May 2016 by Chemical Engineering World

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CHEMICAL ENGINEERING WORLD MAY 2016 VOL. 51 ISSUE 5 Mumbai ` 150

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Technology News / 18

Jet Fuel from Non-edible Vegetable Oils / 20 Indigenous Water Technologies and Green Engineering / 26

Excel Rejuvenation Restores Regenerated HPC Activity to Near Fresh / 28 – Michael Martinez - Porocel Industries, LLC IExplosion Severity Measurement for Hydrogen-Air Mixture in 20-Litre Sphere / 32 – Dr (Ms.) Manju Mittal - CSIR- Central Building Research Institute Optimised Vacuum System Reduces Operating Costs of a Refinery / 38

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MARKET INSIGHT► Technology for Nitration Acid Safe Treatment and Reconcentration / 58 DNP International Acquires Tethys Instruments / 60

MARKETING INITIATIVE ► Bredel APEX35 Hose Pumps Improve Quality and Reduce Maintenance Costs / 61

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4 • May 2016

PROJECT UPDATE ► / 68 BACK OF BOOK Ad Index / 71 Interview / 72 “Indian Petroleum Market Growth is Encouraging” – Mr K Ravi, Chief Operating Officer, Bharat Oman Refineries Limited (BORL) Cover Page Image: GEA Disclaimer: The Editorial/Content team at Jasubhai Media Pvt Ltd has not contributed to writing or editing “Marketing Initiative.” Readers would do well to treat it as an advertisement.

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Chemical Engineering World

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CEW Industry News CII Appoints Pramod Chaudhari as National Committee on Bio-Energy Chairman

The Pradhan Mantri Ujjwala Yojana Launched in Three States

Pune, India: Mr Pramod Chaudhari, Executive Chairman, Praj Industries Limited, has been appointed as Chairman of Confederation of Indian Industry’s (CII) national committee on Bio-Energy for the 3rd consecutive year. Mr. Chaudhari has been actively involved with CII for more than a decade where he Mr Pramod Chaudhari, spearheaded Biofuels movement in India. Executive Chairman He has been the Chairman of CII’s National Committee on Bio-Energy continuously for four years since 2013.

New Delhi, India: The Pradhan Mantri Ujjwala Yojana (PMUY) was launched for the three states of Gujarat, Madhya Pradesh and Rajas than in Dahod. Chief Minis ter of Gu ja ra t, Smt Anandiben Patel, Chief Minister of Madhya Pradesh, Shri Shivraj Singh Chouhan and Chief Minister of Rajasthan, Smt Vasundhara Raje were present at the launch.

Mr. Pramod Chaudhari is an Indian Institute of Technology, Bombay (IIT) alumnus with a career spanning over 40 years of professional and entrepreneurial endeavor. He established Praj in 1983 which is now a global leader in process solutions. Praj focuses bioenergy, renewable chemicals and environmental technologies, having references across five continents. Mr. Chaudhari has also attended Advanced Management Programme at Harvard Business School in 1995. He has been voted amongst ‘Globally Top 100 People’ in BioEnergy space by Biofuels Digest. He is also the recipient of various awards, viz. Distinguished Service Award 2015 by IIT Bombay 2015, BioSpectrum Leadership Award 2013 for promoting the cause of Biofuels in the past three decades; ‘Lifetime Achievement Award 2013’ by Sugar Technologists’ Association of India; Distinguished Alumnus Award’ of IIT, Bombay in the Year 2005.

NCDEX Announces Compensation to Sellers Hit by Castorseed Trade Ban New Delhi, India: After more than three months of ban on castorseed futures, commodity bourse NCDEX has announced a compensation of ` 120/quintal to sellers who had valid deliverable stocks in the exchange-accredited godowns. The compensation will be given from the funds deposited by 16 defaulting brokers and traders who had been barred from the securities market by SEBI in March for manipulation in castorseed trading at NCDEX. In a latest circular, NCDEX said it will pay ` 120 per quintal to sellers who had net short (sell) positions in the castorseed contracts on the exchange platform and correspondingly held valid deliverable stocks in the exchange-approved warehouses as on January 27. Only registered members and constituents of the exchange (other than the defaulting members) are eligible to claim the compensation. The compensation of ` 120/quintal is the difference between the final settlement price (` 3,051/quintal) of castor seed of February futures contract and the close out price (` 2,931/quintal). 6 • May 2016

Minister of State (I/C) for Petroleum and Natural gas, Shri D h a r m e n d ra P ra d h a n p r e s i d e d ove r t h e eve n t . N a t i o n a l President of BJP, Shri Amit Shah also attended the event. Fifteen women from BPL families from the three states were handed over LPG connections at the launch. The scheme would impact the lives of women from BPL families in a major way by reducing the drudger y of cooking with polluting fuels and go a long way in reducing indoor pollution and other health related problems faced by them. Shri Pradhan said that over 5 crore BPL women would be p r ov i d e d L P G c o n n e c t i o n s i n t h e n ex t t h r e e ye a r s. T h e administrative cost of Rs. 1600 per connection, which includes a cylinder, pressure regulator, booklet, safety hose, etc. would be bor ne by the Gover nment. The government aims at providing relief to 5 crore women from the scourge of smoke and disease by the time the countr y celebrates the 150th bir thday of Mahatma Gandhi. He also said that the Gover nment aims to provide 25 lakhs new LPG connections and 15 lakh PNG connections to increase the use of clean fuels in the State of Gujarat.

NPCC Appoints Manohar Kumar as Director (Engineering) New Delhi, India: Shri Manohar Kumar has taken over as Director (Engineering) on the Board of National Projects Construction Corporation Limited (NPCC). A graduate from the then Delhi College of Engineering Shri Kumar later did MBA from MDU, Rohtak. He has put in more than three decades of service in Civil Engineering field. N P C C i s a P S U u n d e r M i n i s t r y Wa t e r R e s o u r c e s, R i ve r Development and Ganga Rejuvenation. NPCC was established in 1957 as a premier construction company to create necessary infrastructure for economic development of the country in the core sectors of irrigation and water resources, power and heavy industries. Chemical Engineering World

CEW Industry News LAPP India Introduces ÖLFLEX FIRE Survival Cables

OPaL to Build New Polypropylene Plant at Dahej

Bangalore, India: Lapp India, a 100 per cent subsidiary of the Lapp Group Germany and a leading supplier of integrated solutions and branded products in the field of cable and connection technology in India, has launched ÖLFLEX FIRE Survival Cables for circuit integrity application in the event of fire.

Dahej, India: India’s ONGC Petro additions Limited (OPaL) aims to start up its 340,000 mt/year polypropylene plant in Dahej Special Economic Zone, Gujarat, by end-May and is currently procuring feedstock propylene from the spot market, a company source said. Platts had previously reported the company was trying to start up the PP plant in mid-April. “We will definitely start pre-marketing material but commercial on spec material may take a month to produce from the plant start up,” the source said.

These cables are passed through C/W/Z fire resistant test and can provide optimum cabling solutions in fire mishaps by maintaining circuit integrity for temperatures up to 950°C, 650°C and 950°C as per application requirements. The inner and outer sheaths of the cables are specially made of halogen free compound which reduces emission of fumes and acid gases in the event of fire. Ö L F L E X F I R E S u r v i va l C a b l e s a r e d e s i g n e d fo r m a j o r infrastructure installations such as – airports, metro rail, rail terminal, bus terminal etc along with building and construction management. Rapid urbanization has escalated the need for high rise buildings, malls, modern houses and offices, all of which depend on wires and cables. As a result, the need for installing quality wire and cables is growing. Approximately 80 per cent Cables around us are not visible once they are installed. During a fire accident, these cables can propagate fire in the building through electrical circuits. So the need of the hour is to minimize loss during fire mishap which can be achieved by providing intelligent cabling solutions in terms of fire safety and fire survivability.

Henkel Reports Good Performance in First Quarter Mumbai, India: Henkel had a good start into the fiscal year 2016 with significant growth in sales and earnings and 16.8 per cent hike in adjusted return on sales. All three business units contributed to the overall good performance, delivering strong organic growth again in emerging markets. With regard to the current fiscal year, Henkel CEO Hans Van Bylen stated: “We expect the overall challenging market environment to continue in 2016 – with only moderate global e c o n o m i c growt h , h ig h u n ce r t a in t ie s in t h e mar kets and unfavorable foreign exchange developments. We will therefore focus on leveraging our strong brands, our leading market p o s i t i o n s a n d o u r i n n ova t i o n c a p a b i l i t i e s t o a c h i eve o u r ambitious targets.” Van Bylen confirmed Henkel’s outlook for the current fiscal year: “For the full fiscal year 2016, we expect organic sales growth of 2 to 4 percent. We expect our adjusted EBIT margin to rise to approximately 16.5 per cent and adjusted earnings per preferred share to grow between 8 and 11 percent.” 8 • May 2016

The plant’s start-up had been delayed earlier due to high project costs. It was heard that the company was looking for new shareholders but this could not be confirmed with the source. OPaL is initially starting the PP plant in isolation, and then hopes to bring on stream its new steam cracker and new polyethylene units by mid-July, according to the source. The company is building two 360,000 mt/year high density polyethylene/linear low density polyethylene swing units and a 340,000 mt/year standalone HDPE unit. Commercial production is expected to start two or three months from the start up, given that it is a new plant and needs time for production to stabilize, the source added. The dual-feed cracker has the capacity to produce 1.1 million mt/ year of ethylene and 400,000 mt/year of propylene. Associated units include a 150,000 mt/year benzene extraction unit and a 115,000 mt/year butadiene unit. The new units will produce the following HDPE grades -- injection, pipe, blow moulding, film and raffia/mono filament; and LLDPE grades -- film, roto moulding, lamination and injection moulding. OPaL is a joint venture between India’s Oil and Natural Gas Corp., GAIL and Gujarat State Petroleum Corp.

Construction Chemical Industry Needs to Work in Organized Manner N ew D e l h i , I n d i a : Mr Surjit Kumar Chaudhar y, Secretar y, Depar tment of Chemicals & Petrochemicals, Government of India, called upon the construction chemical industry to market its products and work as an organized sector. He added that the government would act as a facilitator and continue to support the sector but the industry had to promote itself to change people’s perception. The industry being disintegrated, was not being promoted appropriately. While delivering the inaugural address at the sixth National Conference on Construction Chemicals 2015 on the theme‘Construction Chemicals Industry as Enabler for Smart Cities’ organized by FICCI in association with the Department of Chemicals and Petrochemicals, Ministry of Chemicals & Fertilizers, Government of India, Chaudhary pointed out that the biggest challenge for the industry was environmental compliance and assured that his department wasworking relentlessly with the Ministry of Environment to resolve the issue keeping a balanced approach. He added that industry should look at adhering to the prescribed standards to avoid roadblocks. Chemical Engineering World

CEW Industry News ICT Ink MoU with Curtin University

Govt to Set up All MSME Technology Centers by 2017

Mumbai, India: The Institute of Chemical Technology (ICT) in Mumbai and Curtin University (Perth, Australia) have signed a Memorandum of Understanding (MoU) for collaborative research projects in areas of common interests. The collaboration will include exchange of faculty and PhD students between the two universities. The two already have some informal collaborations including in the areas of coal & biomass gasification and the MoU will formalise the arrangement as well as give structure and scope to several other joint efforts.

New Delhi, India: The gover nment is aiming to complete the work of all MSME technology centres by 2017. “All technology centres should be completed in all respects by 2017 and the two technology centres will be upgraded by this year itself,” said Kalraj Mishra, Minister for MSME (Micro, Small & Medium Enter prises).

An agreement to this effect was signed in ICT on May 9 by Dr Rekha Singhal, Dean, Research, Consultancy and Resource Mobilisation, ICT and Professor Brett Kirk, Associate Deputy Vice Chancellor – Research, Curtin University, in the presence of several faculty members of the two universities. Speaking at the event, Prof. Kirk noted that the 30-year old Curtin University has 50,000 students, including 19,000 international students spread equally between its campus in Perth and satellite campuses in Malaysia and Singapore. It is the largest university in Western Australia and has been ranked amongst the Top-300 universities in the QS World University Rankings.

The government has approved ‘Technology Centre Systems Programme (TCSP)’ under which 15 new technology centres are to be established in the country, and the existing centres are to be upgraded. As per original plan, the programme is to be implemented over a period of 6 years. Mishra ordered to speed up the construction of all the technology centres, while reviewing the wor k of MSME Development Organization. He was assured that the work on at least 10 technology centres will start during the year. In addition, the Minister has ordered that the present technology centres should cater to the needs of industries located at those places and should also work as cluster development centres for industries located in their area.

Ion Exchange Expands Bahrain Business Mumbai, India: Ion Exchange, one of India’s largest environment solutions providers, has announced the launch of a new chemical blending facility in Bahrain. The company is expanding its facility in Bahrain in order to improve the products and services it offers the wider GCC region, a market currently worth around USD 1.5 trillion. The new facility will serve as the chemical export hub for the GCC region and Nor th Arab states, creatingaround30 jobs over the course of the next three years. The Bahrain Economic Development Board (EDB), which provides advice and practical help to companies establishing operations in Bahrain, assisted Ion Exchange with company set up and other business requirements in order to ensure the company’s successful inception. Rapid demographic growth and economic expansion in the GCC in recent years have created a strong demand for water treatment technologies and services. Ion Exchange has over 50 years’ experience specialising in water treatment and provides a complete portfolio of advanced environmental solutions to industrial, institutional, residential, home, rural and urban developments. The company has a strong global presence with plants in various parts of the world, with offices in the Middle East, South East Asia, Africa, Canada and USA. 10 • May 2016

FICCI Suggests Vehicle Replacement Policy to Check Pollution New Delhi, India: A vehicle replacement policy should be introduced by the Government immediately to put an end to the uncertainty surrounding the industry, Ficci said. Earlier this week, the Supreme Court banned registration of diesel-run SUVs and cars having engines beyond 2000 cc in Delhi and NCR from March 1, next year. The National Green Tribunal (NGT) also recently directed that diesel-run vehicles will not be registered in Delhi with immediate effect and asked the central and state government departments not to purchase diesel vehicles. The industry chamber called for “taking balanced and holistic measures based on authentic studies so that the interest of every stakeholder is given due weightage”. “Ficci emphasises the need for immediate introduction of vehicle replacement policy to end the uncertainty surrounding the industry and for the society”, it said. Vehicle replacement programmes are voluntary and supported by some form of policy incentives. These are usually fiscal incentives, such as direct subsidies or fees to eliminate or discourage the use of older vehicles. They may also include other incentive policies such as restrictions on when and where high-emitting vehicles may operate. Chemical Engineering World

CEW Industry News LANXESS Expands its Material Protection Product Portfolio Cologne, Germany: Specialty chemicals company LANXESS is expanding its portfolio of material protection products by taking over the Clean and Disinfect business of US-based chemical company Chemours. The business comprises active ingredients as well as specialty chemicals used especially in disinfectant and hygiene solutions. One of its core products is the Virkon S branded disinfectant, that is being deployed globally in the growth sector of veterinary disinfection and in the combat against major diseases such as Foot-and-Mouth disease or Avian Influenza. Both companies have now signed an acquisition agreement. The enterprise value of around EUR 210 million will be paid by LANXESS from existing liquidity. Closing is expected in the second half of 2016. The transaction is still subject to approval from the relevant antitrust authorities. In another development, LANXESS subsidiary Bond-Laminates GmbH, the Fraunhofer Institute for Production Technology and HBW-Gubesch Thermoforming GmbH together received an award in the “Processes” category at the JEC 2016 Innovation Awards in Atlanta, United States. The winning development involves the addition of local tape reinforcements to Tepex-brand thermoplastic composite sheets in order to optimize mechanical performance, material thickness and weight.

Generational Change at Schwarze-Robitec Köln, Germany: Schwarze-Robitec, the leading manufacturer of tube bending machines bids farewell its Sales Manager Jürgen Korte, who will retire at the end of April 2016. Along with this comes a new alignment from the bottom up that takes place throughout the entire management level of the company. A major objective is to expand the market position and be the first contact when it comes to tube bending solutions, even on an international platform. Jürgen Korte started as Design Manager in 1982 at SchwarzeRobitec, and in 1993 assumed the position of Sales Manager. After 34 years of service with the company, he is retiring at the end of April 2016. With the retirement of Jürgen Korte, Schwarze-Robitec is taking this opportunity to restructure its Sales Department. Heike Ahlers is the new Sales and Marketing Manager and functions as the extended arm of the company’s management. Hired in 2013 by Schwarze-Robitec, she was significantly involved in 2015 with the opening of the current subsidiary in the USA. The objective of the restructuring is to ensure, the company can adapt to the ever faster changing international markets over the long term. 14 • May 2016

Romaco Continues to Grow Karlsruhe, Germany: Romaco has reported a 15.1 per cent rise in incoming orders for the fiscal year 2015. The leading supplier of processing and packaging solutions recorded a particularly big increase in sales of new machines in the past fiscal year. The Romaco Group can look back on yet another very successful fiscal year. Incoming orders rose to 129.9 million euros in 2015, up an impressive 15.1 per cent compared to the previous year. The increase was even bigger in the new machines segment, with 24.2 per cent more orders won than in 2014. This general upward trend is also reflected in the sales figures. In 2015, the leading engineering specialist boosted its sales by 12.6 per cent to 126.3 million euros. Sales of original equipment leapt up 19.2 per cent. Romaco’s revenue from customer services last year was sustained at a very high level. “The significant growth in orders received and the increase in our sales figures are a vindication of our current corporate strategy ‘Beyond Technology’, which places the focus on the customer’s lifecycle”, emphasised Paulo Alexandre, CEO Romaco Group. “Ensuring our customers’ business success is a top priority for Romaco which, conversely, drives our future growth.”

Afton Chemical Corporation Opens Production Plant in Jurong Island Jurong, Singapore: Global petroleum additive specialist Afton Chemical Corporation has announced the opening of its production plant in Jurong Island, Singapore which was marked by a special visit by Singapore’s Minister for Trade and Industry (Industry), S Iswaran. The facility will now commence production of key components that are used in Afton Chemical Corporation’s engine oil additives to meet rising regional and global demand. “Today’s opening marks the end of a significant development and construction process at our new, fully owned facility, which began back in 2014,” said Rob Shama, President, Afton Chemical Corporation. “More impor tantly, it marks the star t of a new chapter where we are able to better secure the supply of key components for our customers to be able to meet their future growth aspirations.” The opening of the plant represents a new phase of Afton Chemical Corporation’s ongoing expansion into Asia Pacific, and is central to the company’s plans to ensure that its specialist additive products are ‘Made in Asia for Asia’. The company’s “Made in Asia” strategy is aimed at ensuring it has the right supply footprint to meet its customer’s needs. The organization already manages a number of other facilities across the region, including Technology Centers, in Suzhou, China and in Tsukuba Japan. Chemical Engineering World

CEW Industry News AkzoNobel Expands Coatings Plant in Indonesia

Ecoark Acquires Sable Polymer Solutions

C i k a r a n g , I n d one s i a : Nether lands-based AkzoNobel has completed the first phase expansion of its performance coatings plant in Cikarang, Indonesia.

