperatures time dependent properties governs allowable stress. Step-6: When “Plastic-Elastic Analysis” cannot be performed or alternatively, simply supported analysis can be performed for tubesheet, where effect of Rotational stiffness of shell/channel integral to tubesheet is not considered. Note: Tubesheet shall also be checked for Shear Stress Criteria as per code. There are still technical advancements &
Also there is no guideline in ASME Sec VIII Div.1 when tubesheet is not uniformly perforated. In such cases code directs for special design beyond scope (normally FEA is performed); however there are guidelines observed for such cases in ASME Sec I.
Change is continuous; in near future we may witness more profound methods of tubesheet design. Industry is thankful to those researchers & engineers who contributed for better engineering and keep on doing so in future. References: 1. ASME Sec VIII Division 1’2015 2. TEMA Standards 9th Edition 3. White Paper on Part UHX of ASME Sec VIII Division 1 by Miller’2002 4. Paper presentation on “Analysis of TEMA design rules-Comparison with up to date code methods” by Osweiller’1986 5. INS National Workshop on Pressure Vessel Design & Fabrication’2016 (Course Material) 6. Intergraph Webinar on “Modeling Fixed Tubesheet Exchangers with PV Elite”
Author’s Details Rupesh M Ubale Mechanical engineer GS E&C Mumbai Pvt Ltd E-mail: ruponline1@gmail.com Saji George (Mentor) Principal Mechanical Engineer GS E&C Mumbai Pvt Ltd E-mail: saji_george@gsenc.com Fig.5-Tubesheet Design considering Simply Supported Chemical Engineering World
March 2017 • 43
CEW Features Technical Article
Small-Scale CO from CO2 using Electrolysis Reliable small and medium-scale CO production is costly and challenging, in contrast to the well-proven technologies available for large-scale applications. Haldor Topsoe has developed a stand-alone unit producing CO on-site and on-demand at competitive pricing. The unit is based on Haldor Topsoe’s solid oxide electrolysis cell technology and uses feedstock carbon dioxide and electrical power to produce CO with high purity. The unit is cost competitive for most operations where the CO supply today relies on cylinders or tube trailers. Eventually, this technology opens up for a whole new segment of green and sustainable chemicals from renewable carbon sources.
Carbon Monoxide in Industrial Applications
Large-Scale
Carbon monoxide is a highly toxic gas with a lot of industrial applications. It is one of the main gas constituents in syngas, used e.g. for methanol production. Many of the industrial applications require huge amounts of CO (>5000 Nm3/hr). Haldor Topsoe is well-known expert for large-scale CO production in reforming plants, as well as in designing processes where CO is used on a large scale (for example methanol synthesis). In these large-scale applications, CO is typically both produced and used locally within the plant. Previously, the hitherto smallest scale, about 1000 Nm3/hr, CO production used to be based on heat exchange reformers, with a membrane removing hydrogen. Thus, well-proven technologies are available for reliable CO production on large scale and Haldor Topsoe is a well-known licensor and catalyst supplier for these plants. New Technology for Smaller Scale OnDemand CO Supply For applications using CO on medium or smaller-scale (typically less than 1000 Nm3/hr), the supply options are more complicated and costly. Many companies having a need for CO on a regular basis have experienced the challenges involved in sourcing CO reliable and affordably. The number of merchant CO suppliers is limited, and ever-rising transportation costs and frequent production shortages 44 • March 2017
only add to the headaches. For many smaller-scale users of CO gas (10300 Nm3/hr), such as companies manufacturing polyurethane plastics, specialty chemicals, etc., there have been no alternatives to buying CO in large gas cylinders, typically in the form of tube-trailers, that are then parked next to the chemical plant until the cylinders are empty. Not only does this mean high costs for these customers, but also an increased safety risk from storing large amounts of hazardous CO on-site. Industrial efficiency and safety continue to require innovations and changes to the way we perform all of our production, supply, transportation, and administration, and innovations to the CO supply can address the above customer pains and add significant value. To address these customer pains, Haldor Topsoe has developed the electrolytic CO solution (eCOs) system, wherein CO is safely produced via the electrolysis of CO 2 at 700-85 0C using solid oxide electrolysis cell technology. On-site CO production is the answer for any distributor or end user needing a steady supply of affordable CO. Transportation of carbon monoxide may be reduced or completely eliminated with on-site CO production using eCOs. On site CO generation is a significant development to the medical, pharmaceutical, metallurgy, electronics and specialty chemicals industries (which includes Carbonylation routes such as phosgene, polycarbonates, polyurethane,
isocyanates etc.), which require carbon monoxide in their processes as well as to gas distributors. The eCOs technology ensures security of supply, eliminates the need to transport hazardous gas, and drastically reduces costs related to storage, rentals and connections. The eCOs technology requires only a power source and CO 2 supply, which often already is established on-site, or is easily established as a commodity. With eCOs, CO can be produced effectively and efficiently. The specific benefits of eCOs are: • •
• • •
On-site production on-demand Multiple sizes and purity options uto 99.999 per cent Grade 5.0 (main impurity CO 2) Fully replaces tube trailer or cylinder supply Cost savings compared to bottles and tube trailers Easy to operate for non-chemical operators
What is an eCOs plant The name eCOs stands for “electrolytic CO solution”, and the heart of an eCOs plant is a solid oxide electrolysis cell (SOEC). The eCOs plant flow diagram as shown in Figure 1 consists of two steps: 1) CO generation step (SOEC) and 2) gas purification step. In the CO generation step, the SOEC efficiently reduces CO 2 to CO through the electrochemical process of electrolysis. This results in a CO rich Chemical Engineering World
Features CEW
Figure 1: eCOs plant flow diagram
stream and an O2 rich stream. The O2 rich stream is vented to the atmosphere or can be exploited for other suitable applications. Any remaining unconverted CO 2 from the CO rich stream is removed from the CO product gas using a gas purification step. Removed CO 2 from the gas purification step, depleted in CO, is recycled back to the CO generation step. Haldor Topsoe’s experiences in fuel cells and separation technology have been the foundation of the development of the eCOs. That expertise has made the eCOs a safe, efficient, reliable, and cost effective system for the supply of CO, without personnel required by the users. The modular containerized design allows for plants as small as 6 Nm3/hr and as big as 200 Nm3/hr with turn down ratio down to 30 per cent. An eCOs plant is delivered as a stand-alone unit with power, CO 2 and product gas connections. The eCOs technology ensures high levels of purity, producing CO ranging from 99.5 per cent to 99.999 per cent purity with minimal contaminants and CO 2 as the main contaminant. For some applications certain impurities normally occurring in merchant CO is virtually non-existing with CO produced with eCOs. For a 99.96 per cent purity grade CO produced with eCOs, most of the contaminants is CO 2 (330 ppm) and N2 (30 ppm). O2 and CH4 Chemical Engineering World
is typically <0.1 ppm, H2O <0.1 ppm and H2 <2 ppm. These contaminants are sometimes critical for certain processes where CO is used and would normally require 5N grade CO if produced with traditional technologies. How SOEC Works Solid oxide electrolytic cells (SOEC), is an energy conversion technology that can be operated to store or convert electricity and carbon dioxide as carbon monoxide and oxygen, with high efficiency and high reaction rates. The cells operate at relatively high temperatures (700-850 o °C) to split carbon dioxide into carbon monoxide and oxygen using the heat and the SOEC cell, thereby self-cooling. The heat which is inevitably produced with electrical current is needed for the electrolysis process. The SOEC consists of three parts: an electrolyte, an anode, and a cathode that are built up of various ceramic (or solid oxide) materials (Figure 2). A cathode of an electrochemical cell is the electrode where reduction reaction occurs, and an anode is where oxidation reaction occurs. Using external electricity, SOECs are able to electrochemically convert carbon dioxide to carbon monoxide at the fuel electrode (cathode). At the same time, pure oxygen can be obtained at the
oxygen electrode (anode). The two electrolysis products, carbon monoxide and oxygen, are formed on each side of the cell. At the cathode, CO 2 dissociates to form CO and O. The oxygen atom reacts with the incoming electrons from the external circuit to form an oxygen ion. The oxygen ion is conducted through the electrolyte to the anode. At the anode, the oxygen donates the electrons to the external circuit to form an oxygen atom. Two oxygen atoms finally combine to form an oxygen molecule at the anode side of the cell. Industrial Experience The first eCOs plant of capacity 12 Nm3/hr is currently in operation at Gas Innovations in La Porte, Texas (Figure 3). CO produced by the eCOs plant has surpassed the purity expectations of >99 per cent purity and demonstrated >99.9 per cent purity, with CO 2 being the main “contaminant”. “We have experienced a very stable daily production of CO on the eCOs unit, since we put it into operation in January 2016. The flexibility is outstanding and we can scale the production and choose the necessary March 2017 • 45
CEW Features Technical Article the coming decades. This will lead to significant changes in the electricity grid and a need for flexible large-scale energy storage due to the intermittent nature of wind and solar power. Solid oxide electrolysis can be used to convert excess electricity to energy carriers such as hydrogen or syngas (H2 + CO), and Topsoe’s SOEC technology can convert CO 2 and H2O to syngas by feeding steam (H2O) and CO 2 to the cells simultaneously. This is actually a specific feature of the SOEC technology and is not possible with conventional lowtemperature electrolysis.
Figure 2: Basic operating principle of SOEC technology
purity for our needs at any given time. So we have chosen to sign a 15-year pay-per-use agreement with Haldor Topsoe for an additional eCOs unit with ten times larger capacity,” says Ashley Madray, Executive Vice President, Gas Innovations. The new unit will be able to produce 96 Nm3/hr CO at up to 99.999 per cent purity and is expected to be online at the end of 2017.
Future Perspectives with SOEC Besides CO 2 electrolysis, the SOEC technology has the future potential to be used in larger scale when the energy supply changes to more and more renewable resources. In order to achieve the climate goals of the Paris Agreement, global leaders at COP21 plan to rapidly increase the fraction of renewable energy supply towards 100 per cent over
The syngas generated in this manner may be stored and later reconverted into electricity at peak demand. It could also be further processed to methane, which could be stored and distributed through the natural gas grid, or synthetic fuels used in the transportation sector. Another possibility is the production of green and sustainable chemicals from renewable carbon sources.