Arkansas, USA: US-based Ecoark Holdings has acquired Sable Polymer Solutions (Sable), a company involved in the recycling and reclamation of resin materials. Sable will be integrated with Ecoark’s wholly owned subsidiary, Pioneer Products, to form a vertically integrated supplier of recyclable products. With the deal, Ecoark Holdings and Pioneer Products aim to boost their service offerings with additional market share within the resin industry.

Carried out with an investment of USD 2.5 million, the expansion will increase the plant’s production capacity by 40 per cent, as well as meeting the growing demand for its products from petrochemical and power sectors. AkzoNobel’s Protective Coatings managing director Mauricio Bannwart said: “This investment is a testament to our commitment to Indonesia, which continues to improve its position as an emerging market. In February last year, AkzoNobel Performance Coatings has invested USD 2.5 million to expand capacity at its Cikarang plant. The expansion has helped the company in meeting the growing demand for its coating products, which are supplied by the Protective Coatings and Marine Coatings businesses. AkzoNobel is a global paints and coatings company and was first established in Indonesia in 1971. Since then the company strengthened its position in the country by becoming the largest paints and coatings producer. The company has three manufacturing facilities, that produces decorative as well as performance coatings. It has a workforce of 1,000 people in Indonesia, while its business is spread across 80 countries.

BASF Wins Eagle Award for Excellence Ohio, USA: The BASF Whitehouse, Ohio, site has received the Eagle Award for Excellence for its exceptional performance in environmental, health, safety and security from the Ohio Chemistry Technology Council (OCTC) at its 38th annual conference in Columbus, Ohio. “Safety is a key pillar of BASF,” said Paul Marshall, BASF technical director. “Winning this award validates the commitment BASF has to the safety and health of our employees and community.” BASF Laboratory Technician Elaine Colyer, who works in the color lab, created a new ergonomic assessment tool for lab employees. Colyer’s dedication to improving ergonomics was a key reason for the award. In addition to the Whitehouse site receiving an award, longtime BASF employee Karl Schnapp, recently retired manager of Site/Administrative Services, received a special Eagle Award for Distinguished Service honoring his more than 20 years of dedicated service to the OCTC. 16 • May 2016

Ecoark said that each year, recyclable products worth USD 11.5 billion are thrown into landfill, with 70 per cent being recoverable plastics valued at USD 8 billion. Sable obtains recyclable materials and formulates them into resin feedstock for industrial and consumer products. By acquiring Sable, Pioneer Products has now become a fully integrated end-to-end solution provider for the entire lifecycle of resin product, from reclamation to development to sale. Currently the company has four active subsidiaries, including Intelleflex, Eco3d, Pioneer Products, and Magnolia Solar, which waste Ecoark intends to reduce waste in operations, logistics, and supply chains across global economy.

Umicore Plans NMC Production Capacity Expansion Antwerp, Belgium: Belgian materials technology firm Umicore is planning to expand its production capacity for nickel manganese cobalt (NMC) cathode materials in China and South Korea. The expansion will involve an investment of EUR 160 million over a period of three years at the company’s existing facilities at Cheonan, South Korea; and Jiangmen, China, as well as new investments on land adjacent to the facilities in both locations. According to the company, the capacity expansion is required to meet a surge in demand for materials used in hybrid and electric vehicles. As part of the expansion, the company will deploy its latest generation of production technologies, which will enable it to triple existing capacity by the end of 2018 across a broad range of material grades. The new capacity should start coming on stream in the second part of next year. It is reported that vehicle electrification is being driven by the need to reduce CO 2 emissions and improve air-quality. The company’s NMC cathode materials are key ingredients in allowing the improvements required for battery technology to increase driving range and reduce the total cost of electrified vehicle ownership. Chemical Engineering World

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CEW Technology News

American Process Launches GreenBox ++

New Techniques Make RFID Tags 25% Smaller

Atlanta, Georgia: American Process Inc, a leading biorefinery technology developer, announces launch of their patentpending GreenBox ++ technology that replaces chemical pulping for production of high-strength, lightweight paper-based packaging using a chemical-free, water-based process powered by nanocellulose.

North Carolina, USA: Engineering researchers at North Carolina State University have developed a suite of techniques that allow them to create passive radio-frequency identification (RFID) tags that are 25 per cent smaller -- and therefore less expensive. This is possible because the tags no longer need to convert alternating current (AC) to direct current (DC) in order for the tags to function effectively.

GreenBox++ technology is a 2nd generation enhancement of API’s GreenBox+ technology. In June 2015, API announced commercial installation of the GreenBox+ technology at Cascades’ Norampac-Cabano paper-based packaging facility in Quebec, Canada where a sodium carbonate-based chemical process was replaced with API’s patented hot-water extraction process. With GreenBox technology, the facility reduces its environmental footprint and process energy costs. According to Dr. Kim Nelson, API’s VP of Nanocellulose Technology, “We have enhanced the performance and market potential of our GreenBox+ technology with addition of a bolt-on nanocellulose processing line. Utilizing nanocellulose produced on site from pulp made from our GreenBox process, the strength of paper-based materials used for packaging such as corrugated medium can be significantly increased. The strength-boost offered by nanocellulose makes GreenBox ++ technology suitable for retrofitting both sodium carbonate and kraft pulping processes. This strength increase may also allow papermakers to lightweight packaging, or reduce the amount of material used.”

Fine Tuning Phosphorous Heterocycle Materials for Organic Electronics Tokyo, Japan: Scientists at Tokyo Institute of Technology have produced airstable 1-ar yl 1,3-diphosphacyclobutane2 , 4 - d i y l m a t e r i a l s by d i r e c t a r y l a t i o n w i t h e l e c t r o n r i c h aromatic substituents. This method enables the fine tuning of the electronic properties of such phosphorous heterocycles compounds for applications including fabrication of organic electronics and hydrogen fluoride sensors. Materials scientists have a strong interest in the development of methods for the synthesis of so-called ‘open-shell singlet P-heterocyclic’ materials systems for applications in the organic electronics industry including organically based sensors and optoelectronic devices. Here, Shigekazu Ito and colleagues at School of Materials and Chemical Technology, Tokyo Institute of Technology repor t on a new method for the production of airstable 1-aryl 1,3-diphosphacyclobutane-2,4-diyls— an open-shell singlet P-heterocyclic’ materials system—by direct arylation with electron rich aromatic substituents. 18 • May 2016

In passive RFID technology, a “reader” transmits a radio signal that is picked up by the RFID tag. The tag converts the AC of the radio signal into DC in order to power internal circuits. Those circuits control the signal that is bounced back to the reader. Passive RFID technology is used in everything from parking passes to merchandise and asset tracking. For example, passive RFID is the technology that tells a traffic barrier to lift when you wave a parking pass in front of the scanner. “By eliminating the hardware that is used to conver t the AC signal to DC for powering the circuit, we are able to make the RFID tag much smaller and less expensive,” says Paul Franzon, a professor of electrical and computer engineering at NC State and senior author of a paper on the work. The research was conducted with NC State Ph.D. students Wenxu Zhao and Kir ti Bhanushali.

Geologists from Cincinnati University Identify Methane Sources across USA Ohio, USA: Researchers from the University of Cincinnati recently studied the sources of methane at three sites across the nation in order to better understand this greenhouse gas, which is much more potent at trapping heat in the atmosphere than is carbon dioxide. The UC team, led by Amy Townsend-Small, assistant professor of geology, identified sources for methane in Carroll County, Ohio; Denver, Colorado; and Dallas/For t Wor th, Texas, by means of an analysis technique that consists of measuring carbon and hydrogen stable isotopes (isotopic composition). This approach provides a signature indicating whether methane is coming from, say, natural gas extraction (fracking), organic/ biologic decay, or the natural digestive processes of cattle. I n f i n d i n g s t o b e p r e s e n t e d a t t h e M ay 1 8 - 2 1 r e g i o n a l American Chemical Society Conference held in Covington, Ky., Townsend-Small will present research results achieved with a team consisting of Claire Botner, recent UC graduate student; Paul Feezel of Carroll County Concerned Citizens; Don Blake, professor of chemistry, University of California-Irvine, and Josette Marrero, former UC-Irvine doctoral student. Chemical Engineering World

CEW News Features

Jet Fuel from Non-edible Vegetable Oils The following article by Anil Sinha talks about a single-step catalytic process [1, 2] which has been developed recently for conversion of plant derived non-edible, waste, low cost oils to produce drop-in biofuel for air-transport purposes. The process is simple and dovetailed to current refinery hydrocracking process with different catalyst and desirable parameters. Thus the process can easily be carried out in the current refinery infrastructure.

lant derived oils (soya, jatropha, karanj, algal) are deoxygenated, selectively cracked and isomerised over a single catalyst to produce aviation fuel with 25-75 per cent yield and with properties and compositions exactly same as those required for aviation fuel. It is a unique single-step process to produce aviation fuel from renewable source. The process is flexible for various kinds of feed stocks. Triglyceride contained in algae, microbes and non-edible plant seed-oils like Jatropha, Karanj, Salvadora Persica (Pilu), Schleichera triguga (Kusum), Palm-distillate (PFAD), Camelina, etc all can be used as feedstock and can be converted to transportation fuel in a single step. T h i s a l t e r n a t i ve, r e n ewa bl e av i a t i o n fuel is exactly similar in properties as a petroleum-derived aviation fuel. It can be used directly in an aircraft without any need to make changes in engine. Novelty of the Process A single-step non-precious metal based catalytic process for conversion of plant

derived oils to produce drop-in biofuel for aviation was hither to not possible because no single catalyst is known that could perfor m all the three functions – complete deox y genation, s elec tive cracking and deep isomerisation. CSIR-IIP is reportedly the only institute in the world to achieve this target in a single step. Currently available processes reportedly use precious metal as catalyst in the second stage. Catalyst developed a t C S I R - I I P i s s t a bl e ; r e u s a bl e a n d has performed well even after several regenerations. Current World Market and Research Trends for Bio-aviation Fuel The global aviation has grown by 45 per cent and is forecasted to grow by 50-70 per cent by 2025. There is now a move by European Union (EU) to charge airlines for these emissions and other countries are expected to follow soon. Use of biofuels in aviation is being increasingly looked upon as a viable alternative and has become a major focus area for researchers, airlines as well as

engine and aircraft manufacturers as they are CO 2 neutral and sustainable. According to data from International Air Transport Association (IATA), the aviation industry would be compelled to blend 5 per cent green fuels within 3-5 years to measure own carbon footprint and cut emissions. Historic ruling on July 1, 2011 by ASTM International, Subcommittee D02.J0 on aviation fuels officially approving the addition of the jet fuel to the alternative fuel (ASTM D7566 – 11) ‘Standard Specification for Aviation Turbine Fuel Containing Synthesised Hydrocarbons’, now allows up to a 50/50 blend of bio-based components with conventional Jet-A fuel. The bio-based components are ‘Hydro processed Esters and Fatty Acids’ (HEFA) fuel derived from biomass feedstocks such as camelina, jatropha or algae. There is already a move in the aviation industry to replace at least 10 per cent of fossil fuels with renewable biofuels in the next 10 years.

Property

Units

Limits

Jet A-1

Biojet fuel

Total Aromatics

% v/v

Max 26.5

12.8

Sulfur, Total

% m/m

Max 0.30

0.2

0.009

Flash Point

°C

Min 38.0

Density (15°c)

kg/m

Min, Max 775.0 , 840

0.7929

0.779

Freezing Point

°C

Max-47.0

-52.2

-51.1

Viscosity ( - 20°c)

mm 2/s

Max 8.00

3.72

3.45

Smoke Point

Min 25.0

Specific Energy

MJ/kg

Min42.80

43.2

43.5

Table 1: Comparison table of CSIR-IIP biojet with the commercial Jet A-1

20 • May 2016

Chemical Engineering World

CEW News Features

Other Product Properties Apar t from biojet, gasoline and diesel makes the process further more attractive and commercially viable. High cetane renewable diesel and high octane gasoline a l o n g w i t h L P G (p ro p a n e ) wh i c h a re virtually sulphur-free, are other valuable side-products of this process. Gasoline produced in this process is good feedstock for the reformer and finally, it could be blended to gasoline pool or it can also be marketed as avgas, after its property improvement through blending various octane boosters. The diesel fuel 22 • May 2016

Dr. Anil Kumar Sinha, Principal Scientist, Head, Hydroprocessing Area, Refining Technology Division, Indian Institute of Petroleum, Dehradun. (Email: asinha@iip.res.in)

Pumps & Valves Special August 2016

The produced bio-aviation fuel is better than biojet fuel available in the international market. (Refer Table 1)

Valves Pumps & Special 16 August 20

Physicochemical Property of Biojet Fuel CSIR-IIP biojet production process is a single step process with a non-precious metal based catalyst. The product contains aromatics along with other hydrocarbons. It has low sulfur content and meets all the required standard ASTM D 4054 and ASTM D1655 specifications. The by-products of the CSIR-IIP process are gasoline and diesel which can be used for land transportation and blended with mineral based gasoline and diesel respectively.

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

Moreover there is no glycer ine as by product and the by-products are green gasoline, green diesel and recyclable residue which can be back processed along with the vegetable oil feed. All the products have better performance and are less polluting than petroleum derived gasoline, diesel and aviation fuel.

1. D eve l o p m e n t o f H y d r o p r o c e s s i n g Route to Transpor tation Fuels from Non-Edible Plant-Oils, A. K. Sinha, M. Anand, B. S. Rana, R. Kumar, S. A. Farooqui, M. G. Sibi, R. Kumar, R. K. Joshi, Catalysis Surveys from Asia 17(1), 1-13. 2. Aviation fuel production from lipids by a single-step route using hierarchical mesoporous zeolites, D. Ver ma, R. Kumar, B. S. Rana, A. K. Sinha, Energy & Environmental Science 4(5), 1667-1671.

ai 2017

The uniqueness of the process is that this Bio-jet Fuel has negligible ‘Sulfur’ content leading to negligible SOx-emissions and it has required level of aromatics content which is not present in any of the products in the market.

produced in this process high very high cetane value (>100), reduced emissions (16 per cent reduction in HC emission, 24 per cent in SOx, 5 per cent in NOx and 5 per cent in CO emission) and also has less fuel consumption when compared to conventional diesel.

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CEW News Features

Indigenous Water Technologies and Green Engineering The annual water demand was about 800 BCM in 2010 and estimated to cross 1200 BCM mark in near future which is more than the utilisable water resources. The emerging water scenario is alarming, writes Prof (Dr) P.K. Tewari.

significant number of villages (82,794 habitations as per Annual Report 2013-14 Ministry of Drinking Water & Sanitation) are known t o b e s u f fe r i n g f r o m ex c e s s s a l i n i t y, fluor ide, nitrate, iron, arsenic, heavy metals and microbial contaminations of ground water. The contaminants lead to water borne diseases. Growing industries and population is putting great stress on the aquatic environment. There is need for advanced waste water treatment, effluent treatment and clean rivers as a par t of green engineering. There is requirement for seawater desalination, brackish water desalination, wastewater treatment including recycle and reuse, water pur ification as well as water conser vation and green engineer ing. Science and Technology play an important role in addressing these issues. There are effor ts directed for the indigenisation of water technologies addressing particularly the unique challenges faced by the country. As an example, Depar tment of Atomic Energy (DAE) has developed several indigenous water technologies for enhancing water availability and improving water quality. An indigenously developed hybrid nuclear desalination plant is operational at Kalpakkam (Tamilnadu). It is the largest capacity (6300 m 3 per day) operating sea water desalination plant attached to a nuclear power plant in the world. It produces two qualities of desalinated water: distilled wa t e r fo r h i g h e n d a p p l i c a t i o n s a n d potable water for dr inking and other u s e s. A n o t h e r i n d i g e n o u s s e awa t e r d e s a l i n a t i o n p l a n t b a s e d o n hy b r i d technology (Reverse Osmosis- Multi-

26 • May 2016

Effect Distillation (RO-MED)) is being set up in OSCOM (Chatrapur, Orissa). A Low Temperature Evaporation (LTE) seawater desalination plant utilising waste heat of nuclear research reactor was set up in BARC Trombay. The technology has been transferred for wider deployment. DAE has developed high quality membranes and membrane based systems (UF/NF/RO) for water purification at household level to community level a n d l a r g e s i ze. T h e k n ow h ow o f t h e membrane based technologies and products for pur ification of raw water contaminated with bacteria, virus, fluoride, arsenic, iron, heavy metals and other contaminants has been transferred on nonexclusive basis. Unique requirements of rural adaptability of the technologies have been demonstrated.

estimated that the total water market in the countr y is about 14 billion USD i n c l u d i n g 4 b i l l i o n U S D wa s t e wa t e r market, 0.7 billion US$ decentralised water market with potential of 7 billion USD decentralised market for domestic units considering rural and remote areas. There are oppor tunities and challenges par ticular ly from the point of view of affordability and sustainability. There is market for the multi-nationals and there is oppor tunity for the indigenisation. There is oppor tunity for working jointly for ‘Make in India’ which will help in value addition and enhancing the employment potential. The major challenges are that a significant population lives in rural areas and remote locations. There is need for technology innovations which are green, simple,

There is requirement for seawater desalination, brackish water desalination, wastewater treatment including recycle/ reuse, water purification as well as water conservation and green engineering. Bicycle mounted solar based units, 10 and 80 litres per hour capacity– RO based and UF based respectively, and Membrane based systems coupled w i t h s o l a r p owe r ( 2 0 0 l i t r e p e r h o u r capacity) are quite popular and technologies have been transferred for wider deployment. Membrane technologies along with c o n v e n t i o n a l t e c h n o l o g i e s w i l l p l ay an impor tant role in cleaning of water bodies, including several initiatives such as Clean Ganga Mission. T h e r e i s n e e d fo r i n d i g e n i s a t i o n t o address the local challenges. It is

affordable, repairable by local technicians and sustainable in rural context. Achievements of scientists and engineers addressing the unique challenges are yet to adequately percolate down to the bottom of the pyramid. The potential to impact the common man’s life is yet to be fully exploited particularly in remote areas. Safe drinking water is required by all: resource rich users as well as resource poor users. The author is a Professor at Homi Bhabha National Institute & Raja Ramanna Fellow, Former As s oc iate Dire c to r Ch e mic a l Engineering Group at Bhabha Atomic Research Centre(Email: pktewari@barc.gov.in) Chemical Engineering World

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Complete Range of Gaskets Sheets & gland packings Ferolite, an ISO/TS 16949:2009 & ISO 14001:2004, company, is India’s No.1 manufacturer of Compressed Asbestos, Non Asbestos Jointing Gasket Sheets & gland packings as per National & International Quality Standards at its state of the art Plant located in Ghaziabad. Ferolite is supplying its products to all Process Industries (Refinery & Petrochemicals, Oil & Gas, Chemical, Fertilizers, Paper, Sugar, Power, Engineering) & OEMs such as Pumps, Valves, Compressor manufacturers etc and having Regional Offices in all Metro cities with nation wide dealers network. We are also exporting the Sheets & gland packings all over the world.

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CEW Features Opinion

Excel Rejuvenation Restores Regenerated HPC Activity to Near Fresh Advances in hydroprocessing catalyst technology over the past several years has resulted in the development of robust, high activity catalysts, which are well suited for re-use. Porocel has developed a new technology, Excel rejuvenation, which can restore the activity of spent hydrotreating catalysts to near fresh levels. The method employs a secondary step beyond conventional regeneration to re-disperse active metal sites and recreate the high activity of the original catalyst. Unlike other rejuvenation technologies, Excel rejuvenation can be applied to a broad range of type 1 and type 2 catalyst grades.

onventional regeneration is a well-accepted industrial process used to restore catalyst activity to 60 – 80 per cent of fresh. The high temperatures applied during the regeneration process effectively convert the active sites back to metal-oxides and remove carbon and sulfur. However, the exposure to high temperatures can cause sintering of the active metal sites and formation of agglomerates in the crystal structure such as CoMoO4 and NiMoO4, which inhibit full sulfiding of the metal oxides. Traditional rejuvenation is a proven method to re disperse the active metal sites and increase the HDS and HDN activity beyond conventional regeneration. However, the rejuvenation technologies available to date have only been effective for a limited selection of catalyst grades. Excel rejuvenation

technology expands the range of hydrotreating catalysts across all major manufacturers and consistently restores Relative Volumetric Activity (RVA) to more than 90 per cent versus the fresh analogue. Excel rejuvenation is applicable to additive and non-additive based Type 1 and Type 2 NiMo and CoMo catalysts. This patented process gives refiners an excellent alternative to fresh catalyst in a wide range of hydrotreating applications from naphtha through heavy gas oil.

evaluated after regeneration and again after rejuvenation to confirm adequate activity. The two-step process consists of an initial thermal regeneration to remove carbon and sulfur followed by a proprietary chemical treatment, which re-disperses metals and restores and/ or stabilises active sites for maximum activity. The process is applicable to Porocel regenerated catalysts or other brands and can performed at all of Porocel’s facilities in North America, Europe and Asia.

Excel rejuvenation can be performed on your catalyst as a post-regeneration process. First, Porocel evaluates the spent catalyst to ensure only high quality uncontaminated catalysts are selected for rejuvenation. Catalyst chemical and physical properties are

Excel Application Support For all Excel catalyst applications, Porocel provides extensive technical support from start-up through the end of cycle to help refiners achieve maximum catalyst performance. Porocel technical staff can help refiners apply a

Feed Properties Density

g/mL (°API)

0.855 (34.0)

D-86 (90%)

C ( F)

358 (676)

D-86 FBP

C ( F)

380 (716)

Sulfur

wt%

1.0

Nitrogen

ppmw

130

o o

Operating Conditions

Test 1

Test 2

LHSV

1/hr

0.70

1.65

Normal Pressure

bar (psig)

51 (740)

24 (348)

Deactivation Period

bar (psig)

20 (290)

16.7 (242)

H2/Oil

NL/L (scfb)

135 (807)

160 (986)

Table 1: Pilot Plant Test Feed Properties and Operating Conditions

28 • May 2016

Chemical Engineering World

CEW Features 100 per cent load of high activity Excel rejuvenated catalysts in low to moderate severity units or combine with fresh catalysts in more demanding units with no negative impact on cycle length or product properties. Both options enable refiners to realise significant catalyst cost saving and decrease the quantity of hazardous waste generated versus installing 100 per cent fresh catalyst. Porocel specialises in working with refiners to analyse and identify suitable spent catalyst from their existing units for successful re-use. Performance Data Porocel has developed an activity testing program to accelerate coking and simulate extended operation in a commercial hydrotreater. The test was designed to verify the performance and stability of Excel rejuvenated catalyst versus fresh. Two tests were performed with different high activity Type 2 CoMo catalysts in environments favourable for coke formation and catalyst deactivation. The tests were conducted using a range of elevated temperatures in a low hydrogen partial pressure environment. By measuring product properties the performance of Excel rejuvenated catalysts were compared to fresh analogues. The feed used was a blend of Light Vacuum Gas Oil (LVGO) and Straight Run Gas Oil (SRGO) from Asian refiners. The feed characteristics and operating conditions for the two tests are given in table 1. The Hydrodesulfurisation Activity (HDS) and Hydrodenitrification Activity (HDN) was calculated based on the Liquid Hourly Space Velocity (LHSV) and the feed and product sulfur and nitrogen measurements. A summary of the results is reported in figures 1 and 2. The test data presented in figures 1 and 2 confirm the performance and deactivation rate of Excel rejuvenated catalysts are similar to fresh after operating in low pressure, high temperature accelerated deactivation conditions. Other tests performed in Porocel’s technology centres have 30 • May 2016

Figure 1: Test 1 - Excel® Rejuvenation vs Fresh (Type 2 CoMo)

Figure 2: Test 2 - Excel® Rejuvenation vs Fresh (Type 2 CoMo)

verified outstanding performance of Excel rejuvenation technology on both NiMo and CoMo catalysts for Type 1 and Type 2 grades. Conclusion With the continuous refining-industry focus on value, Porocel’s latest development, Excel rejuvenation technology, provides the highest hydroprocessing catalyst activity at an unmatched economic value. Refiners seeking high activity hydroprocessing catalyst while keeping a close eye on catalysts costs are very well served by this method of rejuvenation, which can be applied to catalyst from the refiner’s own units (as a service) or to regenerated catalyst from Porocel’s own extensive catalyst inventory. Porocel maintains a global inventory of rejuvenated catalyst available for

use in combination with fresh catalyst or on its own. All Porocel rejuvenated catalysts are analysed to ensure they meet stringent physical and chemical standards and come with a complete certificate of analysis to ensure high performance.

Author’s Details Michael Martinez Global HPC Technical Service Porocel Industries, LLC Email: vjoshi@porocel.com Chemical Engineering World

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CEW Features Technical Article

Explosion Severity Measurement for Hydrogen-Air Mixture in 20-Litre Sphere This paper reports results of experimental measurement of explosion severity for hydrogen gas in air using CSIR-CBRI 20-L sphere under quiescent conditions. Knowledge of explosion hazard of this gas is important to industries that produce or use this gas. The data presented include maximum explosion pressure and deflagration index of hydrogen-air mixture over a range of equivalence ratio (Ø) which can be used to quantify the potential severity of an explosion and for designing explosion safety measures. The maximum explosion pressure is 8.2 bara (Ø- 1.1) and deflagration index is 990 bar.m/s (Ø-1.3). The data reported here generally agrees with the data of previous investigators, but they are more comprehensive than those reported earlier.

arge quantities of hydrogen are produced in the industry today (e.g., in the production of ammonia and refineries). Hydrogen is used in fuel cells, food, chemical processing, pharmaceuticals, aerospace, electronics, petroleum recovery and refinery, power generation and metal production. Also hydrogen is an important energy carrier and considered one of the most promising fuels for global use in future, mainly because it is an energy-efficient, low polluting and renewable fuel. Introduction of hydrogen as an energy source for general public makes great demands on all aspects of safety of hydrogen installations. On release in atmosphere hydrogen disperses upwards rapidly due to buoyancy. It does not spread horizontally very far before the concentration decreases below the lower limit. Hydrogen hazard for gas leak in open is therefore lower. However, the leakage of hydrogen in confined spaces/ enclosures has very high risk of explosion in presence of ignition source as this gas has a wide flammability limit (4-75%) and low ignition energy (Frank,1996). High burning velocity of hydrogen-air mixture generates violent deflagration (pressure~7-8 bara in confined space) and a transition to detonation (pressure upto 20 bara) under favourable circumstances. There have been number of explosion accidents involving hydrogen gas. As an example, a hydrogen gas explosion occurred at a Norwegian ammonia plant as a result of mechanical failure in a water pump which allowed hydrogen discharge from a

32 • May 2016

nearby high pressure vessel into a building (100x10x7m3) for approximately 30 s before the hydrogen and air mixture was ignited by a hot bearing (Bjerketvedt & Mjaavatten,1985). Total amount of hydrogen discharged was 10-20 kg. The explosion was very violent and it caused broken window glasses upto 700 m away from explosion centre. The explosion was followed by a large fire from the high pressure vessel. Two people died from injuries caused by explosion. The rapid rate of pressure-rise due to high burning velocity of hydrogen limits the efficiency of explosion safety/ protection measures like explosion suppression, explosion relief venting. In order to increase the effectiveness of safety measures for handling of hydrogen in closed vessel the explosion parameters–the maximum explosion pressure, rate of pressure-rise and deflagration index are required for worst case scenarios. The deflagration index is very useful to estimate vent areas to prevent catastrophic accidents. Maximum explosion pressure can be defined as the highest value of pressure developed by a deflagration after a series of deflagration tests done over wide range of concentration. This value is normally used to design enclosures and to predict the consequences. From this series of test the value of maximum rate of pressurerise also can be obtained for calculation of deflagration index and predicting the violence of explosion. The deflagration

index will show how fast the pressure will rise following the ignition of gas of known concentration in a container of a specific volume. Deflagration index can be calculated using equation 1: dP .V 1/3 KG = (1) dt Where, P - Pressure, bar t - Time, sec V- Volume, m 3 K G- Deflagration index, bar.m/s (dP/dt) max- Maximum rate of pressure rise, bar/s. Since deflagration index is an intrinsic property of a pre-mixture at certain conditions (i.e., at specified initial temperature and pressure), experiments conducted by different groups should provide nearly the same value of KG for the same pre-mixture at the same condition. Unfortunately, due to different sources of uncertainty, there are substantial discrepancies in the deflagration index measured by different researchers for the same hydrogen-air mixture (Table 1). The present study was undertaken to obtain comprehensive information on maximum explosion pressure and deflagration index of hydrogen-air mixture and to examine the effect of equivalence ratio on this parameter. A wider knowledge of the explosion severity characteristics of hydrogen will be an important contribution to the development of codes, standards and regulations related to hydrogen safety. Chemical Engineering World

Features CEW Reference

Size of Vessel

K G, bar.m/s

Cashdollar et al., 2000

120 L Sphere

1100

Senecal and Beaulieu, 1998

22 L Cylinder

638

Barknecht , 1981

5 L Sphere

550

Jo & Crowl, 2010

20L Sphere

770

NFPA 68, 2007

5L Sphere

659

Ma et al., 2014

20 L Sphere

312

Salzano et al. 2012

5 L Sphere

215

Tang et al. 2009

5.3 L Cylinder

410

Holtappels, 2002

6 L Semi sphere 14 L Sphere 40 L Sphere

640 770 508

Table 1: Deflagration index of stoichiometric hydrogen-air reported in literature at initial temperature 298 K and pressure 1 bar

Experimental Procedure The experimental set-up used for the study consists of 20-L sphere with an automatic gas mixing system, a capacitor spark ignition system and a high speed pressure measurement and data acquisition system (Figure 1). There are ports for connection to vacuum pump and sources of compressed air and the fuel gases. There is a solenoid valve control port for rapid introduction of compressed air to assist in mixing the gases. A sensitive pressure transducer is used for gas addition by partial pressures. At the start of test, the gas manifold and the vessel is evacuated to 0.02 bar using a vacuum pump. Next, the desired concentrations are converted to partial pressures and hydrogen and air are added at partial pressures required to give the desired mixture composition. The reported fuel concentrations are in mole (vol.) % based on partial pressure of fuel relative to total pressure. For hydrogen test in 20-L vessel, the fuel gas was added first and then the air was added rapidly through the solenoid valve as a way of mixing gases. Also a non-sparking internal fan was used for mixing gas-air. Gas-air was mixed for at least 3-4 min. prior to ignition and the fan was turned off 1 min prior to ignition to allow any turbulence and temperature transients to dissipate and provide a well-mixed quiescent system. The absolute pressure at ignition was 1 bar. A number of tests were completed to confirm the gas mixing capability of the control system. Samples Chemical Engineering World

of gas mixtures were collected in evacuated test tubes through a sampling needle at one port of vessel. The samples were analysed by gas chromatography. The results showed a maximum deviation of 0.2 mol. Once the gases are mixed homogeneously the mixture is ignited at quiescent conditions by using 2 electrodes (3 mm dia. brass rods sharpened to a point, 6 mm gap)) inserted at the centre of vessel and connected to a continuous electric spark system. Capacitors with known capacitance were charged to specific voltages and then discharged through a transformer to generate a strong spark with a stored energy (1/2 CE2 where C is the capacitance and E is voltage) of 10-15 J. The piezoelectric pressure transducer was used for sensing pressure as a function of time after ignition. The data were collected using

recorder, storage oscilloscope and data acquisition system. Maximum pressure and maximum rate of pressure rise values were obtained from the pressure vs. time traces. The maximum rate of pressure rise is found by selecting a narrow range in the pressure history containing (dP/dt)max. This maximum rate of pressure rise is used to determine the deflagration index KG given by equation 1. The volume concentration of hydrogen was ranging from 5 to 75%. This is equivalent to equivalence ratio (Ă&#x2DC;) ranging from 0.17 to 2.53. Results & Discussions The experimental maximum explosion pressures for a range of hydrogen concentration are shown in Figure 2. The peak in the maximum explosion pressure is found at equivalence ratio 1.1 for hydrogen in air, which is above the stoichiometric concentration. The pressure-time curve exhibits oscillations near peak pressures. Pressure-time data were smoothed to calculate pressure-rise rate. The maximum experimental deflagration index obtained has a value of 990 bar.m/s at equivalence ratio 1.3 for hydrogen in air. The experimental values of maximum explosion pressure and deflagration index are in close agreement to those reported by Jo & Crowl (2010). It is very important to understand the worst case accidents for developing explosion mitigating measures. For explosion of flammable hydrogen the maximum in explosion pressure and deflagration index

Figure 1: Experimental set-up for measuring explosion severity characteristics of gas-air mixture

May 2016 â&#x20AC;˘ 33

CEW Features are observed at concentrations above stoichiometric fuel concentration in air i.e. 29.6%. The maximum in explosion pressure and deflagration index for hydrogen-air mixtures are obtained at equivalence ratios 1.1 (32.56 vol. %) and 1.3 (38.48 vol.%), respectively. This observation indicates that the worst case accident for a hydrogenair mixture is above the stoichiometric concentration of hydrogen. Conclusions The explosion severity of hydrogen-air mixture has been measured as maximum explosion pressure and deflagration index using CSIRCBRI 20-L vessel. The highest values of these parameters were seen at hydrogen

concentrations corresponding to 1.1 and 1.3 equivalence ratios, respectively. The pressuretime data between those two concentrations reported in this paper are important for designing explosion safety measures to protect hydrogen handling installations. References 1. Barknecht, W., 1981. Explosionscourse, prevention, protection. Springer-Verlag Berlin (Heidelberg) 2. Bjerketvedt, D. & Mjaavatten, A., 2005. A hydrogen-air explosion in a process plant: a case history presented at the International conference on hydrogen safety, Pisa, Italia. 3. Cashdollar, K.L., Zlochower, I.A., Green,

Figure 2: Variation of maximum explosion pressure with equivalence ratio for hydrogen-air mixture

G.M., Thomas, R.A. & Hertzberg, M., 2000. Flammability of methane, propane and hydrogen gases. J. Loss Prevention in Process Industries:13, 327-340. 4. Crowl, D.A. & Jo., Y-D, 2007. The hazards and risks of hydrogen. J. Loss Prevention in Process Industries: 20,158-167. 5. Frank, P.L., 1996. Loss prevention in the process industries, 3rd Edition, Elsevier In. 17/36-17/50. 6. Holtappels, K., 2002. Project SAFEKINEX Contract No. EVGI-CT-2002-00072. Deliverable No.8 Report on experimentally determined explosion limits, explosion pressures and rate of pressure rise. Part I: Methane, Hydrogen and Propene. 7. Jo, Y.D. & Crowl D.A., 2010. Explosion characteristics of hydrogen-air mixture in spherical vessel, AIChE, Process Safety Progress:29(3), 216-223 8. Ma, Q., Zhang, Q., Chen J., Huang, Y. & Shi, Y., 2014. Effects of hydrogen on combustion characteristics of methane in air. Int. J. Hydrogen Energy 39, 11291-11298. 9. NFPA 68, 2007. Standard on explosion protection by deflagration venting, National Fire Protection Association 10. Salzano, E., Cammarota, F., Di Benedetto, A. & Di Sarli, V., 2012. Explosion behavior of hydrogenmethane/air mixtures. J. Loss Prevention in Process Industries, 25, 443-447. 11. Senecal, J.A. & Beaulieu, P.A. 1998. KG - new data and analysis. Process Saf. Prog. 17,9-15 12. Tang, C., Huang, Z., Jin, C., He, J., Wang, J., Wang, X. & Miao, H., 2009. Explosion characteristics of hydrogennitrogen-air mixtures at elevated pressures and temperatures. Int. J. Hydrogen Energy: 34, 554-561.

Authorâ&#x20AC;&#x2122;s Details

Figure 3: Variation of deflagration index with equivalence ratio for hydrogen-air mixture

34 â&#x20AC;˘ May 2016

Dr (Ms.) Manju Mittal Sr Principal Scientist Fire Research Laboratory CSIR- Central Building Research Institute Roorkee, Uttarakhand, Email: mm_s123@rediffmail.com Chemical Engineering World

Process Insight: Beginning in 2017, TIER 3 regulations will reduce corporate average sulfur in gasoline from 30 wppm to 10 wppm. New regulations are expected to strain existing refinery configurations at a time when the US gasoline market is increasing its reliance on low-octane feedstocks from shale and experiencing a turnaround in domestic demand. Uncertainty on future refining margins requires refiners to place a significant emphasis on flexible planning and process debottlenecking to meet target quality and product slate. Planning models make extensive use of linear programming to maximize margins through stream allocation and blending optimization. Accurate prediction of future plant performance in the form of process vector yields is critical. Likewise, the successful estimation of process vector yields must include: (1) rigorous modeling of process equipment, (2) comprehensive simulation of the process layout, and (3) fast evaluation of multiple scenarios for optimization. Under conventional approaches, these models occur at different levels. The rigorous process equipment models are utilized to provide generalized performance criteria to the process simulator. The process simulator links together performance criteria from multiple equipment models in a process layout. Optimization routines then evaluate multiple scenarios within the process layout. The complexity of the conventional layered approach reduces the efficiency of scenario testing and, ultimately, reduces the likelihood of identifying bottlenecks and locating the optimum configuration. All of these distinct models may be moved into a single simulator using ProMax®. In refinery simulations, ProMax replaces traditional boiling-based pseudo-components with species that provide chemical

Advances in Reactor Modeling Streamlines Gasoline Production Debottlenecking meaning to oil fractions. The AutoKinetic™ reactors in ProMax make use of these species to generate reaction sets and their corresponding rate expressions according to the strict chemical rules governing the process. ProMax AutoKinetic reactors provide users with a suite of rigorous reactor models to simulate refining and other hydrocarbon reactor processes. A typical process layout for Gasoline Production would include Blending, Fractionation, Caustic Treatment, Amine Treating, Naphtha Hydrotreating (Figure 1), Catalytic Reforming, Isomerization, Alkylation, Selective Hydrogenation (SHU) and Selective HDS (Posttreating) of Catalytic Naphtha.