Author’s Details
Chetan Mittal Technology Scouting Manager Email Id: chem@topsoe.com
Casper Hadsbjerg Business Director, eCOs solutions Email Id: caha@topsoe.com
Figure 3: eCOs Plant at Gas Innovation Inc., La Porte, Texas, USA 46 • March 2017
Peter Blennow Principal Research Engineer Email Id: pebl@topsoe.com Chemical Engineering World
Features CEW CASE STUDY
Use of Heat Integration and Column Sequencing in the Design of Optimum Small Scale Distillation Systems The techniques like Process Integration, Column sequencing have been used widely in large scale chemical plants. This paper demonstrates how distillation sequencing along with heat integration techniques can be helpful in designing an efficient system even at small scale distillation systems. A representative five component feed liquid mixture case is used to illustrate the use of this technique. The Feed flow rate is deliberately kept moderate so as to check the possible use of such complex techniques at a small scale of operations. Process simulations, sizing, pinch analysis and economic evaluation are done using Aspen plus V 9. It was observed that while the process constraints limits the heat integration and sequencing possibilities, a holistic approach can still lead to considerable cost savings during design stage. Two sequences-direct and indirect with heat integration are compared and it is found that for the particular case study, an heat integrated indirect sequence has 28 per cent less operating cost and about 10% less Total Annualized Cost (TAC) than the conventional direct sequence with no heat integration. Thus by appropriate column targeting, pressure swing and heat integration, both capital and operating costs can be saved even at small scale distillation separations.
Distillation is the most widely used separation operation in chemical industries. In a chemical plant, the distillation alone can consume 40 to 70% of operating costs and capital investment. This makes it imperative to synthesize distillation system that is optimum by evaluating all the possible options. Distillation system synthesis has been well studied for decades. The objective of synthesizing a distillation system is to provide optimal specifications for equipments that meet the design specifications and constraints on product specifications. A design of multi component distillation system starts with determining product requirements like purity and recovery of key products, physical and chemical properties of components in the feed, process constraints and an appropriate separation sequence. While the product requirements are specified by user, transport properties of components and thermodynamics of system like VLE, Chemical Engineering World
interaction parameters etc. are either determined experimentally or used from an existing databank of commercial simulators. Before attempting the process design, it is also important to note the process constraints/boundaries like presence of azeotropic boundaries, product thermal degradation, toxicity, flammability, corrosiveness, reactive and melting points etc. to make the correct design decisions and practical applications safe. A choice of order of separation of components selected in the light of requirements and constraints is a distillation sequence. Distillation sequence can be broadly classified into simple and complex sequence. Simple sequence typically comprises of distillation columns with one feed split into two products. Any components in the middle of light and heavy key become impurity and are separated sequentially in subsequent columns. Complex sequence on contrary can have multiple feed splits, partially or fully thermally coupled or can have a wall dividing column into two or
more sections. This paper focuses on simple multicomponent mixtures without any azeotropes. Such feed streams are commonly encountered in organic chemicals, essential oil distillations that involve isomers. Typically such systems require modest investments to the tune of ` 30 Crore. The capital costs are mainly associated to the number of columns and auxiliary equipments. For an ‘n’ component mixture, if ‘n’ product streams are required, it is necessary a sequence composed by ‘n – 1’ columns. The maximum number of simple column sequences can be predicted by: S n =(2(n — 1))!/ n! (n-1)! ......Eq(1) In a typical small scale distillation system, there are not more 4 main products required with high purity. So according to the above equation, simple sequences do not cross over 5 in number. Before starting the process design, one among March 2017 • 47
CEW Features sequencing can be useful even for small scale industries. Methodology and Case Illustration
Table 1 Feed and Products Specifications
the many distillation sequences has to be chosen. There are various methods for selecting the best configuration out of the subsets. Some of them included use of mathematical models like Stochastic optimization, MINLP (Errico et al., 2014), Simulated Annealing (Wei-zhong and Xi-Gang, 2009), Genetic Algorithm with different objective functions like minimum vapour flow rate, total annualized cost, heat-integration potential and net present value of the process. The shortcomings of such mathematical models are: •
The coding and optimization is often time consuming
•
Process constraints may hinder the convergence
•
Models have to be simplified for the ease of comparison
•
Increase in complexity of the process making it infeasible
•
The results have to be anyways reevaluated with an engineer’s insight and rigorous modelling
Other method includes rigorous modelling of all the sequences based on heuristics and comparing the best in terms of their Total Annualized Costs (Jain et al., 2012) or Net Present Values. Due to process constraints, a number of infeasible split solutions can be discarded, saving design time and allowing accurate comparison of feasible schemes only. In small scale distillation processes, this is highly favored as the set of combinations is small. Of course the best methodology will to club these two together to produce an optimal design. 48 • March 2017
After choosing an appropriate sequence, process design parameters have to be selected. In this step, number of stages, column internals, size, operating conditions, type of condenser/reboiler etc. for various columns have to be chosen. Some of these parameters are inter-related and are best chosen with the designer’s insight. This design stage is crucial since the parameters greatly affect the capital and operating cost of the sequence. While the capital cost is mostly dictated by the type of the equipment and internals required according to product requirement, major operating cost in distillation is the heating and/or cooling requirement. The energy required to separate the components is a major concern for the process industry and consecutively affects the other segments of the industry like utility system, cooling towers, water requirement, CO2 emissions etc. Pinch analysis and Process Integration has been used for reducing the energy consumption of various processes for over two decades now. But their acceptance and use has been limited to large scale industries involving huge Capex. The objective of this paper is demonstrated how pinch analysis along with distillation
A feed that contains reacted phenol derivatives with no azeotropes is used as case study to illustrate the methodology. The feed rate is kept moderate to see the benefits at small scale levels. Conditions of feed and product purity and recovery requirements are given in Table-1 According to the eq. (1), there can be 5 different sequences possible for 4 product separation to find the optimum distillation system; all the alternatives should be compared. Components A to E are termed according to their volatilities starting from A being the light key to E being the heavy key. The five possible distillation splits are given below. Afterwards, the system is designed using rigorous simulations in Aspen Plus and costing is done using Aspen cost estimator and their total annualized cost (TAC) is computed by the formula: CAPEX TAC = ------- + OPEX … … … Eq (2) yr To find out the best sequence, it needs to be compared based on total annualized cost. The payback period is taken to be 3 year and OPEX is calculated based utility and labour prices in India. The total operation time is taken as 8766 hr/ yr. Capital cost for different equipment, structural, piping; instrumentation and fabrication are calculated using in‐ house cost libraries in Aspen Capital Cost Estimator. The distillation systems are designed according to algorithm given in paper I (Sharma and Patil, 2014). All the possible distillation schemes are simulated and it is found that only sequence 1 and 2 can achieve the desired purity/recovery of products. By using 3, 4 and 5 the some of Chemical Engineering World
Features CEW These initial estimates were later modified after column targeting and process modifications are given in the Table 2. The methodology for column and distillation system optimization is taken from paper (Sharma and Patil, 2014). The composite curves generated by Aspen Energy Analyser are given in Figure 3. From the composite curves it can be seen that there is a higher energy recovery potential for scheme 2 than scheme 1. It should be noted that in the Figure 3 b, there is a considerable different between the hot and cold composite curves at the point of pinch. This is favourable for capital cost reduction while maintaining the maximum heat recovery.
Figure 1 Scheme no 1 (Direct split) and initial Process conditions
From Table 2, it can be seen that the heat integration can lead to considerable savings for both the schemes. While the heat integration of scheme 1 can save 30% of hot and 36 % of cold utility respectively; scheme 2, these numbers are 35% and 40%. This is also reflected on the OPEX of both schemes. For scheme 1, OPEX with integration is 19.9% less than without integration; scheme 2 integration results in 21.5% reduction in OPEX.
Figure 2 Scheme no 2 ( indirect split) and initial Process conditions
the targets cannot be met or engineering
appropriate operating conditions are chosen
insights do not favour them. Therefore,
and the optimized using column targeting
these sequences are eliminated from the
tool for minimum energy consumption. The
further study. All columns are simulated
PFD and initial process conditions of
using BX packing with kettle reboilers and
scheme 1 and 2 are given in Figure 1 and
total condensers. For all the sequences,
Figure 2 respectively.
Figure 3 Composite curves a. scheme 1 ( direct split ) Chemical Engineering World
It is found that heat-integration not only saves on the utility consumption but capital cost as well. This is due to high heat transfer coefficients of process streams than hot oil. In terms of capital cost, heat integration results in 5% reduction in HEN design cost for both the
b. scheme 2 ( indirect split)
March 2017 â&#x20AC;˘ 49
CEW Features SMITH, R. 2005. Chemical process design and integration, John Wiley and Sons ltd. WEI-ZHONG, A. & XI-GANG, Y. 2009. A simulated annealing-based approach to the optimal synthesis of heat-integrated distillation sequences. Computers & Chemical Engineering, 33, 199-212.