Figure 1

Combined with the ProMax Scenario Tool™, AutoKinetic reactors can be used to debottleneck and optimize blend stocks and yields in gasoline production trains. By translating regulatory frameworks into targets for sulfur, Reid vapor pressure, and octane number, ProMax users have the ability to evaluate the benefits and/or shortcomings of different process scenarios and test for imbalances, performance losses, surplus capacities as well as to identify opportunities for new capital projects under variable pricing structures and crude availabilities while getting ready to meet TIER 3 gasoline sulfur levels.

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CEW Features Technical Article

Optimised Vacuum System Reduces Operating Costs of a Refinery The following article highlights the significance of using vacuum systems with steam jet pumps for vacuum production. The benefit of optimised and efficient vacuum systems becomes particularly clear when comparing the effects of investment and operating costs across a period of five years, write the authors.

he basic process of petrol processing is distillation, operated as atmospheric distillation and often in the second step as vacuum distillation. The crude oil is broken down into its different components (fractions). The residue of atmospheric distillation is distilled at about 30 to 50 mbar. There are many different highperformance machines for vacuum production, including steam jet pumps as well as mechanically operated compressors. Vacuum systems with steam jet pumps are preferred from a technology point of view, since they are equally suitable for all process conditions while being absolutely robust and reliable. Energy Savings is the Target In spite of the currently low energy prices, the limited natural resources will likely lead to continually rising oil prices. Therefore, technology alternatives for reducing energy consumption while at the same time making the processes more efficient are needed today already. The annual operating energy costs for vacuum production in distillation plants with steam jet pumps are about two to four times as high as the investment costs for the entire vacuum system plant. Therefore, an efficient vacuum system – irrespective of the investment costs – already leads to process optimization and low (consumption) costs. The pay-back period is short. Due to the limited size and the much higher maintenance effort of mechanical 38 • May 2016

compressors, steam jet vacuum pumps are clearly superior. Mechanical compressors are often used in combination with hybrid vacuum systems to evacuate small volumes at the end of a multi-stage steam-jet vacuum system. Technical Basics Steam-jet pumps are thermal systems. They use the kinetic steam energy at the exit of a Laval nozzle to compress the gas mixtures. At the exit of the jet pump, the steam/gas mixture will enter a condenser in which much of the steam condensates. Steam jet pumps have been used in the industry for 150 years. To this day, their economic efficiency and robustness means that these thermal systems are rarely replaced by mechanical compressors. The steam jet pump was continually optimised over time. Innumerable tests with minor changes to the contour have optimised the performance of steam jet pumps. Comparing the test reports from 1960 to the most recent records, it is evident that the steam consumption has dropped by 35 per cent since then. The process technology within a jet pump is so complex that there is no reliable alternative to the practical trial of jet pumps on the test bench yet. This is true, even though several simulation programs have been developed based on a large number of tested jet pumps and some universities tried to develop a simulation software that can map the functional dynamics of a steam jet pump. The database shows more than 12,000 tested jet pumps. The

performance was optimised step by step to this day. These tests continue to be carried out because it is certain that there is still space for improving the efficiency of this equipment. Cost Calculation and Optimisation The importance of an efficient system can be best explained using an example: Consider a 3-stage system. Each stage consists of one or several parallel jet pumps and a surface condenser to reduce the intake volume of the downstream stage. The operating and investment costs for this procedure are calculated in the following example application: Oil refinery for 16 mtpa Crude Oil Three-level Vacuum System: • 1 st stage: suction nozzle DN 1500 • 1 st inter condenser: 2 x DN 2000 x 9000 • 2 nd stage: suction nozzle DN 500 • 2 nd inter condenser: DN 800 x 6000 • 3 rd stage: suction nozzle DN 250 • After-condenser: DN 600 x 3000 • Suction pressure: 30 mbar • Gas flow rate to the first jet pump: 18 t/h • Motive steam consumption: 32 t/h Estimated Operating Costs: • Motive steam costs: 30 Euro/t • Runtime of the plant: at least 8500 h/a • Annual operating costs: 8.168 M Euro • Total investment costs of the vacuum system: 5 M Euro How does optimisation of the vacuum system affect profitability of the overall Chemical Engineering World

CEW Features system? Let us look at a period of five years of uninterrupted operation and assume 0 per cent passive interest – for the sake of simpler calculation – to determine the operating costs. The example shows that the operating costs amount to 40.8 M Euro in five years, at investment costs of only 5 M Euro. This means that the investment costs were about 11 per cent of the operating costs. Assuming a depreciation time for machine technology of 20 years, the investment costs amount to only 3 per cent of the Total Costs of Operation (TCO). This clearly reflects the high influence of operating costs on the economic efficiency of a vacuum system. A reduction of steam consumption by 5 per cent, in contrast, saves nearly 41 per cent of the costs (2.040 M Euro) in relation to the investment costs of the vacuum system over the period of five years.

Figure 1: Flow chart of a vacuum system

Another important argument is saving CO 2 by the more energy-efficient vacuum system. One of the main approaches to climate protection according to the Kyoto protocol is reduction of the emission of greenhouse gases that arise when producing energy and consuming energy for industrial use. Increase of energy efficiency means “less input for a constant output” and thus reduces not only the costs for a refinery in fractioning the crude oil, but also directly improves the emission of greenhouse gases as a ‘win-to-win model’. Result A vacuum system with steam jet pumps creates relatively low investment costs – compared to the later operating costs. Customers are well advised to choose their suppliers not only based on investment costs, but to also consider operating costs. Not least, it should be a decisive factor that the supplier is able to try out the jet pumps on a test bench. 40 • May 2016

Figure 2: A vacuum system with steam jet pumps comes with relatively low investment costs – as compared to the later operating costs. Therefore, the pump manufacturer should try out the jet pump on a test bench.

As already mentioned, it is difficult to make changes to a jet pump without verifying the pump’s function on a test bench. In spite of its simple structure, the jet pump cannot simply be installed in a system without precise review of working manner and capacity. The last years’ experiences show that the operators consider steam consumption very well and that they demand guarantees both for proper function of the vacuum system and for low operating costs. Only an optimally designed and tested steam jet vacuum

system ensures economic and maintenancefree operation for many years. Authors’ Details Dr Alberto Riatti Department Head, Vacuum Systems, GEA Wiegand GmbH Norbert Strieder Department Head, Marketing and Sales, GEA Wiegand GmbH Email: gea-wiegand.info@gea.com Email: suket.gohil@gea.com Chemical Engineering World

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CEW Features Technical Article

Process Safety Management: Functional Safety, Part 1

Going

Beyond

The following article provides the framework and design of a process safety management system that encompasses all of the key elements of people, processes and technology. This article also enumerates the best practices for establishing a process safety management culture, and designing, implementing and maintaining a proactive process safety management system to complement existing functional safety systems and, thereby, extend a plant’s safety performance envelope.

ince the advent of the modern hydrocarbon age, petroleum refining and petrochemical process operations have become increasingly complex and potentially very dangerous if not managed correctly. The importance of providing protection to the safety and well-being of people, the environment and physical plant assets in the event of an unexpected process excursion cannot be overstated. This has led to an evolution of techniques and technologies designed to improve operational safety by reducing the risk of occurrence of a catastrophic event (i.e., the release of toxic, reactive or explosive chemicals) which can result in damage to the environment and/or plant assets, as well as injury and/or death to humans. We begin the journey to Process Safety Management (PSM) by providing a brief history of events and activities that have led to the state-of-the-art in safety management as currently embodied in functional safety systems. These systems enable the orderly shutdown of process units when abnormal situations occur that are beyond the capabilities of the regulatory control system and/ or operators to correct soon enough to prevent a catastrophe. While functional safety has proven successful in reducing the probability of catastrophic events and does recognise the role of human factors, it does not

42 • May 2016

explicitly address the key roles of management and business processes in maintaining the operational integrity and profitable performance of process plants. After providing a working definition of PSM, this article concludes with the presentation of the business case for PSM. History of PSM As industrialisation and technology progressed in the early 20th century, the pattern of intermittent catastrophes began to make its appearance. In 1921, at the BASF plant in Oppau, Germany, explosions destroyed the plant, killing at least 430 people and damaging approximately 700 houses nearby. The explosions occurred as blasting powder was being used to break-up the storage pile of a 50/50 mixture of ammonium sulfate and ammonium nitrate. This procedure had previously been used 16,000 times without any mishap. In 1947, a fire and explosion in Texas City, Texas on the Monsanto Chemical Company’s S.S. Grandcamp while loading ammonium nitrate fertiliser killed over 430 people. There was no specific legislative response to these incidents. 1 Interestingly, the United States Center for Chemical Process Safety (CCPS), which provides leadership and infrastructure to promote and advance PSM, suggests process safety was born on the banks of the Brandywine River in the early days of the 19 th century at

the E. I. du Pont black powder works. Recognising that even a small incident could precipitate considerable damage and loss of life, du Pont directed the works to be built and operated under very specific safety conditions. 2 Below is a brief list of serious industrial disasters that illustrate the dire consequences that result from such incidents: • 1984 – Bhopal, India – toxic material released o 2,500 immediate fatalities o Many other offsite injuries • 1984 – Mexico City, Mexico – LPG explosion o 300 fatalities (mostly offsite) o USD 20 million in damages • 1988 – Norco, LA, USA – hydrocarbon vapor explosion o 7 onsite fatalities and 42 injuries o USD 400+ million in damages • 1989 – Pasadena, TX, USA – ethylene/ isobutene explosion and fire o 23 fatalities and 130 injuries o USD 800+ million in damages In response to such catastrophic safety incidents that hurt the public and/or the environment and result in significant economic loss, governments continue to enact legislation and impose fines aimed at trying to reduce the probability of future such events. Likewise, operating companies have formed safety-related consortiums that include suppliers of process automation Chemical Engineering World

CEW Features technology. The goal of these consortiums is to identify automation solutions that can enable operating companies to avoid catastrophic safety events through early detection and correction. As evidenced by recent safety-related catastrophes, such solutions have not been entirely successful. The current state-of-the-art in the area of safety management includes safety studies (HAZID, HAZOP, Risk Analysis), safety instrumented systems (e.g., Fire & Gas Detection, Emergency Shutdown), abnormal situation management applications and operator guidance tools. The first step in the implementation of a Functional Safety system is the upfront analysis and conceptual design. It begins with a meeting of all stake holders to determine possible hazards and hazard characteristics, and establish the basic scope of the project. Work then proceeds to develop the detailed design of the Safety Instrumented System (SIS). The next steps involve: • Execution of the Process Hazard Analysis (PHA) and Layers of Protection Analysis (LOPA); • Specification of the Safety Instrumented Functions (SIFs) and

preparation of the of the Safety Requirements Specification (SRS) report; • Development of the Safety Integrity Level (SIL) verification worksheet and report. While these approaches to safety management have produced positive results in terms of reducing the probability of potentially dangerous process upsets or failures, they are either static (e.g., HAZOP studies) or reactive (e.g., Emergency Shutdown Systems) in nature. Their performance is also hampered by the problem of complacency. The passing of time without a process incident is not necessarily an indication that all is well. There is always a succession of failings that lead to an incident—the Swiss Cheese model (see Figure 1). If unchecked, all systems will deteriorate over time and major incidents occur when defects across a number of risk control systems materialise concurrently. In effect, the “holes” in the Swiss Cheese model become larger. Without setting leading and lagging indicators for each risk critical control system it is unlikely that failings in these barriers will be revealed as they arise and before all the important barriers are defeated.

Numerous high profile incidents in the last couple of years have heightened the awareness that organisations need to pay more attention to process safety: process safety being a blend of engineering and management skills focused on preventing catastrophic accidents and near hits, particularly, explosions, fires and damaging releases associated with loss of containment of energy or dangerous substances such as chemicals and petroleum products. These engineering and management skills exceed those required for managing workplace safety as it impacts people, property and the environment. The consequences of getting process safety wrong have never been higher, with escalating consequences that include: • Damage to people, the community and environment • Corporations and individuals called to account in public including lawsuits • Increased scrutiny by regulators and governments • Investor confidence is undermined, with resulting loss in stock price.

Process Design Other

Hazard

DCS SIS

Figure 1: Swiss Cheese Model - How a Hazard Can Propagate to Become a Harmful Event

44 • May 2016

Chemical Engineering World

Features CEW In some cases, even when executives and managers have prioritised process safety, things go wrong. Too often, organisations or individuals make process safety decisions under pressure, or without proper context or sufficient information, even in companies that have a long tradition of making safety a priority. What’s missing is the ability to provide plant personnel with real-time, proactive actionable information of a plant’s risk profile via continuous measurement, monitoring and visualisation of key operating and safety-related parameters so that potentially hazardous events can be averted without the need to resort to a plant trip or emergency shutdown. This is the goal of PSM, which involves the next generation of automation solutions aimed at making a step change improvement in the safety performance of companies in the process industries by providing a ‘Safety Early Warning and Hazard Avoidance System.’ A Working Definition of PSM By way of definition, PSM is the application of management systems to the identification, understanding and control of process hazards to prevent process-related injuries and incidents. The goal is to minimise process

PSM is the application of management systems to the identiﬁcation, understanding and control of process hazards to prevent process-related injuries and incidents. The goal is to minimise process incidents by evaluating the whole process. incidents by evaluating the whole process. The phrase process safety management came into widespread use after the adoption of OSHA Standard 29 CFR 1910.119 Process Safety Management of Highly Hazardous Chemicals in 1992. 3 PSM covers the following aspects of plant safety: • • • • • • • • • • • • • •

Process safety information Employee involvement Process hazard analysis Operating procedures Training Contractors Pre-startup safety review Mechanical integrity Hot work Management of change Incident investigation Emergency planning and response Compliance audits Trade secrets

Another definition of PSM is “the proactive and systematic identification, evaluation, and mitigation or prevention of chemical releases that could occur

Figure 2: The Role of Process Safety Management in Supporting Operational Integrity

Chemical Engineering World

as a result of failures in process, procedures, or equipment.” 4 In other words PSM is intended to ensure freedom from unacceptable risk due to: • • • •

Fire Explosion Suffocation Poisoning

Figure 2 shows where PSM fits into the overall context of Operational Integrity (i.e., ‘keeping the process in the pipe’) and how Functional Safety is a key element of PSM. The Business Case for Process Safety Management A cost/benefit analysis is at the center of the process of making investment decisions. To justify the cost it is necessary to determine if the magnitude of the value delivered justifies the cost in terms of time, effort and money. To date, investments in safety—functional safety systems, abnormal situation management applications, etc.—have been made largely on the basis of satisfying legislative requirements in order to maintain the license to operate. So far, there is no legislation that directly defines the requirements for a real-time PSM system or the penalties for not implementing one. Thus, investments in a PSM system may be made if it can be shown that it delivers a significant, tangible reduction in the risk of a catastrophic failure as well as produces a measurable economic benefit for the plant. Table 1 provides estimates of the annual benefits associated with implementing a PSM system. For a 100,000 barrel per day petroleum refinery, operating for 330 May 2016 • 45

CEW Features

Table 1: Estimated Beneﬁts for a PSM System

days/year at an average refining margin of USD 5/barrel, the estimated annual PSM benefit is USD 2.85 million. In addition to the statement of benefits provided in Table 1, the concept of the ‘incremental value-at-risk’ discussed below is intended to provide an ongoing quantified measure of the economic impact of the PSM system. References: 1. “A Canadian Perspective of the History of Process Safety Management Legislation”, 8th Internationale Symposium: Programmable Electronic System in Safety-Related Applications, September 2-3, 2008, Cologne, Germany. 46 • May 2016

2. Center for Chemical Process Safety web site: http://www.aiche.org/ CCPS/Students/GetSmart.aspx. 3. Center for Chemical Process Safety web site: http://www.aiche.org/ CCPS/Students/GetSmart.aspx. 4. Harry J. Toups, LSU Department of Chemical Engineering with significant material from SACHE 2003 Workshop.

Author’s Details Dr Martin A Turk Schneider Electric Email: prabhat.saxena@schneiderelectric.com Chemical Engineering World

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Challenges of Upgrading Diesel Quality from BS III, IV to BS VI in India Indian cities are witnessing a rapid increase in air pollution as a result of industrialisation coupled with phenomenal growth of transportation sector. Pollution needs to be controlled from all sources. Vehicular pollution requires stringent controls as vehicles emit toxic fumes within our breathing zone. The following article discusses the need to upgrade diesel quality norms to BS VI and highlights the challenges associated with the technology upgradation.

he transport sector accounts for 70 per cent consumption of diesel in India. Commercial vehicles and public transportation alone account for about 38 per cent diesel consumption. Emission from transportation vehicles is one of the major global concerns having serious impact on public health. To limit health impacts from road transportation, the levels of vehicular emissions shall be drastically curtailed through regulations. India appears among the group of countries with Highest Particulate Matter (PM) levels. Also, its cities have the highest levels of PM10 and PM2.5 when compared to other cities of the world. According to World Health Organisation, 10 out of 20 most polluted cities in the world are in India. Successful reduction of vehicular emissions requires a coordinated implementation of low sulphur fuel and superior vehicle technology. Stringent limits on vehicle emissions will bring technology innovations in automobile industry as well as in refining sector. Vehicle Emission Standards Starting with Supreme Court rulings in the late 1980’s and 1990’s, India began to take the first steps towards mitigating the public health impacts of vehicular emissions. The initial steps consisted of eliminating lead in petrol, switching to Compressed Natural Gas (CNG) for auto rickshaws and buses in Delhi and, subsequently, other cities,

Chemical Engineering World

and establishing Euro I equivalent emission standards known as India-1 standards for new vehicles. India has since progressively lowered its permissible vehicular pollution emission limits for new four-wheeled vehicles following the path laid out by the European Union by adopting parallel ‘Bharat’ standards. India shifted from Bharat Stage II (BS II) to Bharat stage III (BS III) in 2011 and currently BS III standard (Euro III) has been implemented across the country and Bharat Stage IV (BS IV) in major cities. The Government of India’s Auto Fuel Policy (2003) had envisaged that the Policy undergo periodic revisions to meet the stringent fuel/emission specification requirements. In May 2014 MoP&NG drafted Auto Fuel Policy 2025 which laid a clear roadmap to the year 2025 and also that includes technological and other changes that take place over time in the policy framework. Under this policy, the Expert Committee had recommended that BS IV fuel be required nationwide from April 2017 followed by a further step up to BS V in April 2020 and BS VI in April 2024. Meanwhile in November 2015, a draft notice was published by the Ministry of Road Transport & Highways announcing that BS V would be implemented across the country starting 2019 and BS VI starting 2021. Further the Supreme

Court ruling in early January 2016 asked the government to advance the implementation of BS VI emission standards from those contained in the November 2015 proposals. The government responded by announcing that they would skip over BS V standards and directly implement BS VI standards for new vehicle models by April 1, 2020 and existing models by April 1, 2021. Policy makers in India are determined to accelerate the implementation of BS VI emission norms by 2020. The Oil Ministry supported this move to proceed directly from BS IV to BS VI, whereas the automotive industry felt it is unrealistic. While the automotive industry was supportive of the dates for BS V, they claimed advancing the dates for BS VI by more than 1 year from those recommended by the Expert Committee would not leave sufficient time for testing and validation of Auto designs. Diesel Quality Requirement Fuel quality plays a very important role in meeting the stringent emission regulations. The fuel used in engines influences their performance and design. Diesel vehicles primarily heavy-duty trucks and buses which account for more than 80 per cent of fine particulates (PM 2.5) and nitrogen oxides (NOx) are prime targets for emission reduction. To May 2016 • 47

CEW Features the larger extent these pollutants can be reduced by present day available technologies like Diesel Particulate Filters (DPF) for particulates removal and Selective Catalytic Reduction (SCR) for NOx reduction. However, low sulphur fuels ideally less than 10 ppm must be employed to make these technologies function effectively. Hence, BS VI fuels shall be made available by refinery sector in stipulated time frame to implement BS VI emission norms in India. Sulphur is a pollutant itself, but more importantly it interferes with and eventually disables control technologies for all other air pollutants. Sulphur fouls conventional and advanced technologies to control vehicle emissions, including carbon monoxide (CO), particulate matter (PM), nitrogen oxides (NOx) and hydrocarbons (HC). Hence lowsulphur fuels are the key to reduce the emissions from existing vehicles and

enable advanced control technologies and fuel-efficient designs for new vehicles to function. Challenges Faced by Refinery and Auto Industry We could face two key challenges to implement BS VI norms, firstly the ability of Refining and Marketing companies to quickly upgrade fuel quality from present BS III / IV to BS VI and setting up Pan India fuel supply infrastructure. To achieve reduced Sulphur content in diesel, new process units for Sulphur reduction, hydrogen generation and Sulphur recovery units are to be installed at the refineries. Bigger chunk of investment is, however, required in setting up pan-India BS-VI grade fuel supply. The second and more important challenge comes from Auto Sector that requires combustion system

developments and lot of design changes in vehicles, to accommodate two critical components - DPF and SCR modules. These latter two technology components are also to be adapted for Indian conditions for vehicles, where running speeds are much lower than in most of the advanced countries. For Heavy duty diesel engines, the key emissions challenges have generally been NOx and Particulate Matter (PM). However, techniques to reduce NOx and PM often lead to an increase in unburned hydrocarbon (HC) and carbon monoxide emissions (CO), which poses additional challenges and can be a limiting factor for particularly NOx emissions, how far it can be reduced. Most efficient way to control the vehicle emissions is by modifying the combustion system using Exhaust Gas Recirculation (EGR), using advanced fuel injection systems with higher pressures and multiple injection,

Figure 1: Simplified typical refinery configuration to show impact of upgrading diesel quality to BS-Vi

48 â&#x20AC;˘ May 2016

Chemical Engineering World

Features CEW increased flow range turbocharging and model based combustion control using new sensor technology.

simplified typical refinery configuration showing the impacted units is given in the figure 1.

Other control mechanisms utilise after treatment technologies like SCR where a liquid-reductant agent is injected through a special catalyst into the exhaust stream of a diesel engine and a fuel reformer technology to achieve NOx reductions and DPF to remove diesel particulate matter or soot from the exhaust gas of a diesel engine.

Crude Distillation Unit: For producing BS III/IV diesel, refiners have flexibility to rundown straight run diesel to the diesel pool, while to produce BS-VI diesel, refiners will lose this flexibility. To cater to BS VI spec entire straight run diesel from CDU may have to be treated in hydrotreater before sending to diesel pool. This will lead to increase in capacity of existing Hydrotreaters and these plants require revamp for capacity and quality of product.

The governmentâ&#x20AC;&#x2122;s decision of implementing BS-VI emission norms on new vehicles with effect from April 2020 has drawn concerns from the automotive industry specifically in the areas including rising costs, engine bay design issues, using DPF vs fuel efficiency trade-off, design time for tailor-made solutions for vehicles sold in India. The optimisation and fitment of these technologies too would take few years. Impact on Refinery Units To produce this BS-VI quality diesel, each refinery shall evaluate their existing configuration and operations. Due to diversified configuration of refineries challenges for upgrading BS-III/IV diesel to BS-VI varies from refinery to refinery. The main diesel streams in a refinery are straight run diesel from Crude Distillation Unit (CDU), diesel produced from hydrocrackers, and Light Cycle Oil (LCO) from fluidised catalytic cracking and cracked gasoil from thermal cracking processes. In order to produce saleable product of BS-VI diesel, refiners shall produce Ultra low sulfur diesel, ULSD (around 6-7 ppm sulfur) in diesel hydrotreaters so that blended diesel with wild diesel streams if any coming from other units can meet 10 ppm sulfur requirement for BS-VI standard. The impact on various units in the refinery complex for augmenting the diesel production from present BSIII/IV specifications to future BS-VI specifications is discussed below. A Chemical Engineering World

Hydrocracking Unit: In refineries with hydrocracker configuration, the hydrocracker itself is a source of diesel blending component. The quality of the diesel produced from hydrocrackers is dependent on the operating conditions of the hydrocracker. Typically, the diesel produced from a hydrocracker is superior in quality to straight run production and is lower in sulfur content. In many cases diesel produced from hydrocrackers would not require further treatment even to meet 10 ppm sulfur content. Fluid Catalytic Cracking Unit (FCC): The Light Cycle Oil (LCO), the diesel blending component produced from FCC units is inferior in quality i.e low cetane number, higher polyaromatics, high sulfur content unless the FCC feed has been pre-treated. As diesel specifications have tightened, most refiners have been forced to reduce the amount of LCO which can be blended into diesel pool. Alternatively, refiners can use the LCO as viscosity cutter in heavy fuel oil blending. However, this is not a viable option now as heavy fuel oil demand is reducing constantly. Many refiners therefore making investments to upgrade LCO to low sulphur diesel through diesel hydrotreating units, however it is generally expensive because of their relatively high operating pressure and expensive catalysts.

Delayed Coker Unit (DCU): The Diesel produced from thermal cracking process is inferior in quality with respect to sulfur content, flash point, cetane index. DCU diesel requires hydrotreatment before sending to diesel pool. This will lead to increase in severity and capacity of the existing hydrotreater plant and require additional investment. However, alternate technologies can also be used to treat exclusively these DCU diesel and FCC LCO, if it offers saving in capex and opex. Kerosene Hydrotreating Unit: As Kerosene is used as buffer fluid between white products transportation in cross country pipe lines, in post implementation of BS VI scenario it is necessary to hydrotreat kerosene to 10 ppm Sulphur level, so that the diesel and gasoline products are not adulterated with untreated kerosene. Hydrogen Unit: Meeting hydrogen requirement in the Refinery is challenging to the Refiner as more hydrogen is required for revamping of hydrotreating units for all distillates. The existing hydrogen network shall be studied for augmentation of additional hydrogen requirement, before deciding for setting up of new Hydrogen plant. Sulfur Block: The sulphur block in the refinery consists of sour water stripper, amine regeneration, sulphur recovery and sulfur pelletiser units. Acid gas generation in the hydrotreating units will increase due to ULSD production. This will lead to additional loads to these sulfur block units and require either revamp/modification of existing units or addition of new units or both. Utility and Off Sites Facilities: The revamp or new Diesel Hydrotreating units demand additional utilities like power, cooling water, steam etc. refiners shall work out the adequacy check of existing utility systems before deciding augmentation of utility systems to cater to additional demand of utilities. In most of the cases May 2016 â&#x20AC;˘ 49

CEW Features

Figure 2: Simplified typical DHT Unit flow diagram showing impact of upgrading diesel quality to BS-Vi

augmentation of power system needs to be carried out. In addition to utility system augmentation, possible revamp/ augmentation of offsite facilities like flare system, diesel blending system etc. is also envisaged. Impact on Diesel Hydrotreating Units The most impacted unit in the refinery is the Hydrotreating unit for upgradation of BS-III/BS-IV to BS-VI diesel. Current DHT units operating in India are designed and operated to produce export diesel less than 350 ppm sulphur for BS III and less than 50 ppm sulphur for BS IV. These are now required to produce less than 10 ppm sulfur to meet BS-VI specification. In addition to this, in most of the cases capacity augmentation is required as refiners need to go for entire production of diesel to BS-VI spec. There are many challenges Indian refineries may face to upgrade/revamp existing diesel hydrotreating unit. Few major impacts are discussed and 50 â&#x20AC;˘ May 2016

elaborated with simplified typical flow diagram (figure 2) of DHT unit showing impacted section/equipment. Existing Plant Operating/Design Pressure: Diesel hydrotreating plant producing BS-IV spec, the reactor operating pressure is around 50-75 barg depending on quality of feed processed. To produce BS-VI spec the reactor operating pressure shall be around 90-105 barg. If the existing plant reactor is designed below this pressure, massive changes are foreseen in the revamp of the existing units for producing BS-VI grade diesel. Catalyst: The catalyst plays an important role for producing ultralow sulphur diesel. Typically, cobalt molybdenum (Co-Mo) or Nickel molybdenum (Ni-Mo) catalyst are used in the hydrotreating process. As Sulphur specification of BS-VI diesel is comparatively lower than BS-III/ IV diesel, the revamp of the Diesel

Hydrotreating plant forecasts a change in catalyst type and quantity. In some revamp cases, the installation of new reactor is envisaged to improve the quality of diesel and to increase the throughput of the unit. Hydrogen Requirement: The additional makeup hydrogen requirement and increase in its supply pressure may call for revamp or augmentation of Makeup gas compressor for Hydrogen. In addition to this as higher partial pressure of hydrogen is required for BS-VI operation, the recycle gas loop including Recycle Gas compressor may undergo revamp and augmentation. However, on advent of new generation catalyst formulations the requirement of gas to oil ratio is reduced. This may facilitate use of existing recycle gas loop equipment and lines without major modification. Utility Distribution: The revamp of DHT unit may call for few changes in the utility distribution network within the DHT units. Chemical Engineering World

Features CEW The impact on various units in the refinery complex for augmenting the Diesel production from present BSIII/IV specifications to future BS-VI specifications is discussed below. Plot Area/Plot Plan: The revamp of diesel hydrotreating plant may require modification/addition of equipment like compressor, reactors, heat exchangers, pumps etc. Accommodating all these modifications and new equipment in the existing plot area will be challenging as normally space is limited in existing units. Time Period for Completing Revamp: As per the recent Indian government notification, BS-IV is to be implemented nationwide by Apr-2017 and BS-VI by Apr-2020. At present, some of the refineries in India are still producing BS-III diesel and some are producing partly BS-IV and partly BS-III. The revamp time available for existing Diesel Hydrotreater plant is about 20 to 24 months to meet the dead line of government notification. As it envisages modification/ordering of critical long lead equipment like compressors, meeting this schedule is a challenging task for refiners.

of DPF and SCR to meet BS VI emission norms by 2020/2021. With falling crude oil prices it is economical to justify making this investment to upgrade diesel fuel and vehicles to meet BS VI emission norms. Also, it is business necessity to go for this investment to be competitive globally as most countries are shifting to Euro VI vehicles very soon. References: 1. All India Study on Sectoral Demand of Diesel and Petrol – Petroleum Planning and Analysis Cell 2. Auto Fuel Vision & Policy 2025 – Ministry of Petroleum & Natural Gas 3. Ministry of Road Transport & Highways notification 4. ICCT Global Health & Climate Roadmap Series – 2013 5. Emission Standards: India- Diesel Net

Unit Shutdown Duration: The typical turnaround given by refinery for this type of revamp is normally around 30 day’s duration. In some cases, there is a requirement of installing new critical equipment like compressor, reactors, etc. which requires 2-3 months duration for site installation. In such a case, adequate planning is required to start the revamp activities prior to taking shutdown of the plant without compromising safety aspect of the running plant. Economics Investment cost of refinery for upgrading diesel quality to BSVI grade depends on the existing refinery configuration and its operation. The magnitude of investment could be low if existing refinery configuration is with hydrocracker unit, high pressure diesel hydrotreater and processing low sulphur crude. On other hand huge investments are required if existing refinery configuration is with catalytic cracking unit, low pressure hydrotreater and processing high Sulphur crude. Way Forward World is moving fast to Euro-VI fuel standard and by 2017, it is estimated that most countries, would be using Euro-VI fuel. Most of these countries are fuel and vehicle importing countries and so it could impact our competitiveness if India does not move fast to BS-VI level. As refineries need to undergo revamps, modifications and installations of new units to comply with BS VI Diesel quality requirements, it calls for huge investment to the tune of `50000 crores in coming years. Also, around `40000 crores investment is required in Auto industry for modifications in engine design and addition Chemical Engineering World

Authors’ Details Akshay Choudhary Engineer – Process Technip India Limited AKChoudhary@technip.com Nihar Ranjan Beuria Sr Principal Engineer- Process Technip India Limited NRBeuria@technip.com M K E Prasad Advisor-Process and Technology Technip India Limited MKEPrasad@technip.com May 2016 • 51

CEW Features Opinion

Role of Automation towards Greener Environment Automation can play a crucial role in streamlining green engineering initiatives within industries. The article below highlights some of the efforts towards green engineering and emphasises how automation can help in successfully executing these processes.

n our school days, we all have learnt that plants give us Oxygen and we humans take out Carbon di-oxide which plants take in, thus balance of environment takes place. In the race of industrialisation, we have overlooked this phenomenon, and now when the human life is at risk, various techniques are being invented and stringent laws are made to reduce and control carbon dioxide emissions. When we utter the word ‘Industry’, immediately picture of a chimney with black smoke or dirty water with bad odour comes to our minds. The scenario has changed a bit; however, there is still urgent need to take corrective steps to control unwanted and harmfull emmissions and waste water discharge from the industries. On initiative of UN, Convention on Biological Diversity (CBD) was talked across the globe and India also signed this treaty. This has three main goals namely conservation of biodiversity, sustainable use of its components and fair and equitable sharing of benefits arising from genetic resources. The convention recognised for the first time in international law that the conservation of biological diversity is ‘a common concern of humankind’ and is an integral part of the development process. The agreement covers all ecosystems, species, and genetic resources. It links traditional conservation efforts to

the economic goal of using biological resources sustainably. The convention reminds decision-makers that natural resources are not infinite and sets out a philosophy of sustainable use. The members of the India Business and Biodiversity Initiative (IBBI) acknowledge the objectives.

In the traditional sense, automation systems are for production floors or for automatic operations of the process plants but in the recent times it has emerged as Business enabler, applied to manage resources to the possible optimised way, improve performance and human dependency.

As per the recent government policy, focus is now on ‘Make in India’ to increase manufacturing’s contribution to the GDP to 25 per cent. This again means more industries to come up but they will have to meet the demand of ‘Zero Defect, Zero Effect’ as well. Process employed should also be free from any ecological and environment impact!

Risk of human health and generation of pollution from various sources are high by any time although different measures being taken. Need of the hour is to use automation systems to integrate with environment so to conserve and improve the human health and natural ecosystem.

With this now in picture, the demand for energy will also increase which again means more Power stations. Coal has fuelled the generation of 41 per cent of the world’s electricity demand in the 21 st century so far, according to a fact sheet released by the World Coal Association. It is also to be noted that coal continues to be the world’s favourite and fast growing fuel. In fact, coal is expected to overtake oil as the world’s main source of energy for power production by 2020. To meet all above, automation is realised as a strategic choice in gearing for the future in the fastest possible way. This has enabled the automation sector to devote itself solely to the solution of real plant problems in real time.

Automation is realised as a strategic choice in gearing for the future in the fastest possible way. This has enabled the automation sector to devote itself solely to the solution of real plant problems in real time. 52 • May 2016

Studies are being conducted and various conventions are taking place as how to make our environment more & more clean to breath and live. Some of the efforts towards Green Engineering are: 1. Reduction of fugitive emissions from plants 2. Optimisation of the plant operations 3. Water & Wastewater treatment technology (Read the complete article on www. cewindia.com, the title of the article)

Author’s Details Vivek Gupta General Manager & Head – Instruments DCM Shriram Ltd Email: vivek_gupta@dcmshriram.com Chemical Engineering World

Features CEW Technical Article

Blast Resistant Building The need for blast resistance in the plant buildings (substation and/or control room) within the petrochemical industry has evolved over recent years, taking into consideration the increased need for safety precautions. Petrochemical processes have become more complex with enhanced capacities, thus increasing the risk of accidental explosions. In the past, such explosions have demolished the plant buildings resulting in substantial casualties and business loss. Such incidents have heightened the concerns of the industry, plant management, and the regulatory agencies, prompting consideration for blast protection in such plants.

1. Objective of Blast Resistant Building Design The primary objectives for providing blast resistant design for the buildings are: 1.1 Personnel Safety: Past incidents have shown that many fatalities and serious injuries were due to the building collapse and the objective would obviously be to minimise the probability of this during an explosion. 1.2 Cascade Failure: Another objective of considering blast resistant building design is preventing cascading events in the other process units, which are not involved in the explosion. One primary reason for this could be failure of process control systems housed in the affected building. 1.3 Financial Consideration: Any infrastructure which would constitute significant interruption or financial loss to the owner if destroyed should be protected. 2. Process for Evaluating the Requirement of Blast Resistant Building 2.1 Blast Resistant Design Process: The overall process involved in the evaluation and design of petrochemical plant buildings for explosion hazards is illustrated in Figure 1. This flowchart shows fifteen basic steps in the overall blast assessment and design process, as follows: a. Define Scope: Steps 1 & 2 are to define the ownerâ&#x20AC;&#x2122;s requirements and needs for the building. b. Analyse the Explosion Hazards: Steps 3 and 4 are to identify the Chemical Engineering World

explosion scenarios to be used to quantify the design blast overpressures. Performance Criteria: Step 5 is to determine how the building should perform during the explosion scenario. Determine the Blast Loads: Step 7 is to determine the blast loadings for the various components of the building. Structural System, the Material and the Response Criteria: Steps 6, 8 and 9 are to choose the structural materials and systems for the building and the associated structural properties and

response limits consistent with the performance requirements for the building. Structural Analysis & Component Design: Steps 10 to 12 are to select and perform the level of structural calculations appropriate for the particular situation. Finalise and detail the design: Steps 13 to 15 are to proportion and detail building components and document design.