Figure 2 Utility and Total cost of schemes per year
schemes. Though, this has little effect on the overall CAPEX as it is dominated by the column packing. The CAPEX of scheme 2 is less than the scheme 1 due to the less number of stages required in the column 1, lower energy consumption in C1, C2 and C3 (which affects the diameter of the columns) and the heat integration. Without integration, the scheme 2 has 0.52% lesser capital cost than scheme 1. Overall, scheme 2 has 2.7% and 3% less TAC than scheme 1 without and with integration respectively. Conclusion The choice of distillation sequence is crucial to obtain an energy efficient design. It is important to screen all the possible options before designing a system. To analyse the best sequence, total annualized cost has been used as the criteria for comparison in this paper. Using a case study, it is illustrated that there can be different sequences possible for obtaining the specified products. Upon selection of the feasible set, a detailed optimization and costing is used to analyse the sequence options. Heat integration can help designer in improving system’s efficiency and in some cases, can save on the capital cost of the system. Two schemes for a given case study are been compared and the best sequence is selected based on the lowest TAC. For the particular 50 • March 2017
case study, indirect scheme is found to be better than the direct scheme. It can therefore be concluded that techniques like heat integration and sequencing can be beneficial for reducing energy and capital cost even in small scale industries. References ERRICO, M., PIRELLAS, P., TORRESORTEGA, C. E., RONG, B.-G. & SEGOVIA-HERNANDEZ, J. G. 2014. A combined method for the design and optimization of intensified distillation systems. Chemical Engineering and Processing: Process Intensification, 85, 69-76. ERRICO, M. & RONG, B.-G. 2012. Modified simple column configurations for quaternary distillations. Computers & Chemical Engineering, 36, 160-173. JAIN, S., SMITH, R. & KIM, J.-K. 2012. Synthesis of heat-integrated distillation sequence systems. Author’s Details Journal of the Taiwan Institute Chemical Engineers, 43, 525-534.
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SHARMA, M. & PATIL, A., 11-12 Nov, 2014. Use of heat integration and sequencing in the design of energy efficient small scale distillation systems – Part I Technical Meet on “Industrial Waste Heat recovery” Federation of Indian Chambers of Commerce and Industry.
Manish Sharma Senior Process Engineer Synergy Process Systems Pune, India Avinash Patil Managing Partner Synergy Process Systems Pune, India Email: agp@synergypune.com Chemical Engineering World
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Marketing Initiatives
Innovative Vacuum Solutions in Pharmaceutical Industry: The Right Solution from Toshniwal
V
acuum pumps and systems are common place across a tremendous range of industries. Once the essential principles are understood, the possibilities for application become apparent. In order to properly select a vacuum system, the principles of basic vacuum technology should be understood. Once the application is clearly defined, a solution can be found by applying these methods. Since we understand and can relate to atmospheric pressure, it is chosen as a reference point. Vacuum is simply a pressure that exists below atmospheric pressure. To create a vacuum in a vessel, a vacuum producing device needs to remove mass from it. The more mass that is removed, the lower the pressure that exists inside the vessel. This is why it is important to understand what vacuum is and how to select the right type of equipment. It is very important to size vacuum piping correctly to minimize pressure loss. The greater the pressure loss, the larger the vacuum equipment needs to be.
of mainly non-condensable, then most types of pumps can be used. If the gas consists of non-condensable and condensable, then the choices will be limited. Therefore a right solution considering the load of condensable and ultimate vacuum should be struck. System selection To select the best type of system for a particular application, the following list needs to be considered. Once it is determined which criteria is the most important from the list, then the vacuum pump that best meets this can be selected. •• •• •• •• •• •• •• •• ••
The type, quantity of gas handled, and the operating pressure, normally defines what vacuum pump can be used. If the gas consists
•• •• •• ••
Operating cost Solvent recovery Effect on process Materials of construction Operating range Reliability Waste generation Pollution abatement Emission reduction Maintenance cost Ease of cleaning Serviceability Purchase price
Pharmaceutical and Chemical Industry The pharmaceutical and specialty chemical industries use vacuum for distillation and drying. Various types of dryers are used to purify products under vacuum. The chemicals
are precisely mixed and then heat is applied in the dryer to evaporate the excess chemicals. This is done under vacuum for purer end products; reduce the amount of heat energy required for drying, and also to recover any of the solvents evaporated off thereby not affecting thermally sensitive products. Pumps that are reliable and easy to service in the field are the most important for this industry. If an unreliable pump is tried and it fails in the middle of a drying cycle, then the product is not useable and profit is lost. A typical setup used for this application is: •• Combining mechanical roots blower along with oil lubricated vacuum pump. This kind of setup is used to minimize utility costs, drying cycle time and contamination. A properly designed process condenser between your vacuum process and vacuum producing system will yield significant advantages. A process vacuum condenser can significantly reduce the size of the vacuum producing system, recover for reuse valuable product carried from your process with noncondensable gases, reduce amount of wastes produced by the vacuum system, and lower the operating cost of your process. Matching a vacuum condenser with the vacuum producing equipment is the best way to meet the objectives of your process. Toshniwal manufactures both the process condenser and the vacuum producing equipment. This single-source responsibility provides you with a unitized system matched to your process.
Contact Details: Toshniwal Instruments (Madras) Pvt Ltd 267, Kilpauk Garden Road Chennai - 600010 Contact: +91 4426445626 / 8983 Email: sales@toshniwal.net Website: www.toshniwal.net Chemical Engineering World
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CEW Features
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Pick Heaters Inc.â&#x20AC;&#x2122;s Jet Cookers: Unique Concept of Direct Steam Injection Heating
S
peciality Alliances, Mumbai bring the most efficient Jet Cookers m a nu fa c t u r e d by P i ck H e a t e r s Inc., USA for the Indian Industry. These cookers, technically known as Direct Steam Injection [DSI] Systems, are manufactured in U.S. by the Pioneers & Patent Holders Pick Heater Inc. in both
Industrial & Sanitary models. In 1945, Pick Heaters developed & patented a unique concept of direct steam injection heating & is still the leader in this technology. Pick Industrial Direct Steam Injection System can be used to heat any water miscible liquid or aqueous slurr y
instantly on a continuous straight through basis. The Pick system injects steam into the liquid through hundreds of small orifices in the injection tube. Fine bubbles of steam are instantly absorbed by the liquid, resulting in 100% transfer of heat energy. A unique spring loaded piston prevents pressure equalization between steam & water pressure, thus e l i m i n a t i n g s t e a m h a m m e r. H e l i c a l flights in the chamber promote thorough mixing prior to discharge F u r t h e r, P i ck S a n i t a r y D i r e c t S t e a m Injection System can be used in vir tually any segment of food industr y that processes liquids or slurries, including those containing bite sized pieces. Pick sanitar y does away with the inherent process inefficiencies & maintenance headaches of traditional batch process cooking. Pick Sanitary DSI allows in line heating with precise temperature control & 100% energy efficiency. Pick Sanitary DSI systems are available with complete instrumentation as well as components to produce culinar y steam.
Contact Details: Speciality Alliances 87, Sunita, 15th Floor Cuffe Parade, Mumbai 400005 Contact - +91 022 22154135 Email - specialityalliances@gmail.com 52 â&#x20AC;˘ March 2017
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Products CEW Versatile Liquid Level Sensor AMETEK Drexelbrook has enhanced the communication capabilities of its Total Tank Level Measurement System to include dual 4-20 mA and Hart outputs in addition to the standard Modbus protocol for measuring total level, interface level and temperature.The rugged and versatile level measurement system is an accurate, costeffective alternative to flexible SS cable probes. It incorporates proven magnetostrictive sensing technology and features multi-variable functionality. The system is accurate to 0.01% of measured span, less than 1-mm absolute over the full measurement range. The system make it an ideal choice for oil and gas, chemical and petrochemical storage tank and inventory control applications. Its five temperature sensors are evenly distributed over the active length of the polymer or SS probe. The probe is available in a rigid SS-316 version and in flexible PVDF in lengths up to 50 feet, an industry exclusive.The system meets FM, FMc, ATEX and IECEX hazardous area approvals and requires minimal maintenance. A variety of floats and mounting accessories are available to fit virtually any application. The probes are offered with a choice of mounting configurations. AMETEK Drexelbrook offers a full range of process level measurement solutions, including RF Admittance/Capacitance, TDR/GWR, Radar, Ultrasonic, Magnetostrictive, Hydrostatic, Vibration, Conductive and Float devices.Drexelbrook level measurement instruments are used in a wide range of industries, including petroleum, chemical, petrochemical, water/wastewater, power, pharma, mining, aggregates among others. For details contact: AMETEK Drexelbrook 205 Keith Valley Rd, Horsham, PA 19044, U.S.A. Tel: +1 215-674-1234, Fax: 215-674-2731 E-mail: drexelbrook.info@ametek.com or Circle Readers’ Service Card 1
Water Meter The operation of the water flow meter is a simple user-friendly way to operate easily. The water flow meter is an impeller multi-jet type flow meter with measuring inserts made up of engineering plastics. The water meter has a provision for fixing of external digital pulse sensors suitable for remote and digital pulse transmissions for monitoring through BMS systems and batching purposes with PLC, etc. This flow meter is used to measure the water consumption in apartment/flats, IT park area, hospitals and malls. Features cold (50 oC) and hot water (130 oC); removable/interchangeable element; sealed register water-proof (IP 67); corrosionfree powder coated body; EEC pattern approval; unaffected by external magnetic fields; and pulser’s coated body fitted without breaking the seal for remote flow totalisation and flow-rate indication.
For details contact: Toshniwal Hyvac Pvt Ltd 267 Kilpauk Garden Road, Chennai 600 010 Tel: 044-26448558, 26448983 Fax: 91-044-26441820 E-mail: sales@toshniwal.net or Circle Readers’ Service Card 2
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CEW Products Universal Diaphragm Actuator Forbes Marshall universal diaphragm actuator Series UI, UIII and UV features a pneumatic actuator designed for applications that demand high actuating power. Its optional reinforced spring with compact air chamber delivers up to 14,000-lbf thrust force for extreme pressure control applications. These diaphragm actuators can be fitted with standard accessories like positioner, feed-back transmitter, limit switches and air-filter regulator. Optional hand wheel is provided for emergency operation. For details contact: Forbes Marshall Arca Pvt Ltd A-34/35, MIDC, H-Block, Pimpri Pune, Maharashtra 411 018 Tel: 020-27442020, 398581199 Fax: 91-020-27442040 E-mail: vsales@forbesmarshallarca.com or Circle Readers’ Service Card 3
Hydraulic Pallet Truck JAY hydraulic pallet truck is an economical way for one person to move heavy pallet loads without the use of a forklift/ stacker. The pallet truck includes two articulating steering wheels and four front load wheels. The reinforced formed steel forks provide twice the strength of standard single formed racks. Hydraulic pallet trucks are also available in roll lifting, weighing scale and stainless steel versions with load capacity of 2,500 and 5,000 kg. For details contact: Jay Equipment & Systems Pvt Ltd Plot No: 47, Survey No: 66/1 Sativali Road, Valiv Phata Village Valiv, Vasai (E), Dist: Palghar, Maharashtra 401 208 Tel: 0250-6586749, 6454749, 6060749 E-mail: sales@jayequipment.com or Circle Readers’ Service Card 4
Detectors Thermo Scientific optical detectors are available for UV/VIS absorbance, fluorescence and refractive index detection of a wide variety of analyses. Thermo Scientific charged aerosol detectors provide universal detection of any non-volatile analytic and many semi-volatile compounds, with or without chromophores. Detectors are available for both the Vanquish UHPLC system and the UltiMate 3000 platform. ThermoScientific Dionex UltiMate 3000 ECD-3000RS electrochemical detector offers easy direct measurement to femtogram levels in very limited sample volumes with minimal preparation. It readily eliminates matrix interferences to enhance selectivity. Users have a choice of both coulometric and amperometric sensors for extremely selective analysis using microbore to normal bore columns for both HPLC and UHPLC. This is the only electrochemical detector compatible with gradient chromatography.