It is expected that the owner will directly provide items a, b and c (steps 1 to 5),

Figure 1: Process for evaluating the requirement of blast resistant building

May 2016 â&#x20AC;˘ 53

CEW Features with Center for Chemical Process Safety Committee (CCPS) Building Guidelines, CCPS Explosion Guidelines, and API RP-752 providing guidance. The design engineer’s responsibilities fall between d to g (steps 6 to 15) of the process, and these are the main focus of this article. 3. Location of Blast Resistant Building: The location of a typical plant building is unlikely to be based upon a single factor. Hazards, exposures, future expansions and spacing establish the selected site. Hazards in the adjacent and nearby processing operations and the possible results of an incident involving these hazards must be considered as well. The blast resistant buildings should be located in a way to meet the appropriate guidelines for fires such as those in IRI 1984 and company engineering practices. Blast protection can be provided by adequate spacing from a potential hazard or by strengthening the building. Spacing should be the primary choice in providing blast protection. One should consider following while locating buildings: a. The building should be oriented such that the short side faces the most probable explosion source to reduce the blasting force on the building and minimise the overturning effect. b. Any building personnel are not required for actual operation of the unit and must be located as far away as possible. c. The building has to be located away from areas of congestion and confinement as these contribute to the severity of the explosion. d. This building should not be located downhill from potential release sources of heavier than air materials. 4. Buildings Requiring Blast Resistant Design: The decision regarding blast resistance requirements is made by the owner. It may be through standard practices or by following a site specific methodology as described in Center for Chemical Process Safety committee (CCPS) building guidelines or API RP-752 (Guidelines for evaluating plant building). Both decision mechanisms may employ a plant 54 • May 2016

Figure 2: Pre-fabricated Blast resistant substation

classification or categorisation approach based on the severity of blast hazards.

Figure 3: Blast resistant building under construction (Image courtesy: Safety Integrated Engineering Solutions)

The requirements for the buildings are greatly influenced by the factors of distance from the blast source, criticality of functions, and expected occupancy. When a building or installation is located within the blast radius from the blast source, the building is exposed to damaging over-pressures. A blast resistant building design is then recommended if either of the following apply: • The building meets the owner occupancy criteria (API RP-752) • The building or installation is expected to perform critical services.

The foundations or floor slabs should not be elevated or constructed with an open ventilated space beneath the building. Unless specifically designed for the additional blast load, air-conditioning units should be located either on the ground floor or in the basement, and not on top of the building. Hand-operated fire extinguishers should be installed strategically throughout the building, especially close to all the exit areas. The fire-fighting water hose reels shall not be installed in the building. Fire suppression FM200 / Inergen system shall be used for firefighting.

4.1 Configuration of Blast Resistant Building: The blast resistant building should be as compact as possible, rectangular in shape without reentrant angles or protruding canopies. The roof can be flat or have a maximum pitch of 10°. The overall height of the building and the flat span of the roof should be minimized to limit the effects of an explosion. Roofs should not be covered with gravel, loose concrete tiles or other objects that could become flying hazards in the event of an explosion.

4.2 Structural Design: The structure of the building, as well as all related components, such as windows, panes, and doors, has to be designed to withstand the blast loads and deform within the prescribed limits. The table below indicates the three response categories of deformation. The ‘Low’ response range can be used for Control Rooms, FARs (Field Auxiliary Room) and occupied buildings. The “Medium” response may be used for substations and analyser houses. The “High”

Response

Description

Low

Localised building/component damage. Building is still capable of fulfilling its functional requirements. Minor repairs may be required. Total cost of repairs is moderate.

Medium

Widespread building/component damage. Building cannot fulfill its functional requirements until repaired. Total cost of repairs is significant.

High

Building/component has lost structural integrity and cannot fulfill its functional requirements It may collapse due to environmental conditions (e.g., wind, snow or rain). Total cost of repairs approach replacement cost of building. Chemical Engineering World

Features CEW response should be used for sheds and compressor houses. d. 4.3 Material and Component Properties: The brittle constructions, such as unreinforced concrete, pre-stressed concrete, un-reinforced masonry (bricks or blocks) and cement based corrugated panels, should not be used for load carrying components of blast resistant buildings. The reinforced concrete or fully grouted reinforced masonry of appropriate strength and thickness should be used as external wall construction. Materials with many joints, those subject to large thermal movements/cracking or which are difficult to seal, such as profiled metal sheeting, should be avoided. 4.4 Ancillary and Architecture Items: 4.4.1 Blast Doors: The following common requirements shall be applied to resist blast loads as general practices: a. For the blast loading (peak sideon over-pressure) between 5 kPa and 20 kPa, blast resistant doors should be used. b. For the blast loading (peak sideon over-pressure) between 20 kPa and 65 kPa, enhanced blast resistant doors should be used.

Blast resistant doors shall be provided according to the following requirements: In large buildings which need more than one exit door according to the requirements of the local building codes, at least two doors should be designated as exit doors. This is for the purpose of limiting the damage to these doors when subjected to blast loads. Designated exit doors must not be located on the same side of the building. Air locks need to be installed to maintain the required over-pressure inside the building. All outer doors should be provided with automatic door closers. The emergency exit(s) must be installed at the rear or sides of the building, not facing the process area. If it is only to be

Chemical Engineering World

e. f.

used for emergencies, then the exit door does not need an air lock. No windows should be provided in the outer doors; only small peepholes must be provided to check that in the event of fire, the area outside the door is safe for evacuation. Door frame shall be integral part of the wall. Blast door manufacture shall provide Figure 5: Blast Resistant Window (Image courtesy: Portal San Francisco)

• •

Figure 4: Blast Resistant Doors (Image courtesy: Vulcan Industries LLC)

calculations or type test data/ certificate to verify adequate blast resistance and door performance for the design load conditions. The outer & inner doors shall have good seal between doors and frame to maintain the different pressures between the various rooms and outside of the building. At least, one of the external doors shall be big enough for handling switchgear / cabinet.

4.4.2 Windows: The following common requirements should be applied to resist blast loads as general practices: a) For the blast loading (peak side-on over-pressure) between 5 kPa and 20 kPa, laminated safety glass and catch bars should be used and the pane area should be < 1 m 2. b) For the blast loading (peak side-on over-pressure) between 20 kPa and 45 kPa, resilience in the structure and structural components should be provided. The laminated safety glass and catch bars must be used and the pane area must be < 1 m 2. If the building is being designed to be blast resistant, the following rooms are considered essential for controlling the operation of the plant, and should have no windows

• • •

in the outer walls: The electrical equipment and battery room The heating, ventilating and airconditioning machine room The air locks The first aid compartment or room Control room

4.4.3 Exterior Wall Penetration: a. The wall and the roof penetrations in reinforced concrete and masonry should be sleeved. The sleeve can be bonded tightly with the reinforcement in order to hold the position of the sleeve during blast. b. The penetrations in metal clad structures should be anchored with substantial framing attached to structural steel members. c. Holes need to be provided for possible future cable penetrations. These holes shall be positioned in a way as to clear the reinforcement bars in the walls. d. The openings have to be sealed in a manner that provides a fire rating similar to the wall, roof or floor they penetrate. e. All the service entries have to be sealed to be gas and water tight (unless otherwise specified). f. The holes for cable entries need to be sealed gas and water tight. Multi Cable Transit (MCT) blocks or acceptable alternatives should be used. Unused cable entries must be closed with a manufactured closure (in the case of MCT with spare solid blocks). g. The other entries into the building should be made below ground level and above ground water level at such a level as to exclude any chance of May 2016 • 55

CEW Features be secured to structural framing members. Anchorage should remain secure during design blast loading.

Figure 6: MCT (Image courtesy: North London Electricians)

Figure 7: Blast Resistant Valve (Image cour tesy: Daloc Shelter)

rainwater, fire-fighting water, oil, liquefied gas or other liquids finding their way into the building. Bus duct shall be of sandwiched type and shall enter from below the substation via transit frame. Blast resistant valve shall be used in HVAC ducts passing through the external wall of building.

4.4.4 Suspended Items: The aluminum grid ceiling, the light fixtures, and the diffusers should be constructed or suspended in such a way that the panels are secured in position and cannot fall down during an explosion. The equipment and furnishings such as ceilings, HVAC ductwork, and the light fixtures suspended from the roof inside the building shall 56 â&#x20AC;˘ May 2016

4.4.5 Externally Mounted Items: To avoid the potential for hazardous debris, large non-structural features such as canopies and signs on the building exterior have to be minimized. However, small items such as instruments, fire alarms, lights, strobes and beacons may be mounted on the exterior walls. No auxiliary equipment, unless otherwise specified, (e.g., HVAC equipment) should be installed on the roof or walls, other than intake and exhaust facilities. Only the air intake and exhaust facilities, fresh air intake stack, aerials, TV cameras and similar equipment should normally be placed on the roof. Transformer/DG set shall be placed outside, away from the blast direction. 4.4.6 Interior Items: The entire fixed floor supported items, such as lockers, electrical cabinets, racks, etc. need to have a minimum clearance from the exterior walls, equal to the maximum calculated lateral blast load deflection. Wall tiles must be avoided or glued firmly to the wall with special tile adhesive, to prevent them from coming loose in the event of an explosion. Wall mounted panel is not possible to fix in blast resistant RCC wall hence panel shall be mounted on selfsupported structure. 4.4.7 Floors: The top of the finished ground floor of the building should be at least 600 mm (2 feet) above the surrounding ground level. Underground cables entering the basement should be covered with a layer of sand of 600 mm (2 feet) minimum thickness. Cable entry to panel is always a challenge with short span of column and several beams in blast resistant construction, requirement of dummy panel shall be carefully identified during designing.

4.4.8 Walls and Ceiling Finishes: All the surface finishing materials for walls and ceilings in the control room, the computer room, and the instrument auxiliary, computer basement or room, have to meet the fire resistance rating of the local building code. Fire resistance should meet the material requirements of construction and composition listed by Underwriters Laboratory, a worldwide safety consulting and Certification Company. In these spaces, the surface of all walls, ceilings and floors, where dust is liable to accumulate, must be sealed with epoxy paint or PVC coating. 5. Cost comparison between normal RCC building and blast resistant building The commercial aspects of blast resistant building design depend on the distance of the substation from blast hazard and the pressure to be handled during blast. By rule of the thumb the cost of blast resistance RCC building is approximately 1.4 to 1.5 times cost of conventional RCC building, cost of prefabricated blast resistant building (substation / control room) is approximately 1.6 to 2 times cost of blast resistance RCC building. Blast resistant substations shall be designed for the blast intensity as specified by the owner meeting the structural response as desired.

Authorsâ&#x20AC;&#x2122; Details

Amit Gandhi Principal Engineer Aker Solutions India Kailas Tamore Lead Engineer Aker Solutions India Chemical Engineering World

Features CEW Opinion

World Economy is Not Moving, Needs a Bit of De-oiling!

conomists are rattled as price has dropped from over USD 100 to below USD 30 (now hovering around USD 45) for a barrel of Brent crude oil, in just about 2 years. Some may recall that the beautiful Columbian singer Shakira had sung a wonderful number during the 2010 FIFA world cup, the song was captioned Waka Waka. If she was to sing a theme song for the oil sector now, and trust me the industry can do with a bit of glamour, she would surely be chanting VUCA VUCA. VUCA is an acronym for Vulnerability, Uncertainty, Complexity and Ambiguity! The global churns have elevated, if I may, VUCA (which has its origins in the military) to describe a difficult war strategy, to our peace time commercial world. It is used to describe the inability to cope with or predict almost anything in the context of global business and more so in the oil sector. The past RBI Governor Dr Y V Reddy had once said that “In India it is not only difficult to predict the future but it is also difficult to predict the past”. That’s because our data collection methods were always questionable then. However, in the global context, in fact tables have turned, and today, India is at least seen somewhat as a stabilising factor. On the other hand, the world outside of India has become difficult to predict, even in the present! So Did It All Fall From the Sky? It is Einstein who once said that “The only reason for time is so that everything doesn’t happen at once”. It surely looks like it’s all fallen out of place together, but in my humble opinion, the imbroglio was building up. For the sudden drop in demand for oil and many other commodities, I am not referring Chemical Engineering World

to or addressing to the suspects like - the 8 year business cycle, the fuel efficient cars that have been entering the market, the soon to flow sanctions free Iranian oil or the challenge posed by the American Shale producers. Sure, they do add to the pain but I am going to list out the intangibles that have been silently building up that have led us here, to the sorry situation at hand. The 5 Factors that are Undoing the Global Order are: (A) De-globalisation: It is said that before the global financial crises of 2008, oil was traded 30 times before reaching its destination and price of oil which had reached its peak then, was predicted to even cross USD 200 a barrel. Since 2008, the world had never truly recovered. Data by CRISIL shows that trade used to grow at a speed, twice as fast as the GDP i.e., we had a frenzy economic activity and that dropped drastically vs. GDP in 2009 i.e., just after the infamous Lehman Brothers moment. Trade growth rose again briefly in 2010 due to the combined efforts by the leaders of G20 nations and yet again fell in 2011 to just match that of the GDP growth. Since then trade growth has retarded to just about keeping pace with GDP, from earlier being twice that of GDP. It may be interpreted as the desire by most nations, notwithstanding the promises made at the G20, to slowly shift inwards or sourcing more domestically to perhaps protect local jobs through imposition of both tariff and non-tariff trade barriers on imports. Also, the losses in stock markets in that era may have led to a consumption behaviour which was more need based and less speculative. (B) Financial Jugglery: Much of innovation had since last few years moved away from science and engineering into finance. To

keep up growth at any cost, practice of artificially low interest rates was followed by unbridled money printing as a reaction to the financial crises. That had to bring in long term volatility. Today, when the American Fed talks of increasing the rates, it automatically infuses fear of money being sucked out from the global monetary system. Further, the US dollar also gets stronger and making it that much more difficult for say low margin oil producers to get finance. On the other side of the world, export dependant emerging economies have been engaged in competitive devaluations in currency, adding to the trust deficit. On another level, country allocation are becoming less important and thus portfolio investments directed towards the BRICS nations lost interest in favour of huge unlisted companies or ‘Unicorns’. Also, disruptive technologies like the ‘FANG’ or Facebook, Amazon, Netflix and Google took the shine away from the conventional industry. (C) Unprecedented Wear and Tear in Democracy: All time high partisan politics among the democratic nations is not only slowing down even the most basic progress and reforms, but polarisation across the aisles is leading to an unprecedented acrimony between political parties. The same has been undermining the expected decorum in both national and international posturing. Public discourse has been finding new lows, hurting investor confidence more. Read the complete article on Shah’s blog - kevinmshah.blogspot.in/2016/03/.

Author’s Details Kevin M Shah Managing Director Kevin Enterprises Pvt Ltd kevins@kevincpp.com May 2016 • 57

CEW Market Insights

Technology for Nitration Acid Safe Treatment and Reconcentration

itric acid is used for the production of ammonium nitrate and calcium ammonium nitrate, which are used as fertilisers. A majority of the non-fertiliser use of nitric acid is for nitration which is the addition of a nitro group to an organic molecule. Nitration is needed for the production of explosives, fine chemicals, fibres, plastic raw material, dyes and perfumes which has usage ranging from automobile to footwear. The explosives produced using nitration are used for military, industrial and mining operations. Trinitrotoluene (TNT) and nitroglycerin are the two well-known explosives. TNT is also used in hydraulic fracturing for shale gas production. KBR Inc., USA, has recently acquired PLINKE GmbH, a German engineering company, which has roots in the invention of explosive acid treatment during the First World War. India is emerging as one of the countries with the highest growth in demand for these technologies. PLINKE is a world leader with more than 1,100 plants globally. PLINKE’s first plant in India came up in 1962. Currently, PLINKE is in discussion with various Indian companies for new plants. Technologies from PLINKE can be applied at clients’ processes that require pre- or high concentration of fresh or spent nitric acid, sulfuric acid and hydrochloric acid, as well as acid containing waste water. PLINKE also offers ancillary technologies that may be adopted on a caseby-case basis, depending on the client’s situation and objectives, including stabilisation of spent acids, bleaching, NOx absorption, etc. The Market According to Keith Bundil, CEO, PLINKE GmbH, the market for nitro compounds including explosive chemicals is growing, with new applications coming up. For example, explosives find applications as a propellant for airbags in automobiles, nitro-glycerine is widely used in pharma sector in breathing devices, and EHN is used as a diesel additive to enhance its cetane number. The producers of these nitro compounds are developing various new

58 • May 2016

applications. This is in addition to the well- known usage such as requirement of explosives for civil purposes like constructing dams, tunnels, etc. PLINKE’s customers use nitro compounds for polyurethanes (25%), nitric acid (15%), explosives (20%), fibres/lacquers (10%), chemical and other applications (30%). Bundil expects that there will be increased demand for all of these nitro compounds in India and the sector will grow at a rate higher than the country’s GDP. PLINKE has also shifted its focus on India. “Some 10 years back, our focus was on China; now this has shifted to India. All international companies, global industry associations, trade organisations are betting big on India, whether it is pharma, food, or any sector. India is a fast growing large economy in the world. We believe that India will emerge as one of the key drivers of global economic growth,” says Bundil. Business Environment Bundil also comments on the business environment and opines that India is not more complicated than doing business in any other country in the world. “With Indian Prime Minister Modi’s efforts, we hope to see higher industrial growth and increasing ease of doing business here. Indian industry has a very strong technical approach. While setting up the plants, engineers from India exchange ideas and needs at a very detailed level. This facilitates the flow of engineering know-how,” he adds further. According to Bundil, Indian industry is also focussed on cost. Bundil adds, “These technologies require use of exotic material for construction such as glass-lined steel, tantalum, niobium, silicon carbide and PTFE, which may not have been accounted for during budget phase. So, this requires discussing and maintaining balance between the technical standards, design criteria and the budget.” Bundil also rates Indian regulation positively and says, “Regulations in India are at par with other countries or are coming closer to the International regulations. Treaties such as the Chemical Engineering World

Market Insights CEW “Regulations in India are at par with other countries or are coming closer to the International regulations. Treaties such as the double taxation avoidance treaty help International businesses to collaborate with Indian businesses.” double taxation avoidance treaty help International businesses to collaborate with Indian businesses.” Plinke’s Technologies and Expertise PLINKE is a German engineering company with 69 years of experience, based on 100 years of acid treatment knowledge. Established in 1947, the founder of the company Adolf Plinke worked with Prof Pauling who was the inventor of concentration technology for sulfuric acid, during 1920s. With such a glorious past, PLINKE is a world leader with longest experience and widest range of applications. As per its estimates, it has 40 per cent of the global market share for these technologies.

As Bundil reveals, PLINKE’s technologies offer energy saving, environment protection, emission reduction, minimum effluent water, maximum safety for personnel and environment, maximum reliability and availability, and high quality product acid. “All PLINKE processes are in accordance with International and European Guidelines for environmental protection, energy saving and Integrated Pollution Prevention and Control (IPPC) using Best Available Techniques (BAT),” Bundil affirms. With its engineering expertise, the company offer lowest OPEX while fulfilling all international and local environmental standards.

staff and the environment. We provide intensive training to the maintenance staff in-house at PLINKE office and at the plant. We also offer simulation programme for safe, efficient and reliable operations. Our solutions are tailor-made for the plant. We can also offer training at other similar global plants,” Bundil concludes.

“Our process offers, as safely as possible, operational excellence for

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May 2016 • 59

CEW Market Insights

DNP International Acquires Tethys Instruments

NP International - a company specialised in design and development of industrial analyser systems, with several years of experience in design, development, commissioning and start-up of complete process analyser systems for almost any application – has acquired Tethys Instruments, SAS, a France-based organisation that develops, manufactures and sells online water and gas analysers dedicated to environmental and industrial process applications. TETHYS Instruments, created by its President Philippe Minghetti in 2003, forms a team having more than 20 years expertise in instrumentation and multidisciplinary skills in physics, chemistry, optics, software and electronics. Located in the middle of Grenoble Valley (France), in the Inovallée technological and industrial zone, TETHYS Instruments takes advantage of the dynamism and resources of largest French high technology cluster after Paris with: 4 universities, 62,300 students, and 15,000 researchers in more than 200 laboratories (CEA, CNRS, IRA…) Commenting on the acquisition, Uday Patel, Director, DNP International, said, “DNP has very strong background in sales and marketing of analysers and Tethys has state-of-the-art products which are manufactured at world class manufacturing facility at Grenoble, France supported by strong Research and Development team.” Patel opines that three is immense scope for these product and technologies in India. The Government of India has taken initiative to direct industries and sewage treatment plant

Tethys manufactures analyser based on UV Spectroscopy technique. It has state-of-the-art analysers for water and gas application. Tethys analysers have wide application for Environmental and Process related application in various Industrial and Municipal sectors. The company also boasts of a strong Research and Development centre at manufacturing facility at Grenoble, France. 60 • May 2016

(L-R) Uday Patel, Director, DNP International & Philippe Minghetti, President, Téthys Instruments SAS sings on acquisition agreement

to invest money to monitor and control the pollutant before discharge to nature. Further, other initiatives like ‘Clean River Ganga’ and ‘Smart City Project’ are likely to attract good investment for environment related analysers and monitoring systems in India. “Other emerging economy also faces lot of environmental challenges and we expect very good business growth for Tethys products. DNP would like to invest money in research and development of new innovative technology which meets present and future challenges of environmental monitoring,” Patel reveals. DNP International was founded and registered on 21st May, 2005 as a privately owned company. The priory activities are the sales and services of on-line analysers. Over the years DNP became a reputable full service Analyser Systems Integrator. It has a long list of satisfied customers in all most all segments of the markets like power, petrochemicals, refineries, steel plants, fertilisers, chemical plants, cement plants, pharma & biotech, oil & gas, water and waste water treatment plant, municipal sewage and drinking water treatment plant, sugar plants, etc. Chemical Engineering World

Marketing Initiative

Bredel APEX35 hose pumps improve quality and reduce maintenance costs - Flow consistency of APEX pumps aids process quality - APEX pumps run longer without maintenance - Maintenance also quicker and spares less expensive

lasting hose elements, and increase it pump uptime arrives as a consequence of selecting the right pump for the application.

he benefits of APEX35 hose pumps from Watson-Marlow Pumps Group are proving impossible to ignore in the US, where two leading plants are among the latest to adopt this new and innovative technology.

Advantag es to customers handling abrasives When handling abrasive substances, a major advantage of APEX hose pumps i s t h a t t h ey h ave n o c o s t l y w e a r i n g components like seals, valves, membranes, stators, rotors or glands to maintain. Selfpriming, dry running, and with no internal va l ve s , h o s e p u m p t e c h n o l o g y a l s o helps users improve their processes by eliminating troublesome ancillary items like anti-siphon valves, back-pressure valves, degassing valves or run-dry protection.

The New Braunfels, Texas plant of the Canyon Regional Water Authority is keen on sourcing an alternative to its progressive cavity (PC) pump to increase the accuracy of pH control. The potable water plant currently controls pH by dosing lime slurry using a PC pump, which runs for approximately 12-16 hours a day at a rate of 900 litre/hour. Reliable, consistent flow Watson-Marlow has supplied a Bredel APEX35 hose pump to the New Braunfels CRWA plant so that engineers can see the benefits of using a hose pump to handle the lime slurry. First of all, insufficient flow consistency of the PC pump is prone to causing fluctuations in the pH control, which means variations in water quality. Installation of the APEX35 hose pump with its stable and consistent flow means that these problems have already been eliminated. Another huge practical advantage of this new hose pump at the site is reduction in maintenance. The abrasive nature of the lime slurry means that maintenance is required on the PC pump every three months and takes up to five hours to complete. Furthermore, this often requires expensive consumables such as stators, rotors or linings. In contrast, the APEX35 pump has required no maintenance in its first six months of operation at CRWA, and when maintenance is finally required, it will take no more than 30 minutes, with the only consumable part being a single hose element. Chemical Engineering World

Direct comparison The outstanding success of the CRWA APEX pump trial was replicated at the plant of Addenda Corporation, which is in the process of comparing its existing hose pump to a new Bredel APEX35. Here the task involves the accurate transfer of a very abrasive, high solids, lead-based slurry between process stages. The existing hose pump and the APEX35 are being run under exactly the same process conditions, with flow at approximately 2500 litre/hour. The companyâ&#x20AC;&#x2122;s existing pump requires hose replacement ever y 8-9 months; a ver y acceptable and cost effective uptime period. The APEX35 pumps' hose replacement significantly is not expected before 14 months running is complete. This is thanks largely to the APEX design, which is optimised for medium pressure applications and long

Consequently, APEX hose pumps are perfectly suited for transfer and metering abrasive, corrosive, viscous, shear-sensitive, gaseous, crystallising fluids, or even fluids with a combination of these properties. Designed for longevity Another important factor in being able to reduce maintenance costs at Addenda is that the APEX35 requires 18% less hose compressions for the same volume transferred by the existing hose pump (which needs around 1500 strokes for each 1000 litres). Whatâ&#x20AC;&#x2122;s more, the direct coupled technology and self-supporting rotor on the APEX35 help maximise gearbox and bearing life to further add to the package of savings for the plant. Contact: Watson Marlow India Pvt Limited Survey 77/1, Z P Road, Malan Farms, Tathawade, Pune: 411033, T: +91 20 67356200, M: +91 7030611663 W: www.wmftg.in/com May 2016 â&#x20AC;˘ 61

CEW Products Condition Monitoring & Predictive Maintenance

Radiometric Thermal Imaging Camera

NORD Drivesystems offers drives with advanced condition monitoring capabilities that support predictive maintenance. NORD employs frequency inverters with an integrated PLC to monitor the complete drive system, evaluate sensor data, and assess the system state by means of intelligent algorithms. An industrial gear unit demonstrates the condition monitoring approach based on sensors and dedicated evaluation technology. Vibration and oil sensors provide crucial live data about the wear and tear. Vibration analysis then enables conclusions about the state of the bearings as well as the gearing, and oil analysis can help determine when the lubricant needs changing.

InfraTec offers its new ImageIR 10300. This model of the high-end ImageIR Series features the world’s first radiometric camera with a cooled detector of (1,920x1,536) IR pixels for industry and science. Compared to the ImageIR 9300, the sister model with its smaller SXGA detector, the pixel pitch has now decreased to just 10 µm. This news-breaking development for the IR camera Series has opened the door for InfraTec to create thermograms with unprecedented image detail and sharpness. At the same time the geometric resolution of greater than 3 Megapixels translates to a substantial increase in efficiency of testing extremely small micron sized structures on large targets. For details contact: InfraTec GmbH Infrarotsensorik und Messtechnik Gostritzer Str 61-63, Dresden 01217 Deutschland Tel: +49 (351) 871-8620 E-mail: thermo@infratec-infrared.com

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: jyoti.mishra@nord.com or Circle Readers’ Service Card 1

or Circle Readers’ Service Card 2

Industrial Gear Units NORD Drivesystems added a new size with 190 kNm output torque. The Series now comprises 9 sizes and covers torques from 25 to 250 kNm. The addition of the new size 14 units allows for configurations tailored even more precisely to individual applications. Featuring a single-piece UNICASE housing as is standard for all NORD gear units, they achieve a longer bearing life than gear casings from jointed parts and ensure efficient power transmission and high tolerance for load peaks and jolts. They can be assembled as two or three-stage helical inline or helical bevel gearboxes with nominal transmission ratios from 7.1:1 to 400:1, or even up to 30,000:1 with an auxiliary primary stage. The input and output direction can be freely selected. NORD industrial gear units can be mounted on any of the six sides. The manufacturer configures industrial geared motors for a diverse range of uses from steel works to process plants. Application-specific features and options include reinforced bearings and shafts, extra-large bearing distance, extended output shafts, and Drywell designs with an additional oil drip disc and a leakage oil display or oil sensor. Disc and drum brakes, dual-gear setups, auxiliary motors, IEC motor adapters, turbo couplings, axial fans, motor swing bases, torque limiting backstops, and cooling and heating systems are available as well. 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: jyoti.mishra@nord.com or Circle Readers’ Service Card 3

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Products CEW Valve Integrity Management Solution IRM Systems (IRMS) offers the Valve Integrity Management Solution (VIMS), an innovative method of maintaining critical pipeline valves to the highest performance standards and criteria that can save up to 70% in lost production, excluding the substantial cost of associated labour, equipment and specialists. VIMS was developed in direct response to the distinct lack of analysed data associated with valve integrity and maintenance in the industry. Following a comprehensive audit of the number - and condition - of all valves on a designated pipeline, IRMS logs and analyses the data, integrating it via the VIMS into the operator’s existing systems and processes. Data on individual valves and assets can then be immediately accessed, in order to review a full range of benchmarked factors in, for example, design, construction, maintenance and reliability. By using this standardised approach to valve integrity maintenance - which relies upon solid risk and reliability engineering – operators can make informed decisions about inspection plans and repairs, saving time and money. For details contact: IRMS UKWA Aberdeen, Scotland, U.K. Tel: +44 1224 224 416 E-mail: d.obatolu@irm-sys.com or Circle Readers’ Service Card 4

Flow Meter for Fuel Metering The meters Type OV have been developed especially for use in loading systems for tank trucks and tank cars. The sizes available and the materials selected are coordinated with the requirements placed on modern loading facilities for petroleum products (motor gasoline, diesel, fuel oil). The meters are suitable both for top and bottom loading facilities. Aside from the oval wheels, the loading meter contains no moving parts and thus no wearing parts. It is designed as a volume transmitter. Models are available in digital and mechanical display. It is approved for Custody Transfer and has the approval of Department of Legal Metrology - W & M Certification. It is non-sensitive to vibrations, pulsations and pressure changes, and has high long term stability. 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 5

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CEW Products Online Calculation and Configuration

Troubleshooting with Active Thermography

Fabrication and assembly is now simplified by the ‘release’ operation by a gas detector. Using the Quintex program, allowing the parameters to be quickly set which then automatically ‘select’ the required enclosure type and size calculating the price instantly for the created system using standard ‘off-the-shelf’ components.

Complex analysis algorithms within IRBIS 3 active form the basis for gaining more robust results. The software allows for the superimposition of different views at the pixel level, such as time with domain images, layout or visual images with amplitude or phase images. This enables the successful and precise pinpointing of abnormalities at their location. Users can easily adjust the desired degree of image superimposition using the menu. The values for a selected measurement point can also be viewed separately for all angles of measurement. Simultaneous zooming for the respective views is even possible.

Using “Calculation for pressurised enclosures” one can configure a system suitable for operation in an Atex Zone 1 or 2, gas or dust environment certified area by calculation. Quintex have already paved the way with their SPZ Series standard sized enclosures (specific for connections under low pressure) to allow all customers to carry out their own installations and assemblies using an approved overpressure system that is already approved and certified for use without any necessary flushing phase or pre-set requisites. For details contact: Quintex GmbH i_Park Tauberfranken 13, Lauda-Königshofen Baden-Württemberg 97922, Germany Tel: +49 (9343) 6130-118 | Fax: +49 (9343) 6130-105 E-mail: anja.budow@quintex.inf or Circle Readers’ Service Card 6

The test management feature of IRBIS 3 active allows various parameter settings to be set easily, neatly organized and quickly retrieved. This shortens the preparation time and ensures that measurement tasks can be performed by different processors under identical conditions. For details contact: InfraTec GmbH Infrarotsensorik und Messtechnik Gostritzer Str 61-63, Dresden, 01217 Deutschland, Germany Tel: +49 (351) 871-8620 E-mail: thermo@infratec.de or Circle Readers’ Service Card 7

Multi-Gas Monitors Industrial Scientific offers the Ventis Pro Series multi-gas monitors. The Ventis Pro Series is backed by the industries only guaranteed for life warranty and offers a wide range of sensor options to detect up to five gases. The Ventis Pro4 is compatible with four of the following sensors: LEL/CH 4, O 2, CO, CO/H2 Low, H 2S, SO 2, NO 2 or HCN making it ideal for industries such as fire service, steel and construction. The Ventis Pro5 detects up to five gases including any covered by the Pro4 in addition to NH 3, CO 2/hydrocarbon IR, CO 2/ CH 4 IR and CO/H 2S. Industries such as oil and gas, petrochemical, power generation, metal and coal mining, gas utilities and refrigeration, which typically need a larger five-gas instrument, can easily transition to the smaller, lighter Ventis Pro5. Both the Ventis Pro4 and Pro5 are equipped with a variety of new safety features that raise the bar on worker safety. iAssign Technology tracks users and sites in real-time using Near Field Communication (NFC) to help safety managers identify and address jobsite gas hazards and improve asset management. A dedicated panic button and man-down alarm help to alert nearby workers when someone is in distress or has lost consciousness. Acknowledgeable gas alerts let users know when they are in the presence of gas below the low alarm level enabling them to take safety precautions while continuing to work. Alarm action messages provide written instructions during low and high alarm events, helping workers to react appropriately. For details contact: Industrial Scientific Corpn 1 Life Way, Pittsburgh, PA 15205-7500, U.S.A. Tel: (412) 788-4353, (412) 788-4353 | Fax: (412) 788-8353 E-mail: ekeblusek@indsci.com or Circle Readers’ Service Card 8

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Products CEW Digital Earth Resistance Tester Kusam-Meco offers digital earth resistance tester, Model KM-1520. It can be used for earth resistance measurement by 3 terminal method and earth voltage measurement. This meter display is 2,000 counts. The ranges are 0-20/0-200/0-2,000 with accuracy ±2% rdg +2 dgt. Earth voltage range is 0-200 V AC (40-500 Hz) with 1% rdg +2 dgt accuracy. In this meter low battery indication is shown as ‘B’ symbol, which appears on the display and for data hold DH, over load indication “1”. This meter’s measuring current is 2 mA, which permits earth resistance to be tested without tripping earth leakage current breakers in the circuit. It is battery-operated. To conserve the battery when not in use, it has auto power Off function. The timer operates automatically about 3-5 minutes after the Push Button Switch and Timer On buttons are pressed together. This will keep the test On for about 3-5 minutes then auto power Off. It has also data hold function. It is small and light in weight and meets IEC 1010 CAT.III 200 V safety. It has power source of 1.5 V x 6 batteries and dimension is 163 x 100 x 50 mm (L x W x D) with 480 g approximate weight. This meter is supplied with test leads auxiliary earth bars, heavy-duty case, instruction manual and batteries. For Details contact: Kusam Electrical Industries Ltd G-17 Bharat Indl Estate, T J Road, Sewri (W), Mumbai 400 015 Tel: 022-24124540, 24181649. 24156638 | Fax: 91-022-24149659 E:mail: kusam_meco@vsnl.net or Circle Readers’ Service Card 9

LPG/Natural Gas 2nd Stage Regulators Mesura of France, a leading manufacturer of gas regulators, systems and services for regulating and measuring of natural gas, and Nirmal Industrial Controls Pvt Ltd, India’s leader in the field of high pressure regulators, slam shut valves and gas conditioning, pressure regulating and metering stations set up a JV, Mesura Nirmal Gas Controls Pvt Ltd, offers highly accurate, ruggedly constructed, attractively priced and ex-stock delivery of LPG and natural gas regulators. Safety shut-off devices can be supplied in a gas train. Regulators are wellprotected against corrosion with consistent powder coating. It has extreme temperatureresistant diaphragms, SS screws and bolts, and 1/4” connections for inlet pressure gauge of 1 to 17 Bar/outlet pressure gauge of 30 to 300 mBar, 30 Nm3/hr of LPG flow, and 1/2” x 1” NPTF end-connection. Flows tested in accordance with UL144. The Cavagna Group’s top-line of LPG regulators for residential, commercial and industrial use is also offered by the JV. It is the 2nd stage regulator for residential gas banks. Suitable for commercial use in hotels, malls, hospitals, IT parks, educational institutes and ideal for use after 1st stage directly to the inlet of user appliance or in installations with Pressure Governors. It finds application in hot air generators, furnaces, gas engines, burners and boilers, painting, powder coating, glass and ceramic, food, agriculture, automobile and foundry industry. For details contact: Nirmal Industrial Controls Pvt Ltd Samriddhi Bldg, 1st Floor LBS Marg, Mulund (W), Mumbai 400 080 Tel: 022-67746282, 67746200 E-mail: tawde@nirmalindustries.com / vrushank.shukla@mesuranirmal.com or Circle Readers’ Service Card 10

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May 2016 • 65

PRESENTING ARC’S FOU RTEENTH I N DIA FORUM

Industry in Transition: Navigating the New Age of Innovation J U LY 7 - 8 , 2 0 1 6 • B A N G A L O R E

FEATURED TOPICS: Industrial companies in India are beginning to move beyond the computer-enhanced business models of the late twentieth century. Many are embracing new models that take advantage of intelligent connected products coupled with potent software and analytics. Expect to see innovations in smarter products, new service and operating models, new production techniques, and new approaches to design and sourcing. Also anticipate changes throughout the value

IMPROVING ENERGY EFFICIENCY ADVANCE CONTROL STRATEGIES SMART GRID AND SMART CITIES COLLABORATION AT THE USER AND DEVICE LEVELS

competitors and new threats.

MANAGING LEGACY AND AGING INFRASTRUCTURES

ARC Advisory Group’s Fourteenth India Forum for process and discrete

3D TRAINING AND SIMULATION

network with new partners and new opportunities, along with new

industries is a not-to-be-missed event for all stakeholders – technology solution providers, end users, industry trackers, decision and policy makers, and the media. In an advanced automation and informationdriven world, terms such as Industrial Internet of Things (IIoT), Smart

SOCIAL MEDIA ADVANCED ANALYTICS AND BIG DATA

Manufacturing, Industrie 4.0, Digitization, and Connected Enterprise,

CLOUD COMPUTING

are clearly moving past the hype stage to the point where real

IMPACTS OF MOBILE COMPUTING

solutions are emerging backed by strong associated business cases. This is the new age of innovation. Join us at ARC’s Fourteenth India forum to learn more about how this industrial transformation will unfold. Discover what other companies are doing today to prepare for the new age of industrial innovation and how they expect to improve their business performance by doing so. TO REGISTER: Space Is Limited! Call India +91-80-2554-7114 or USA +1-781-471-1000, Register on-line at www.arcweb.com/events/arc-industry-forum-india/, or e-mail ramang@arcweb.com.