For details contact: Thermo Fisher Scientific India Pvt Ltd 102, 104 Delphi C-Wing Hiranandani Business Park Powai, Mumbai 400 076 Tel: 022-67429494 Fax: 91-022-67429495 E-mail: sagar.chavan@thermofisher.com or Circle Readers’ Service Card 35
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Products CEW Combo Deduster + Metal Detector Combo deduster + metal detector consists of vertical bottom to top deduster integrated with digital metal detector. The deduster is provided with frequency and power control drive ensuring effective dedusting and deburring. The entire dedusting settings are controlled from the metal detector. The inlet can be rotated through 360o and hence the same can be used for right or left outlet of compression machine conveniently. The system is designed to ensure ease of cleaning and the entire deduster assembly can be dismantled and assembled within minutes without any tools. Area of application includes tablets. For details contact: Technofour Electronics Pvt Ltd Gat No: 3(PT), 5(PT), 243(PT), Kasurdi (Kheba) Khed Shivapur-Saswad Road, Post: Khed Shivapur, Tal: Bhor Dist: Pune, Maharashtra 412 205 Tel: 02113-305200, 305246 Fax: 91-02113-305250 E-mail: pcssales@tepl.co.in / teplinbox@gmail.com or Circle Readers’ Service Card 6
Multi-column Distillation Plant Indu Ionpure India Pvt Ltd multi-column distillation plant is based on FINN-AQUA design. It consist of specially designed columns which make optimum use of the principles of interstage heat exchange (multi-effect distillation method) to produce pure pyrogen-free sterile distilled water for injectables as per IP/BP specification. The vapour with high velocity and under pressure passes over a specially designed spiral baffle system which develops tremendous centrifugal force and thus eliminates any chance of pyrogens carryover in the vapours. By multi-effect distillation method significant energy is saved when compared to the conventional method. All contact parts are made out of AISI 316 quality SS and mirror polished. All pipes and tubes are essentially seamless. The unit is mounted on sturdy MS tubular stand and duly painted by epoxy paint. For details contact: Indu Ionpure 1513 Ghanshyam Enclave, Laljipada Police Station Link Road, Kandivli (W) Mumbai 400 097 Tel: 022-28680079 E-mail: sales@induionpure.com or Circle Readers’ Service Card 7
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CEW Products Triple Duty Valve Kirloskar Brothers Ltd (KBL) is the first valve manufacturing company in India to be ISO 9001/ISO 1001/ISO 50001/ OHSAH 18001 accredited/CE marked/FM approved and UL listed. It manufactures valves ranging from 25-mm to 5,000-mm in various design standards and material of constructions as per customer needs/specifications. KBL has been manufacturing and supplying range of valves for various types of applications in the chemical industry. The KBL valves applicable for the chemical sector are resilient seat gate valves, tamper-proof kinetic air valves, butterfly valves, forged steel gate valves, steam trap device, suction diffuser, etc. One of the other valves that KBL manufactures is the triple duty valve. It is a noise-free operating multi-purpose valve that performs all the required functions on the discharge side of the Hydronic System Pumps (HVAC). Apart from the chemical industry, the valves also have other industrial applications in pharma manufacturing plants, bottling plants, and chemicals and food and beverage industries. Besides industrial applications, the valves also witness a high demand in the building and construction sector and are widely installed in multi-storied buildings, malls, airports, etc.The single valve behaves as an isolating-cum-regulating-cum-non-return valve. The disc opening responds even at 25% of the rated pressure of the valve. The spring will assist in disc closure soon after the pressure drops down to prevent flow reversal and water hammering. The hand-wheel rotation assists in adjusting the flow discharge through the valve. In addition, its centre guided soft seal disc ensures zero leakage. The rising spindle design includes a position indicator (on request) for accurate disc positioning for throttling service. There is a provision for fitment of standard gauge taps at both the inlet and outlet side.The triple duty valve is made from cast-iron or ductile iron or cast steel with a stainless steel trim. Its flange drilling is customised to IS/BS/ASME/ANSI Standards in view of meeting the desired requirements (on request). The primary feature of this low pressure drop and balancing valve with by-pass function is its unique re-positional inlet body for angle mounting configuration. For details contact: Kirloskar Brothers Ltd Global Headquarters, Yamuna Survey No: 98/(3-7), Baner Pune, Maharashtra 411 045 Tel: 020-27214444 or Circle Readers’ Service Card 8
Fluid Bed Processing Tapasya Engg Works Pvt Ltd’s classic for all batch executed fluid bed processes for testing granulation, drying and coating processes. Ideal for minimum batch sizes of 50 g to 2,500 g. Processes in bottom and top spray methods. Flexible retrofitting if needed. The TAP-FBP-10 SaiPro is multi-functional fluid bed equipment designed for research and development of drying top spray agglomeration and bottom spray encapsulation process.The Lab Model fluid bed processor processes minimal quantity with maximum quality. This feature makes it an ideal machine for drying, granulation and encapsulation trials on a small scale. Feasibility studies can be extensively conducted on lab scale unit. This innovative small machine is easy to handle and extremely easy to clean. These detailing makes it perfect for use in pharma research and development laboratories. It is an unique all in one unit to suit drying, granulation and coating in single unit (standalone fluid bed dryer also available). This lab unit is optimised for scale up requirements of R&D like process parameters, geometrical impact and spray rate.Swivel bow with position locking allows convenient material handling.It has special attachment for drying small quantiites up to 50 g. For details contact: Tapasya Engg Works Pvt Ltd Plot A-212, Road No: 30, Wagle Indl Estate Thane, Maharashtra 400 604 Tel: 022-61579400, Fax: 91-022-25825243 E-mail: sales@tapasyaindia.net or Circle Readers’ Service Card 9
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Chemical Engineering World
Products CEW Electric Stackers Stacking and handling made easy with the Ezi electric stackers with side stabilizers from JAY for extra support. The only manufacturers of stackers with lifting height of up to 6.7 metres are ideal equipment for wide range of materials handling operation. Ezi Series electric stackers with side stabilizers can be widely adopted in any industrial/warehousing/logistics environment. This equipment feature stabilizers for giving extra load capacity and support for handling loads at height, can work in narrow aisles and gangways. The Ezi Series electric stacker with side stabilizers is essential for in-plant equipment used for intensive stacking and transporting in minimum cycle time. ES-16 SS Models are designed with stand-on platform, which has the unique feature of merging with the body thus having no projection outside the body when platform is closed. Ir can be used even in narrow aisles. For details contact: Jay Equipment & Systems Pvt Ltd Plot No: 47, Survey No: 66/1, Sativali Road, Valiv Phata Village Valiv, Vasai (E), Dist: Thane, Maharashtra 401 208 Tel: 0250-6586749, 6454749, 6060749 E-mail: sales@jayequipment.com or Circle Readers’ Service Card 10
Laser Scanner FARO offers a new entry price-performance standard for its entire FARO Focus laser scanner portfolio. The FARO FocusM 70 solution provides an ideal entry point for all professional users considering laser scanning in the construction BIM/CIM and public safety forensics markets. The FARO FocusM 70, coupled with FARO SCENE, is the first professional grade scanner solution to be offered does not compromise on the industrial grade performance included in the award winning FARO Focus Laser Scanner portfolio. Key features include an Ingress Protection (IP) Rating of 54 for use in high particulate and wet weather conditions, HDR imaging an acquisition speed of almost 500,000 points per second and extended temperature range. Additionally, users have unrestricted freedom of choice to leverage the software tools most beneficial to their own workflow as data captured by the FARO FocusM 70 can be used with various third party software packages.The FARO FocusM 70 is specifically designed for both indoor and outdoor applications that require scanning up to 70 meters and at an accuracy of +/-3 mm. For details contact: FARO Business Technologies India Pvt Ltd E-12, B-1 Extension, Mohan Co-op Indl Estate Mathura Road, New Delhi 110 044 Tel: 011-46465644, 46465664, 46465656 E-mail: amrita.gokhale@faro.com / india@faro.com or Circle Readers’ Service Card 11
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CEW Products Overload Protection for Drives mayr power transmission offers a new disengaging torque limiter on which all functional processes can be automated through the drive. It is easy to handle, permits long run-out times and re-engages again through slow backwards rotation. Housing also makes the clutch resistant to dust or spray water. In case of rough operating and ambient conditions such as dust, dirt, spray water, heat or cold, the drive lines, particularly in heavy mechanical engineering, are frequently encapsulated and therefore hard to access. But these machines in particular require reliable overload protection. Therefore, mayr power transmission has now developed with the EAS-reverse a robust, disengaging torque limiter which can withstand both high loads and automatically re-engages. On the EAS-reverse torque limiter, all functional processes can be automated via the drive alone. In case of overload, if the torque exceeds the value set on the clutch, a patented disengagement mechanism separates the input and output almost residual torque-free with high switch-off and repetitive accuracy. The kinetic energy from the rotating masses stored in the system can slow down freely. After responding, the clutch can withstand long drive run-out times. Through slow reverse rotation, the EAS-reverse torque limiter re-engages automatically without the use of pneumatics or hydraulics.The new EAS-reverse torque limiter transmits the torque with exceptionally low wear (<0.05°) and features hardened functional parts. It is easy to handle and represents adaptable, branch-optimised solutions with its numerous versions and additional characteristics. The EAS-reverse can also easily be integrated into a solid housing with standard IEC or NEMA dimensions. The new torque limiter already covers the first three construction sizes with a torque range from 80-2,500 Nm, and this range is now to be extended with a fourth construction size up to 5,000 Nm and a bore dia of up to 100 mm. For details contact: National Engg Co (NENCO) J-225, MIDC Bhosari, Pune, Maharashtra 411 026 Tel: 020-27474529, Fax: 91-020-27470229 E-mail: nenco@nenco.org or Circle Readers’ Service Card 12
Dual Circuit Control & Monitoring Unit Thermon Group Holdings, Inc offers TraceNet TCM2 dual circuit control and monitoring unit, the latest addition to the TraceNet family of remotely-operated heating control and monitoring systems. Like the 18-circuit TraceNet TCM18 control and monitoring unit, the TCM2 unit makes it possible to remotely maintain heat trace circuits that play a critical role in industrial processing facilities. To help operators better monitor and control temperatures of pipes, tanks and heated instruments, Thermon designed the TCM2 to reliably operate in harsh environmental conditions around-the-clock to ensure that pipe temperatures are monitored and efficiently controlled. This allows the TCM2 to be extremely versatile. The TraceNet TCM2 can be operated locally, by remote control or networked via wireless or hard-wire to a computer or distributed control system (DCS) in the facility’s control room. The system continuously monitors every set point, including temperature, current and ground-leakage current. It then reports locally and transmits key data remotely to the control room. The operator can review each circuit for temperature, ground current, heater current, the frequency at which it is performing and alarm status. As with every TraceNet controller, the TCM2 relies on resistance temperature detector (RTD) temperature sensors to monitor temperature on the designated pipe or equipment. The system then cycles the heat required to maintain the target temperature. If required, the operator can also adjust every circuit set point on the unit or via remote locations.
For details contact: Thermon San Marcos, Texas, U.S.A. Tel: +1 512-396-5801 Ext 2239 E-mail: lance.bielke@thermon.com 11 or Circle Readers’ Service Card 13
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Chemical Engineering World
Products CEW V-Cone Flow Meter McCrometer’s V-cone flow meter is an advanced differential pressure instrument, which is ideal for use with liquid, steam or gas media in rugged conditions where accuracy, low maintenance and cost are important. With its DP bV-Cone is especially useful in tight-fit and retrofit installations. Features flow meter accuracy to +/-0.5%; flow meter repeatability to +/-0.1%; wide flow range; pre-conditions flow; requires minimal straight pipe; no recalibration; low head loss and maintenance. For details contact: Toshniwal Hyvac Pvt Ltd 267 Kilpauk Garden Road, Chennai 600 010 Tel: 044-26448558, 26448983 Fax: 91-044-26441820 E-mail: sales@toshniwal.net or Circle Readers’ Service Card 14
Automatic Blow Moulding Machines Kamal Carboys Pvt Ltd an ISO 9001:2008 Company offers designs for manufacturing various types of objects. Their automatic blow moulding machines are perfectly suitable toproduce carboys, jerry cans, drums and various other types of containers, which are suitable for packing in chemical industries. Kamal offers the full range of classic and modern carboys and round drums. Kamal range includes HDPE in 1, 5, 10, 20, 25, 30, 40, 50, 60, 80, 100 and 125 litre capacities. These are products of various weights and colours to suit customers’ taste or requirements. If required Kamal can also develop special container to suit your exclusive needs. Kamal products have wide range of applications. They can safely be used for packing and storing of emulsions, acids, pigments, textile auxiliaries, metal treatment or water treatment chemicals and in pharma industries. Not only this, even food stuff can be packed and stored in their containers.Kamal also have in-house facility of screen printing on the containers. The company’s logo, name or any other details can be nearly printed at a small additional surcharge. Kamal has many moulds to satisfy their clients. They also manufacture carboys in a special colour if anyone requires it in a large quantity. Kamal have in-house testing facilities at their plant as per guidelines laid down by BIS 6312 and Indian Institute of Packaging, Mumbai, such as hydraulic pressure test; drop test; stack load test; and pin hole test. Many more tests will be done at their plant to check the carboys before delivering like printing test, stability test, handle strength test, wall thickness profile, etc. For details contact: Kamal Carboys Pvt Ltd 204 Shanti Apartments No: 2, Military Road Marol, Andheri (E), Mumbai 400 059 Tel: 022-29252920, Fax: 91-022-28369404, 29202336 E-mail: kamalcarboys@yahoo.in / contact@kamalcontainers.com or Circle Readers’ Service Card 15
Chemical Engineering World
or Circle Readers’ Service Card 11
March 2017 • 59
CEW Products Compact Coriolis Mass Flow Meters & Controllers For Liquids And Gases Coriolis mass flow meters are highly appreciated for their accuracy and independence of fluid properties. The direct coriolis mass flow measuring principle is generally used for higher flow rates. Moreover, mini CORL-FLOWTM instruments have an integrated PID-controller and a batch counter to control the fluid flow. Features direct flow measurement, independent of fluid properties; fast response time; high accuracy, excellent repeatability; additional density and temperature output; compact design (same footprint as CORI-FLOW M50 Series); and excellent price/performance ratio. Visit . www.bronkhorst.com
Direct Drive Pumps Over three decades of expertise in vacuum technology, Toshniwal Instruments (Madras) Pvt Ltd offer customized solutions ranging from individual products to a complete system. Toshniwal‘s direct drive high vacuum pumps, the 72-D Series double stage model is with ultimate vacuum. These vacuum pumps are compact, since they are directly mounted on motor flange. These pumps have pumping speeds and high water vapour tolerance. The oil consumption is extremely low and air cooled. 72-D Series highly reliable double stage 120-1,000 LPM portable pump with advanced lubricating system offers improvement in the areas of quieter operation and easy maintenance For details contact: Toshniwal Instruments (Madras) Pvt Ltd 267 Kilpauk Garden Road Chennai 600 010 Tel: 044-26445626, 26448983 E-mail: sales@toshniwal.net
For details contact: Toshniwal Hyvac Pvt Ltd 267 Kilpauk Garden Road Chennai 600 010 Tel: 044-2644 8558, 26448983 E-mail: sales@toshniwal.net or Circle Readers’ Service Card 16
or Circle Readers’ Service Card 17
Precision Fans & Custom Cooling Systems AMETEK Rotron offers SemiCool custom cooling sub-systems for high-reliability cooling of semiconductor production processes. Including the Rotron MAXIAX vaneaxial fans originally designed for critical military and aerospace applications, the SemiCool systems offer precise temperature control in a compact package. SemiCool systems include high reliability fans, optimized heat exchangers and custom ductwork. Alternatively, customers can integrate the MAXIAX fans into their own cooling subsystems. Optimized fans with diameters ranging from 152.4 mm (6”) to 203.2 mm (8”) provide airflows of 425 l/s (900 CFM) at 254 mm WG (10 IWG), with efficiencies approaching 60 per cent. This is a significant departure from standard 0.9 m (3’) tall industrial blowers commonly used in semiconductor production facilities. Designed to operate with 400 Hz industrial power converters, the fans feature rapid response, infinite speed control and minimal space requirements. SemiCool systems can meet the cooling needs of all heat-intensive process steps in semiconductor production. Systems are compliant with semiconductor industry traceability and configuration control requirements. They can be certified to TUV requirements and are produced in an AS9100, ISO9001 manufacturing environment. For details contact: AMETEK Instruments India Pvt Ltd 148, EPIP Phase, 1st Floor, Prestige Featherlite Tech Park Whitefield, Bengaluru, Karnataka 560 066 Tel: 080-67823259 Fax: 91-080-67823232 E-mail: ananth.h@ametek.com or Circle Readers’ Service Card 18
60 • March 2017
Chemical Engineering World
Products CEW Electro Magnetic Meter The instrument works on the principle of Faraday’s law of Electromagnetic Induction. A magnetic field is generated by the instrument in the flow tube. The fluid flowing through this magnetic field generates a voltage that is proportional to the flow velocity. This voltage is measured by the electronics and a corresponding output provided. Universal power supply accepts any voltage from 90 to 265 V AC. Bi-directional flow measurement measures the flow in both forward and reverse directions.Built-in totaliser provides a separate totalized volume value for flow in each direction.Remote monitoring is easy monitoring of the process even in hard to reach places.Conforms to International Standards - designed to meet global requirements and available with international approvals. with international approvals. For details contact: Toshniwal Hyvac Pvt Ltd 267 Kilpauk Garden Road, Chennai 600 010 Tel: 044-26448558, 26448983 Fax: 91-044-26441820 E-mail: sales@toshniwal.net or Circle Readers’ Service Card 19
Frequency Inverters Frequency inverters from NORD Drivesystems can react flexibly in case of disrupted communication with a central control system. The on-board, pre-programmed PLC can take control, initiate a defined state for halting operations or keep the application running. In process plants this can help avoid costs by preventing spoiled batches. In manufacturing facilities, material flow can be maintained. As NORD intelligent drives feature various interfaces and are able to evaluate sensor and actuator data, optimal integration in the application is ensured. Autonomous control capability obviously has other uses beyond fallback scenarios. In some instances, users may wish to deliberately switch the smart drive over to local control. For set-up, testing or maintenance, the distributed frequency inverter can additionally be equipped with switches for manual drive direction and speed control. The integrated PLC functions are programmed using IEC 61131-3 Structured Text or Instruction List text-based languages. For straightforward, user-friendly application development, NORD CON software is provided without any charge or license fees. For details contact: NORD Drivesystems Pvt Ltd 282/2, 283/2, Village Mann Tal: Mulshi, Adj Hinjewadi MIDC II, Pune, Maharashtra 411 057 E-mail: marketing.in@nord.com / Muthusekkar@nord.com or Circle Readers’ Service Card 20
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March 2017 • 61
CEW Products Liquid Ring Vacuum Pumps Toshniwal provides solution to your vacuum needs in manufacturing of liquid ring vacuum pumps that offer optimum performance and reliability.They offer minimal water consumption and an innovative impeller design that assure extremely quite operation and extending its life even under harsh condition, the most advanced manufacturing process, with the objective to reduce manufacturing time and shor tening delivery time. Hydrotwin - PLC-controlled roots + LRVP package for high vacuum application with total liquid recirculation capacity to 3,900-m 3/hr, max vacuum 2-mbarHydro sys - Centralized package vacuum units with total or partial water re-circulation. capacity to 3,500-m 3/hr, max vacuum 33-mbar. It finds application in distillation, drying/material transfer/power and steel/food processing/paper/general vacuum/textile, etc. For details contact: Toshniwal Instruments (Madras) Pvt Ltd 267 Kilpauk Garden Road, Chennai 600 010 Tel: 044-26448983, 26448558 E-mail: sales@toshniwal.net or Circle Readers’ Service Card 21