V ISION , E XPERIENCE , A NSWERS

FOR I NDUSTRY

ENTERPRISE AND PLANT ASSET MANAGEMENT SUPPLY CHAIN MANAGEMENT INCLUDING SERVICE LIFECYCLE MANAGEMENT CYBERSECURITY AND SAFETY

Oil & Gas World Expo 2016 Concurrent Events: SMP World Expo, EnerTECH World Expo Dates: 3 – 5 March 2016 Venue: BC&EC Mumbai, India Details: Platform to showcase services, technologies, innovations and current & future trends of entire value chain of hydrocarbon industry. Contact: +91 22 40373636 Email: sales@jasubhai.com Website: www.chemtech-online.com Watertech India 2016 Dates: 15 – 16 September 2016 Venue: New Delhi Details: An event for water, wastewater and solid waste management products/ technologies/services Organiser: Messe Frankfurt Trade Fairs India Pvt. Ltd. Contact: +91-22-6144 5900 Email: prashant.lade@india. messefrankfurt.com Website: www.watertechindia.com

Chemcon Europe Understanding the Global Petrochemical Industry Dates: Sep 30-Oct 02, 2014 Venue: London, UK Details: The conference will cover impact of shifting feedstock slates: shale gas and oil, coal, and bio-based feeds are expanding feedstock options worldwide Organiser: IHS Inc Contact: 000 8000 016 775 (Toll Free) Website: www.ihs.com

Chemspec South East Asia - 2016 Dates: 30 Nov to 01 Dec, 2016 Venue: Queen Sirikit National Convention Center, Bangkok, Thailand Details: Exhibitions for the fine and speciality chemical industry Organiser: Mack Brooks Exhibitions Asia Ltd Contact: +66 (0) 2684 6894 Email: wendy@mackbrooks.com Website: www.chemspec-southeastasia.com

India Chem 2016

SOMChE - 2016

Dates: 1 – 3 September, 2016 Venue: Bombay Exhibition Centre, Mumbai Details: Event of chemicals and petrochemicals industry in India in its 9th edition Organiser: FICCI Contact: +91 22 2496 8000 Email: vishal.ganju@ficci.com Website: www.indiachem.com

Dates: 1-3 December 2016 Venue: Miri Marriott Resort & Spa, Malaysia Details: an established platform for chemical engineers from academia and industries to disseminate their latest research and to highlight new technologies. Organiser: Curtin University, Sarawak Malaysia Contact: +60 85 44 3939 Email: somche2016@curtin.edu.my Website: www.curtin.edu.my

Automation 2016

The 2016 Automation Summit

Dates: 22 – 25 August 2016 Venue: Bombay Exhibition Center, Mumbai Details: Automation 2016, a four day automation event is set to introduce new and upcoming technology this year Organiser: IED Communications Ltd Contact: 91 22 22079567 Email: jyothi@iedcommunications.com Website: www.iedcommunications.com

Dates: 27 – 30 June, 2016 Venue: Las Vegas, USA Details: Siemens Automation Summit – A User Conference. All areas of industrial automation will be covered including factory, process, motion, and drives. Organiser: Siemens Industry, Inc Contact: +1 800 241 4453 Email: rich.chmielewski@siemens.com Website: usa.siemens.com/summit

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May 2016 • 67

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 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 ascertained. 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, ortho anisidine/para anisidine from 100-TPM to 1,100-TPM, ortho 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 CPP. 10-MW power requirement is to be met from MGVCL and 10-MW from the CPP. The effluent will be treated in proposed effluent treatment plant. Saras Plywood Products is planning a 60-TPM urea formaldehyde resin manufacturing plant in New GIDC Gundlav, district: Valsad, Gujarat. The existing land area is 1.5 acres. The estimated cost of the project is ` 7.5-million. Kalyan Industries is the equipment supplier. The project is waiting for environmental clearance. Civil work will commence in 3 months. The project is planned for completion in this year. According to SEIAA sources, the company has proposed primary treatment plant followed by evaporator for treatment of industrial effluent and has also proposed a multi-cyclone separator. FMC India is planning an expansion of its chemical manufacturing unit at IDA Patancheru, district: Medak, Telangana. The estimated cost of the project is ` 17.5-million. As of September the project was waiting for the environmental clearance. According to MoEF sources, the plot area is 4.027 acres. The company proposes to manufacture 50-TPM of products as part of the expansion. Green belt on 33 per cent of the land area will be developed and maintained. Power requirement will be made available through SPCPDCL. The project will be completed within 2 years. Globex Laboratories (R&D) proposes a pigments manufacturing unit at village: Dabhasa, district: Vadodara, Gujarat. According to MoEF sources, the project will come up in the existing land on 9,312-sq m. Kadam Environmental Consultants, Vadodara is the environmental consultant. The project will entail manufacture of 40-TPM red pigments, 40-TPM yellow pigments and 450-TPM dilute phosphoric acid. Environment clearance has been obtained for the products – red pigments and yellow pigments. Construction work has begun, as EC and NOC have been received. Effluents generated will be treated in effluent treatment plant having MEE. The company has applied for Amendment in Environmental Clearance dated 26th September 2012 68 • May 2016

for change in fuel from LDO to agro waste briquettes and addition of one raw material, ie, phosphoric acid and generation of dilute phosphoric acid (25 per cent basis) as by-product. Bohra Industries is implementing an expansion of its chemical and fertilizer manufacturing unit at Umarda, district: Udaipur, Rajasthan on 14,500-sq m of existing land. The project will entail expansion of single super phosphate capacity from 400-TPD to 600-TPD, granulated super phosphate from 200-TPD to 300-TPD and addition of new products namely 150-TPD triple super phosphate, 550-TPD synthetic gypsum, 30-TPD di-calcium phosphate, 160-TPD phosphoric acid, 0.3-TPD potassium fluoride, 150-TPD H2SO4 and 0.3-TPD sodium tri poly phosphate (STPP). Machinery has been ordered from China. Civil work is in progress. The project is scheduled for completion in 2018. Ami Lifesciences proposes expansion of its synthetic organic chemicals manufacturing unit (viz, pharmaceutical bulk drugs and drug intermediates) from 65.70-TPM to 131.60-TPM in Padra, district: Vadodara, Gujarat. The estimated cost of the project is ` 87.046-million. Environmental Consultant to this project is Envisafe Environment Consultants. According to MoEF sources, total plot area is 23,760-sq m (existing 10,270-sq m and 13,490-sq m for expansion). The unit currently manufactures 2-TPM 1-Acetyl Naphthalene, 1-TPM 2-Acetyl Naphthalene, 6-TPM Itopide HCl, 1.20-TPM Loxapine Succinate, 0.30-TPM Amoxapine, 6-TPM Venlafaxine, 6-TPM Progunil HCl, 6-TPM CB-2-L-Valine, 0.60-TPM Nateglinide, 0.60-TPM Quetiapine, 24-TPM Carbomazepin and 12-TPM Oxacarbomazepin. The expansion will involve addition of new products. Water requirement from ground water source will be increased from 34.53-cu m/day to 181-cu m/day after expansion. Effluent generation will be increased from 9.35-cu m/day to 79.5cu m/day after expansion. Highly concentrated effluent will be sent to captive incinerator for incineration. Remaining effluent (70-m3/day) will be treated in the ETP comprising primary, secondary and tertiary treatment. Treated effluent will be sent to CETP for further treatment. ETP sludge, inorganic residue and incineration ash will be sent to TSDF. Spent carbon, organic residue will be sent to incinerator. Adi Finechem is planning a 40-TPA specialty products manufacturing project on a 2-acre land at an estimated cost of ` 400-million in village: Chekhala, district: Ahmedabad, Gujarat. The project is waiting for environmental clearance. RSPL is planning a 1,500-TPD soda ash plant and 40-MW captive power project in village: Kuranga, district: Jamnagar, Gujarat. Land acquisition is in progress. 85 per cent of land has been acquired. The project is waiting for environmental clearance. The entire project is planned for completion in 5 years from zero date. Chemical Engineering World

Project Update CEW • MINING Metabluu Power, a sister concern of Minera Udyog India, is planning a 75,000-TPA iron ore mining project in village: Devikonda, district: Karimnagar, Telangana. The project is awaiting Government approval. Aryan Ispat & Power is planning an expansion of its coal washery in village: Bamoloi, district: Sambalpur, Odisha. The project will come up in the existing 204.65-acre integrated steel plant premises. The capacity of the project is to be augmented from 0.70-MTPA to 5.70-MTPA. The cost of the project is ` 600.7 million. The project is awaiting environmental clearance and planned for completion in 1-year from zero date. According to MoEF sources, the expansion is based on heavy media cyclone (wet process) technology. The washery will produce washed coal of an average ash around 34% (GCV 4,350-Kcal/kg), middling (ash content about 58%) of GCV around 2,350-Kcal per kg useable as fuel in FBC boilers. The proposed expansion will be the state-of-the-art with close circuit water system, classifying cyclone, high frequency screens, thickener and multi-roll belt press filters. Power requirement of 5-MVA will be sourced from its own power plant connected with the Grid Corporation of Odisha. NTPC is planning the Kudanali-Luburi coal mining project in district: Angul, Odisha. The company has signed an agreement on June 15, 2015 with Jammu and Kashmir State Power Development Corporation (JKSPDCL) for promoting a joint venture company with 67:33 equity participation for undertaking exploration, development and operation of jointly allocated Kudanali-Luburi Coal Block at Odisha by the Ministry of Coal. DSP Associates is planning a 15,17,600-TPA sand (minor mineral) mining project in the mines of Tikola-1 Sand Unit at village: Tikola, district: Gurgaon, Haryana. Mining lease area is 42.50-hectare. The estimated cost of the project is ` 55-million. The project is waiting for environmental clearance. Mining work is expected to commence soon. According to MoEF sources, out of the total area, 31.50-hectare area falls in the river bed and 11-hectare area falls in agricultural land (outside river bed). Method of mining will be opencast semimechanized without drilling and blasting. The mine will be excavated out in layers up to a depth of 3-m in riverbed and 9-m in agricultural field. Letter of Intent (LoI) for mining contract has been granted for a period of 9 years. • NON-CONVENTIONAL ENERGY Viaton Energy, promoted by the 3F Group and Creative Group, is planning a 10-MW power project in Punjab. Discussion is in progress with the Government for allocation of site. The company is already operating a 10-MW biomass-based IPP at village: Khokhar Khurd, district: Mansa, Punjab from July 2013. The generated power is being sold to the Government of Punjab. Hubli Electricity Supply Company is planning solar RTPV grid connected power plants in district: Belagavi, Karnataka. E-tenders have been floated to design, manufacture, supply, installation, testing and commissioning of solar RTPV grid connected power plants on roof-tops of 31 HESCOM office buildings in Belagavi Zone Jurisdiction for total load of 136-KWp including

It is time to Migrate to an advanced Structural Analysis Software

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operation and maintenance for a period of five years. The approximate amount put to tender is ` 18.62-million.

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

Email: sales@iges.in

www.iges.in TOLL FREE : 1800 102 4437 May 2016 • 69

CEW Book Shelf A Working Guide to Process Equipment, Fourth Edition Author/s: Price: Pages: Publisher:

Elizabeth T Lieberman, Norman P Lieberman ` 4,831.20 624 (Hardcover) McGraw-Hill Education

About the Book: Applicable to a broad range of technicians and industries and fully updated throughout, A Working Guide to Process Equipment, Fourth Edition, explains how to diagnose, troubleshoot, and correct problems with chemical and petroleum refining process equipment. Nine new chapters cover Tray design details, Shell-andtube heat exchanger design details, Relief valve system design, Vapor lock and exchanger flooding in steam systems, Steam generation operating and design details, Wastewater strippers, Thermodynamics - how it applies to process equipment, Centrifugal pumps - reducing seal and bearing failures, Hand calculations for distillation towers and Vapor - liquid equilibrium, absorption, and stripping calculations Filled with examples and illustrations, this practical resource demonstrates how theory applies to solving real-world plant operation problems. Selected hand calculation methods are also provided.

Plant Equipment & Maintenance Engineering Handbook Author/s: Price: Pages: Publisher:

Duncan Richardson ` 7,990.00 592 (Hardcover) McGraw-Hill Education

About the Book: This practical, one-of-a-kind field manual explains how equipment in industrial facilities operates and covers all aspects of commissioning relevant to engineers and project managers. Plant Equipment and Maintenance Engineering Handbook contains a data log of all major industrial and power plant components, describes how they function, and includes rules of thumb for operation. Hundreds of handy reference materials, such as calculations and tables, plus a comprehensive listing of electrical parts with common supplier nomenclature are also included in this time-saving resource.

Oil Refining & the Petroleum Industry Author/s: Price: Pages: Publisher:

Matthew P Brouwer ` 4,440.13 146 (Hardcover) Nova Science Publishers Inc

About the Book: he U.S. petroleum refining industry experienced what some have called a “golden age” during the years 20042007. During this period, the demand for petroleum products, especially gasoline, increased rapidly both in the United States and world markets. Refiners found favourable price-spreads between heavy and light crude oils, as well as between crude oil and refined products. The industry operated plants at nearly maximum capacity and posted record profit levels. This book examines current production capacity of refineries operating in the US and the sources and changes in crude oil supply; the changing characteristics of petroleum and petroleum product markets; and, a discussion of the policy and regulatory factors that are likely to affect the structure and performance of the industry during the next decade. 70 • May 2016

Petroleum Refining Technology Author/s: Price: Pages: Publisher:

Mall I.D. ` 430.00 CBS

About the Book: It is one of the important courses in chemical, petroleum engineering and petrochemical courses at B Tech and M Tech programs. The book contains 26 chapters dealing with introduction to petroleum refining, status of global and Indian petroleum industry, various aspects of crude oil production and processing, and recent trends in petroleum refinery processes, natural gas processing and integration of petroleum and petrochemical, biofuel and separation processes in petroleum refining. In addition, the book also presents energy management, environmental protection, corrosion control and selection of construction material in petroleum refining industry. Oil movement, storage, crude and product blending and handling have been also discussed. The appendix contains glossary of terms; list of abbreviations; properties of important hydrocarbons, petroleum, natural gas and petroleum products: standards and specifications; list of major petroleum and petrochemical complexes; and list of major consultancy and research organisations dealing with exploration, petroleum and natural gas processing. Chemical Engineering World

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May 2016 • 71

CEW Interview

‘Indian Petroleum Market Growth is Encouraging’ Bharat Oman Refineries Limited (BORL), the joint venture company of Bharat Petroleum Corporation Limited (BPCL) and Oman Oil Company SAOC, Sultanate of Oman (OOC), is augmenting its refining capacity from 6.0 MMTPA to 7.8 MMTPA in next three years. In the backdrop of this development, Mr K Ravi, Chief Operating O f f i c e r, B h a r a t O m a n Refineries Limited, elucidated the detail expansion plan in line with the implementation of Euro VI fuel emission standard by 2020 and changing business environment of the Indian refining sector, in an interaction with CEW.

72 • May 2016

Chemical Engineering World

Interview CEW In 2014-15, most refiners were saddled with huge inventory losses due to falling prices that hurt their profits. Spot crude purchase gives flexibility in terms of the types of crude a refiner want to purchase, depending on the demand of the products and refinery configuration. Will you please brief us on the capacity expansion plan of BORL from existing capacity of 6 MMT to 7.8 MMTPA in next three years? BORL is augmenting its refining capacity from 6.0 MMTPA to 7.8 MMTPA through low cost refinery debottlenecking project. This will increase the refining capacity by 30 per cent with low capital investment and in line to meet requirement of Auto Fuel Vision & Policy 2025. The project is scheduled to be completed by 2018-19. How do you evaluate the current Indian refinery sector and its growth drivers? Indian petroleum market growth is encouraging and all petroleum products have registered growth, except Kerosene. The changing economics of oil and narrowing price gap between diesel and petrol has resulted in a shift again towards petrol driven vehicles. More usage of personal vehicle compared to public transport will boost the demand of transportation fuel. Hence these factors would encourage refining sector. As crude oil continues its slide, Indian refineries have gained better refining margins. However private refiners score better against their public sector counter parts. What are your views on this? India imports more than 80 per cent of crude requirements from oil producing countries and therefore fluctuations in oil prices are being tracked more closely in the domestic markets. Since mid-2014, global crude price have been halved. The purchase term agreements for refiners usually last a year with prices Chemical Engineering World

fixed every month on the basis of a formula dependent on the average prices in the international market topped by a premium/discount. In 2014-15, most refiners were saddled with huge inventory losses due to falling prices that hurt their profits. Spot crude purchase gives flexibility in terms of the types of crude a refiner want to purchase, depending on the demand of the products and refinery configuration. Private refiners procure more crude from spot market based on their refinery configuration and negotiations available at that time. However Indian Government is also looking into setting up a trading desk for PSU’s which will also give them edge. With the changing business environment, refiners have switched to cheaper crude, especially heavy oil and contain high sulphur to keep higher refining margins. How have Indian refiners, especially BORL, upgraded refining configuration & processing capability of such crudes? BORL is designed to process 100 per cent high sulphur crude processing and some of other refineries are also switching over to process heavier crudes by way of revamp/ modernisation. Government has proposed to implement Euro VI by 2020 by skipping Euro V altogether. How is BORL gearing up in technology & refinery upgradation and funding to match the emission norms in definite time frame? Government proposal of direct switch over from Euro IV to Euro VI grade fuel is a great challenge for all refiners.

BORL would be able to supply 100 per cent Euro IV fuel from April 2017. Once the debottlenecking is complete BORL would be able to supply Euro VI fuel. What are the future challenges that Indian refineries will face in the coming years while complying with stricter environment, regulatory & fuel emission norms with the demand of middle distillates, etc? In line with climate change objectives and environmental legislations, every country is to cut down its Carbon Dioxide emissions and make fossil fuels more environment-friendly. The quality of crude oil imports to India - mainly ‘sour’ - is a challenge as a result of the stringent product quality requirements currently in place. India is also adopting strict measures to increase the quality of fuels which will make them environment friendly. These measures include phasing out lead, reducing benzene in gasoline, cetane improvement of diesel and sulphur reduction. This brings a great challenge for all Indian Refiners to meet Stringent Product quality in cost effective manner. Please brief us future expansion plans of BORL existing units to raise its refining capacity and new units in pipeline? As indicated above BORL is augmenting expansion project with capacity enhancement from 6 MMTPA to 7.8 MMTPA through low cost debottlenecking project Schedule to complete in 2018-19. May 2016 • 73

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