New Platform of HMI Workstations Eaton has expanded its range of MTL GECMA HMI workstations, introducing two new products – a Thin Client or Circle Readers’ Service Card 10 (TC) and Personal Computer (PC) version. The company can now offer a complete range of workstations based on a common platform design. As such, plant managers can reduce operation costs, optimise productivity and increase plant safety, with the additional benefits of reducing space in the cabinet and future-proofing the plant. The TC and PC versions complement the existing MTL GECMA Remote Terminal (RT) which has a unique modular design. These next generation HMIs feature state-of-the-art technology to offer unparalleled levels of safety and are approved to global hazardous certification for Zone 1 environments. As a result they offer safe handling on site and guarantee high reliability in hazardous EX zone areas in chemical, pharmaceutical, refinery plus the oil and gas industries worldwide.The TC version is designed for virtualisation applications, eg. batch control. The workstation works with a client server in the safe room across a LAN. This saves space in the cabinet as users do not need a dedicated PC and the user can control up to 255 HMIs from a single server.The PC version is stand-alone working across the LAN. It has state-of-the-art system hardware, which meets the needs of the most complex applications with high computing power demand, eg, packing. The workstation has a watch dog function which automatically monitors the operating system and if there is no input from the system it automatically re-starts itself. This avoids hard re-starts, which saves time associated with turning the system On and Off, and minimises any stress on the system for increased reliability. RT is a point-to-point device, with one workstation assigned to one PC in the safe area. It features a keyboard, mouse and video, and is perfect for controlling tablet coating or dry granulation machines. The RT terminal’s modularity means upgrades to existing installations are quick and easy, which can save time, and minimise costly maintenance and downtime. Traditionally, the whole unit would have to be dismantled off-site, but with MTL GECMA, individual parts can be replaced simply on-site, increasing plant availability. For details contact: Eaton Butterfield, Great Marlings Luton, Bedfordshire LU2 8DL, U.K. Tel: +44 (0)1582 723633 E-mail: mtlenquiry@eaton.com or Circle Readers’ Service Card 22
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Chemical Engineering World
Tooltec
Water India 2017 Dates: 10-12 May 2017 Venue: Pragati Maidan, New Delhi Event: This event showcases products, services and solutions available in the water industry worldwide. The event will provide comprehensive insight into the water industryâ&#x20AC;&#x201C;best practices, latest technologies, alternative solutions, emerging opportunity and business prospective.
Dates: 4-7 April 2017 Venue: Singapore EXPO Convention and Exhibition Centre Event: Tooltec will showcase wide variety of drilling and die casting based equipment and ser vices associated with this field. Thus an event like this will gather all the eminent and distinguished exhibitors from this field and in tur n they will showcase products and ser vices like angle measuring
For details contact: Organiser: Exhibitions India Group Email: mumbai@eigroup.in Website: www.waterindia.com Contact No.: +91 9821062872 Machine Tools Engg & Technology Expo Dates: 12-14 May 2017 Venue: Brilliant Convention Centre, Indore Details: METEX caters to industrial products and equipment, heavy and light machines, engineering systems and services, industrial equipment and accessories, industrial technologies, software and hardware, and other parts and components. It is an exciting event that witnesses the best buyer and seller relationship, and brings out the best of products and services. For details contact: Organiser: Indore Infoline Pvt Ltd Email: info@indoreinfoline.in Website: www.ind-expo.com Contact No.: +91-731-2703000 Plastasia 2017 Dates: 08-11 July 2017 Venue: Pragati Maidan, New Delhi Det ails: This event has built a reputation as the ideal place to discover the latest innovations in plastics, live demonstration/s, share ideas and most impor tantly secure orders. Today, Plastics has become omnipresent and an integral par t of day-to-day activities. For details contact: Organiser: Triune Exhibitors Pvt Ltd Email: info@plastasia.in Website: http://www.plastasia.in/ Contact No.: 080 - 43307474
devices, balancing systems, bending machines, blowers, dr yers, boring machines, drilling and taping machines associated with this sector. Beside this the event will cordially invite all the eminent and distinguished exper ts from this field For details contact: Organiser: Singapore Exhibition Services Pte Ltd Contact: Tel: +(65)-62336638,Fax: +(65)-62336633 China (Shanghai) International Chemical Technology & Equipment Fair Dates: 23-25 August 2017 Venue: Shanghai New International Expo Centre (SNIEC) Event: The event will showcase wide variety of chemical technology and equipment associated with this field. Thus event like this will organize wide variety of workshops, seminar presentation and open forum questionnaires with the help of it the exhibitors will showcase products and services like pumps, compressors, thermal process, instrumentation, control, automation techniques, chemical industry apparatus and also regarding plants associated with this field. In addition to this the event will cordially invite all the eminent and distinguished exper ts associated with this field. For details contact: Organiser: Guangzhou Zhenwei International Exhibition Co Ltd Contact: Tel: + 86 (0)20 83953253 China Adhesive Dates: 23-25 August 2017
India Machine Tools Show
Venue: Shanghai World Expo Exhibition And Convention Center
Dates: 28-31 July 2017 Venue: Pragati Maidan, New Delhi Details: IMTOS a biennial event showcases path breaking ideas and innovation in machine tools, material handling and automotive technology. The show witnesses participation from over 500 companies every year..
Event: China Adhesive is not only an event for adhesives industry but for all these related industry like package, construction materials, wood, windows, textile, aerospace, electricity, coating and decoration. The exhibition is expected to attract more than 300 exhibitors to display the latest products and technologies. Over 15,000 professional visitors from more than 20 countries and regions will attend the exhibition.
For details contact: Organiser: K & D Communications Ltd Email: kandd@engimach.com Website: http://www.kdclglobal.com/ Contact No.: 079-26460624 Chemical Engineering World
For details contact: Organiser: CCPIT Sub-Council of Chemical Industry Contact: Tel: + 86-10-64288748 March 2017 â&#x20AC;˘ 63
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 M Chemicals proposes an expansion from 10-TPM to 35-TPM of its synthetic organic chemicals manufacturing unit in GIDC Sachin, district: Surat, Gujarat. The estimated cost of the expansion is ` 12-million. The current status of the project could not be ascertained. According to MoEF sources, EIA report has been prepared by Aqua-Air Environmental Engineers. The existing plant manufactures 10-TPM 6-Nitro, 1-Diazo, 2-Napthol, 4-Sulphonic Acid. The expansion entails addition of new products namely, 25-TPM G-Salt, R-Salt, Amido G-Acid, Aniline 2,4 DSA, Aniline 2,5 DSA, Para Nitro Chloro Benzoyl Sulphonic Acid, Sulfo Tobias Acid, Para Cresidine Ortho Sulphonic Acid, Schaffer’s Acid, Broenner’s Acid. Total plot area is approximately 1,650-sq m, out of which, 300-m 2 has been used for green belt development. 5-KLD effluent will be treated in-house ETP and 10-KLD effluent will be sent to common MEE of MEPL for evaporation.
Modvadar, district: Kutch, Gujarat. The current status of the project could not be ascertained. According to MoEF sources, existing products are 3-million sq m per month plywood, flush door, block board and veneer. The manufactured resin will be used for in-house consumption at the wood products plant. The project will come up on 11,603.62-sq m of existing land. The greenbelt area is 600-sq m. A base platform will be constructed for the resin plant; remaining will be MS structure.
Mamta Texdyes (Samba) proposes a synthetic organic chemicals manufacturing unit in GIDC Sarigam, district: Valsad, Gujarat. The project is spread over 2,250-sq m. The estimated cost of the project is ` 32-million. The current status of the project could not be ascertained. According to SEIAA sources, Eco Chem Sales Services is the environmental consultant. The proposed products are 200-TPM sulphur black grains, 300-TPM sulphur black liquid and the by-products are 250.1-TPM sodium thio sulphate crystal and 47.12-TPM sodium chloride salt. 700-sq m area has been proposed for green belt development. Industrial waste water will be treated in primary and tertiary treatment plant and treated waste water will be discharged into CETP Sarigam.
Eternis Fine Chemicals proposes an expansion of synthetic organic chemicals manufacturing unit from 42,200-TPA to 60,000-TPA in MIDC Kurkumbh, district: Pune, Maharashtra. The current status of the project could not be ascer tained. According to MoEF sources, total land area is 100,400-sq m and built-up area is 42,710-sq m. 33 per cent will be developed as green belt area. The project will entail: 1) capacity expansion of existing products and by-products; 2) addition of similar products and by-products; 3) introduction of new eco-friendly biomass boiler as replacement to furnace oil. Project involves manufacturing of fragrance from organic raw materials by chemical process like hydrogenation, esterification, Diels-Alder reaction, cyclisation, dehydrogenation, aldol condensation, etc, followed by distillation to match precise quality standards. By-products capacity will be augmented from 11,400-TPA to 20,000-TPA. The estimated cost of the project is ` 1,050-million. The power requirement 12,000KVA will be available through Government Electricity Board.
Resipol Adhesives proposes an expansion of synthetic organic chemicals manufacturing unit in village: Rajpur, district: Mehsana, Gujarat. The estimated cost of the expansion is ` 40-million. The current status of the project could not be ascertained. According to SEAC sources, the manufacturing of existing products, 2.0TPM benzyl alcohol, 1.1-TPM benzyl benzoate, 3.0-TPM benzoic acetate, 1.4-TPM sodium benzoate, 1.8-TPM sodium acetate will be discontinued and 300-TPM polyester resins (different grades) and alkyd resins (different grades), 90-TPM melamine formaldehyde resin and 85-TPM urea formaldehyde resin will be manufactured as new products. The plot area is approximately 6,033.00-sq m. Unit has proposed 2,000-sq m area for green belt development. Industrial effluent of 0.42-KLD after primary treatment will be evaporated in kettle type evaporator. Two DG sets each of 65-KVA will be provided. It was decided to recommend the project to SEIAA, Gujarat for grant of environmental clearance. Royal Wood proposes a 90-TPM phenol formaldehyde resin, urea formaldehyde resin, melamine urea formaldehyde resin and melamine formaldehyde resin manufacturing unit in village:
Panoli Intermediates (India) proposes an expansion of its specialty chemicals manufacturing unit and a new 10-MW coal-based captive power project in Unit-III, GIDC Nandesari, district: Vadodara, Gujarat. The estimated cost of the project is ` 100-million. The current status of the project could not be ascer tained. According to MoEF sources, the total plot area is 15,480-sq m. The capacity of isomers and DNCB such as 2:4 DCNB, 2:6 DCNB, 2:5 DCNB is to be augmented from 200-TPM to 2,200-TPM, or tho anisidine/para anisidine from 100-TPM to 1,100-TPM, or tho nitro aniline/para nitro aniline from 300-TPM to 2,300-TPM, isomers of DCA from 80-TPM to 1,080-TPM, isomers and DCNB such as 2:3 DCNB, 2:5 DCNB. isomers of DCNB such as 2:3 DCNB, 2:5 DCNB, 3:4 DCNB from 200-TPM to 2,200-TPM, H-acid from 50-TPM to 500-TPM and addition of a new product namely, 1,500-TPM derivatives of nitro phenol and a new 10-MW coal-based captive power project. 10-MW power requirement is to be met from MGVCL and 10-MW from the captive power project. The effluent will be treated in proposed effluent treatment plant.
64 • March 2017
Chemical Engineering World
Book Shelf CEW Principles and Modern Transfer Operations
Applications
of
Mass
Author : Jaime Benitez Price : USD 105.63 Pages : 648 (Hardcover) Publisher : Wiley-Interscience About the Book : A problem-solving approach that helps students master new material and put their knowledge into practice. The second edition of the acclaimed Principles and Modern Applications of Mass Transfer Operations continues to provide a thorough, accessible text that gives students the support and the tools they need to quickly move from theory to application. This latest edition has been thoroughly revised and updated with new discussions of such developing topics as membrane separations, ion exchange, multistage batch distillation, and chromatography and other adsorptive processes. Moreover, the second edition now covers mass transfer phenomena in biological systems, making the text appropriate for students in biochemical engineering as well as chemical engineering. Complementing the authorâ&#x20AC;&#x2122;s clear discussions are several features that help students quickly master new material and put their knowledge into practice, including: Twenty-five to thirty problems at the end of each chapter that enable students to use their newfound knowledge to solve problems, examples and problems that help students become proficient working with Mathcad Figures and diagrams that illustrate and clarify complex concepts and processes.
Diffusion: Mass Transfer in Fluid Systems Author : E L Cussler Price : USD 88.99 Pages : 647 (Hardcover) Publisher : Cambridge University Press About the Book :This overview of diffusion and separation processes brings unsurpassed, engaging clarity to this complex topic. Diffusion is a key part of the undergraduate chemical engineering curriculum and at the core of understanding chemical purification and reaction engineering. This spontaneous mixing process is also central to our daily lives, with importance in phenomena as diverse as the dispersal of pollutants to digestion in the small intestine. For students, diffusion goes from the basics of mass transfer and diffusion itself, with strong support through worked examples and a range of student questions.
Mass Transfer: Numerical Analysis with Measurements Authors : Price : Pages : Publisher :
Preston Runner USD 109.95 256 (Hardcover) Clanrye International
About the Book : In this book, experts provide recent developments in scientific findings and technologies, and introduce new theoretical models concerning mass transfer for sustainable energy and environment. The expertise of mass transfer processes has been extended and applied to different realm of science and engineering, including industrial applications in recent years.
Authors : James Welty, G L Rorrer, D G Foster Price : USD 216.51 Pages : 768 (Hardcover) Publisher : Wiley
Since mass transfer is a primeval phenomenon, it plays a vital role in the scientific researches and fields of mechanical, energy, environmental, materials, bio and chemical engineering. The chapters have been grouped under a section advances in numerical analysis and measurement. The topics cover the developments in broad research areas; hence, the book will be informative not only to research engineers, but also to university professors and students.
About the Book :Fundamentals of Momentum, Heat and Mass Transfer, Revised, 6th Edition provides a unified treatment of momentum transfer (fluid mechanics), heat transfer and mass transfer. The new edition has been updated to include more modern examples, problems, and illustrations with real world applications. The treatment of the three areas of transport phenomena is done sequentially. The subjects of momentum, heat, and mass transfer are introduced, in that order, and appropriate analysis tools are developed.
Bridging the gap between research and practical application, this book is written for engineering professionals in the biofuels industry, as well as academic researchers working in bioenergy, bioprocessing technology and chemical engineering.
The Future of the Chemical Industry by 2050
Chemical Engineering World
March 2017 â&#x20AC;˘ 65
CEW Ad Index Sr. No.
Client’s Name
Page No
Sr. No.
Inside Cover I
11
Jay Water Management Pvt Ltd
Client’s Name
Page No
1
Atomic Vacuum Company (Exports)
15
2
Avcon Controls Pvt Ltd
31
12
Kevin Enterprise
3
Bry-Air (Asia) Pvt Ltd
31
13
Paharpur Cooling Towers
35
4
Busch Vacuum India Pvt Ltd
19
14
Sahajanand Valves Pvt Ltd
33
5
De Dietrich Process System India Pvt Ltd
11
15
Sandvik Asia Pvt Ltd
23
6
Ekato India Pvt Ltd
17
16
Suraj Ltd
29
7
GRPC
21
17
Uni Klinger Ltd
8
Hi-tech Applicator
3
18
Vac Enterprises India
9
HRS Process Systems Ltd
5
19
Chemtech Gujarat 2018
10
ImageGrafix Engineering Services Pvt Ltd
55,57,59,61
20
Chemtech Hyderabad 2017
7
9 29 Inside Cover II Back Cover
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
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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
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I Hemant K Shetty, hereby declare that the particulars given above are true to the best of my knowledge and belief. Date: 24 th February 2017 66 • March 2017
Signature of Publisher Chemical Engineering World
INTERVIEW CEW
“Heavy Engineering Industry to Witness Opportunities in Nuclear Power, D e f e n c e and Process Sector” Customers are becoming more demanding and also looking for long term partnerships, based on trust and transparency. The organizations need to be agile in responding in time, to customer queries. Customers nowadays expects complete transparency from suppliers and are interested in long term relationship which will help both parties in the long run says S N Roy, Member of Board & Whole-time Director, L&T (Power, Heavy Engineering & Defence) in an exclusive interview with Chemical Engineering World.
What are the factors responsible which has resulted in significant underutilization of capacity? Heavy Engineering is the workshop to all industry. It’s where the machinery and equipment that serves a wide range of sectors get made. You name it –power, defence, oil and gas, refinery, nuclear, chemical and petro-chemicals, machine tools, consumer durables, fertilizers, automobiles, textiles, steel, cement, paper, construction, mining – heavy engineering keeps them all humming. The current share of national manufacturing is 16 per cent of GDP, which Government Chemical Engineering World
plans to increase to 25 per cent by 2022, through its ‘Make in India’ program. Despite its almost ubiquitous application, Heavy Engineering around the world has faced many headwinds recently. It has been buffeted by slowdowns, postponement, and / or outright cancelation of major projects. This hit is broadly due to domino effect of depressed oil prices, the nuclear incident in Fukushima, Japan, slow moving defence procurement procedures in India, EU depression and the crash of steel prices etc. When economies are ailing,
Heavy Engineering runs a temperature. It requires sustaining power, deep pockets and you need to build large capacities that may sometimes lie dormant. Clearly, it’s not a business for the faint of heart! Having said that, I think the worst is behind us, and the industry is readying itself to move forward with positive sentiments. India’s Machinery and Capital Goods Industry is composed of a mix of government owned and private companies as well as the giant capital goods manufacturing MNCs. How has this affected? March 2017 • 67
CEW INTERVIEW fear that data confidentiality of data may be breached.
Overall India’s indigenous equipment manufacturing sector? Equipment manufacturing organisations which are a part of large EPC conglomerates vis-à-vis standalone equipment manufacturers?
•
Sometimes the manufacturer might have to play by the EPC’s rules even if it means loss of clientele, business, time or profits.
I am of the opinion that once the economy gets going, there will be room for all - manufacturers who are part of large EPC conglomerates as well as standalone equipment manufacturers. Each has its pros and cons.
•
As the scale of operations of the EPC is massive, usually by default it is ensured that the EPC is given the priority at times in the conflict of interests
Order Management: Manufacturers and their parent EPCs can mutually benefit from each other where EPC can get orders which are given to the in-house manufacturing unit to supply the equipment Economies of scale: EPC Companies can utilize the benefits of economies of scale to procure raw materials at a cheaper scale, hence decreasing costs and being more competitive EPCs can provide easy and economical access to warehouses / storage facilities, engineering capabilities and transportation / logistics capabilities, thereby providing a one stop solution, for the manufacturer This model provides ease in project management, contract management and related complexities Optimised Financial Management: The manufacturer along with EPC, has an advantage of strong financial management by optimising working capital expenses, having common cost heads, thus creating a win-win situation for both EPC and manufacturer and increasing the bottom line. There is a bit of downside too: •
Other EPC companies may treat the Manufacturer-EPC with trepidation. The manufacturer might not be considered for certain projects for
68 • March 2017
T h e evo l v i n g m a r ke t h a s p a ve d w a ys f o r c h a n g i n g d y n a m i c s o f c u s t o m e r ’s b e h a v i o u r, leading t o c h a n g e i n m a r ke t d e m a n d a n d s i g n i f i c a n t i n c re a s e i n a d v a n c e d t e c h n o l o g i e s. I n yo u r v i ew h ow f a s t i s t h e I n d i a n m a r ke t evo l v i n g a n d re s p o n d i n g t o t h e m u c h needed demand of advanced t e c h n o l o g i e s i n n e a r f o re s e e a b l e f u t u re - b o t h a s a c o n s u m e r a n d a s a m a n u f a c t u re r ? How competitive are Indian manufacturers of heavy machinery and equipment compared to their foreign counterparts? What are the opportunities for domestic manufacturer in evolving Indian market as well in matured international markets? What are the challenges for domestic manufacturer in evolving Indian market as well in matured international markets? Customers are becoming more demanding and also looking for long term partnerships, based on trust and transparency. I feel organizations need to be agile in responding in time, to customer queries. Customers nowadays expects complete transparency from suppliers and are interested in long term relationship which will help both parties in the long run. These days a complete value proposition makes a greater impact in comparison to the price, which is no more, the sole differentiating factor. Customer demands are ever increasing and we need to be open and flexible in
dealing with the changing requirements. Most clients are willing to collaborate in drawing up a common, mutuallyacceptable solution that serves the interests of all parties. And to sustain long term relationship between both the parties, a structured and transparent claim management system is preferred to take care of interests of both the parties. As I see it, the Heavy Engineering industry will witness a number of opportunities in the areas of Nuclear Power, Defence and Process Industry. Let me list out the opportunities: Nuclear Power: With a focus on generating clean energy, the Government has plans in place to construct 12 indigenous Nuclear Reactors and 16 Foreign technology Nuclear Reactors in India. This opens up great potential for Heavy Engineering. Defence Sector: India is seeing a spurt in investments and indigenisation initiatives in the Defence Industry. A large number of projects and capital acquisition by the Indian Armed Forces are on anvil. This includes acquisition of six diesel fired submarines, an aircraft carrier, a programme to refit some aged submarines, a new class of warship, landing platform dock – a platform for helicopters and to carry battle tank and army, shallow water antisubmarine crafts, artillery programmes (Tracked SP Gun, Ultralight and Towed Gun), futuristic infantry combat vehicle (FICV) and a number of land-based platforms etc. I am sure that the Heavy Engineering industry is keenly waiting for all this to move from planning to procurement stage. Process Plant Sectors (Power, Petrochemicals and Fertilisers): A combination of a recovery in crude prices and implementation of stricter emission norms (i.e. Euro 5/6 internationally and BS VI in India) is Chemical Engineering World
INTERVIEW CEW resulting in newer, large scale plants coming up worldwide. There are good opportunities in Asian & African markets (as the economies develop), with new refinery, petrochemical and power plants coming up. Many plants in the fertilizer and refinery sector are ageing which translates into excellent potential for revamp and upgrade. All of these factors will result in great potential for heavy equipment manufacturers in the years ahead. Challenges: No opportunity is without its own set of challenges. Here are some of the challenges I envisage the Heavy Engineering industry in India will need to counter. •
Lack of indigenous material sources
major
•
Higher interest cost and inflation
•
Poor transportation infrastructure in India
•
Forex volatility
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Excess capacity in the global market coupled with poor investment appetite
•
Dearth of young talent who prefers working in the service industry instead of manufacturing.
•
Cartelizing by integrated players
and
raw
power
Availabilit y of skilled workforce is one of the key challenges that are looming over heav y engineering sector. Even on the global scale, India ranks 45 in terms of availabilit y
of scientists and engineers and 130 in terms of qualit y of scientific research institutions. How does it affect the heav y industries sector? As an organization, how do you address the issue of training & retaining the human resources for the future and cultivate the culture of innovation? In today’s knowledge economy, expertise and experience is a key differential. In the manufacturing industry, dealing with high-end technology, a person’s experience and knowledge could spell the difference between winners and also-rans. Retaining talent has become more challenging in today’s VUCA world for two reasons. One, increasing Gen Y workforce is more demanding in terms of work-life balance, culture, career growth & challenging work. Two, in today’s highly connected & competitive world, employment opportunities for the talented is a fingertip away. At L&T, we are working towards building capability for the future and retaining talent, through various initiatives. A few of them include •
A structured 7 step leadership development framework for building employees’ capabilities and talent pipeline at all levels in collaboration with world’s finest management institutes
•
A project management institute and a learning academy for various technical & behavioural training programs
•
Talent Mobility Policy where employees are given opportunities to acquire new skills & work in challenging
assignments (India & Abroad – Foreign Postings etc.) through job rotations •
Platforms for fostering innovation and knowledge sharing through culture of cross-functional collaboration
The GST Bill has been passed by both the houses & is all set to be implemented across the spectrum of various industries in the country. How do you see the impact of its implementation on the heavy equipment manufacturing industry? In your opinion, what are the lacunae that still need to be addressed to create a level playing for Indian manufacturers in the domestic market; and building globally competitive industry? Let me say that GST is a game changer. Its implementation will change the manner in which business is carried out in comparison with the ways of the current tax regime. With a single rate being applied to all goods and services, there will be a significant redistribution of taxes across all categories resulting in reduction in taxes on manufactured goods and hence impacting the pricing of the product, positively. The most important benefit of implementing GST is that it would integrate the economy and provide for a common national market. This in turn will help in delocalization of ordering and hence will place all vendors on same platform instead of dividing them into geographic regions. Paper work and logistics will also be reduced which is another way where money can be saved. Though there will be minimum impact of GST on export orders as
In today’s knowledge economy, expertise and experience is a key differential. In the manufacturing industry, dealing with high-end technology, a person’s experience and knowledge could spell the difference between winners and also-rans. Retaining talent has become more challenging in today’s VUCA world for two reasons. One, increasing Gen Y workforce is more demanding in terms of work-life balance, culture, career growth & challenging work. Two, in today’s highly connected & competitive world, employment opportunities for the talented is a fingertip away. Chemical Engineering World
March 2017 • 69
CEW INTERVIEW they are mostly exempt from most taxes, it will certainly be a boost to the domestic market. Under the “Make in India” initiative, domestic manufacturing supplemented with beneficial incentives has being promoted extensively. According to you, how beneficial would it prove for the Indian Capital Goods Manufacturing sector? The initiative has paved for accelerated growth opportunities in sectors like Automotive, Engineering, Chemicals, Defence, etc. How L&T does plans to leverage the opportunity? Let me say that L&T has championed ‘Make in India’ long before it was announced as a national programme. This is an excellent measure to promote domestic production coupled with increase in ease of doing business, foreign direct investments, skill and jobs for the youth and national manufacturing. In my opinion, the programme will have a huge positive impact and will help in developing domestic suppliers’ thereby reducing delivery time and costs, making India much more competitive in the long run. However, for ‘Make in India’ to be truly successful, I feel multiple follow up steps from both government and companies are essential. Companies should take the effort to adhere to or upgrade to global quality standards, sensitise employees to IPR & other trade confidentialities and introduce a greater measure of transparency and flexibility in customer dealings. Simultaneously, in its part, the government should support these initiatives by ensuring that there are adequate barriers to price dumping by foreign companies and safeguards for domestic produce. They also ought to assist companies for doing business in countries with high risk and encourage the Government / PSU bids to ensure indigenisation, reduce 70 • March 2017
profitable products from the portfolio
cost of capital etc. to ensure long term success of the programme.
•
What is the present size of order book at present for L&T Heavy Engineering Division and please share insights into the some of the key ongoing projects and future projects.
Planet (Energy Conservation and Green Initiatives):
What are the future plans of L& T for Indian Capit al G oods M a nuf acturing Sector? As stated in our Annual Report, L&T Heavy Engineering has an Order Book of ` 7507 Cr., as on March 31, 2016, - a 10 per cent decline y-o-y basis. Recently, we have completed our exercise of fiveyear strategic plan with goals i.e. Lakshya 2021, wherein we have plans in place to increase the order book and bottom line. Considering factors like the revival in oil prices, the thrust by government towards new nuclear power projects and increase in defence capital acquisition through indigenisation, we see good opportunities in the times ahead. L&T Heavy Engineering regularly discloses its sustainability performance across the triple bottom line. I feel that sustainable organisations are the ones that will navigate the future best. Our plans across the triple bottom line are as follows:
•
Creating unique selling proposition and generating key differentials in selected products to help increase the bottom line
Our major plants - Hazira and Powai – the manufacturing base for Heavy Engineering - use 50 per cent & 22 per cent renewable energy respectively
•
All
our
campuses
are
‘Zero
Discharge’, i.e. we don’t release any waste into the environment •
Most of our plants (Hazira, Powai, Vadodara,
Talegaon)
are
water
positive: •
Consume less than what we conserve through various measures
•
Use of energy efficient manufacturing methods in welding, fabrication, heat treatment & various other stages of manufacturing
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Use of variable Frequency Drives in overhead cranes & machine tools, so as to conserve energy
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Transition to energy efficient LED lights for plant as well as offices is in progress. We also have several
People:
green buildings in our campuses
•
Taking care of all stake holders and creating value for them
40
Increasing morale of employees and preparing them for future endeavours and greater responsibilities
30 per cent reduction in overall
•
•
per
potable
cent water
reduction
in
consumption
and
energy consumption
Treating supplier as partners and developing a long term, mutually beneficial working relationship which will help both the partners flourish together
Profit: •
Concentrating more on lucrative business opportunities and high profit jobs, while pruning nonChemical Engineering World